My MKII GTI 20V 1.8T AWP Swap

[vrrrrr]

any 100mm mk2 axle

[Batrugger]

I have a question about the clutch master cylinder. I am using pedals from a G60 Corrado so I had planned on getting the master cylinder from a Corrado. I just got my O2J finally and i was looking at the line and was wondering if the MKIV line will connect to the Corrado master cylinder and if not how can I make it work? The other option is I have the MKIV master cylinder, but it does not have the looped end to connect to the G60 pedals. Is there a way to make it work with those pedals?


Modified by Batrugger at 5:25 PM 1-5-2010

[johnsomj]

I am using an MK3 subframe in my '92 GTi AEB swap. I'm making lots of little mods, but this has been one hell of a project, I hope you are having better luck than I. It makes me go a lot

[hiawata]

Quote, originally posted by Batrugger »

I have a question about the clutch master cylinder. I am using pedals from a G60 Corrado so I had planned on getting the master cylinder from a Corrado. I just got my O2J finally and i was looking at the line and was wondering if the MKIV line will connect to the Corrado master cylinder and if not how can I make it work? The other option is I have the MKIV master cylinder, but it does not have the looped end to connect to the G60 pedals. Is there a way to make it work with those pedals?

I cut the rod to the A3 (equal to G4), threaded it and made a small bracket to fit the pedal. Similar to what I did the brake master:

Alternate you need a tool to fit a threaded end to the tube to fit the G60 master. But then you cannot use a bigger brake amplifier than the original G60. Sorry I didn`t have a pic of the clutch part.

[Batrugger]

Thanks for that. It helps a lot. The other way I was told was to run a Corrado master, slave, and line and it will bolt right onto the O2J. Your way is cheaper since I already have all of the stuff from the MKIV. I checked out your bulid before and you have mad skills.


Modified by Batrugger at 1:14 PM 1-6-2010

[VWChilcoat10]

looks like im watching this one

[Batrugger]

Got my O2J transmission Tuesday and even though I don't have a clutch or flywheel, I went ahead and got it bolted onto the engine.

Here is a shot of the front and driver's side mounts installed:

I am going to go ahead and drop it into the bay to see if everything fits. I am also going to start running the wires and figure out where all of the accessory brackets need to be installed.

I am going to pick up the front cross member this weekend since it is having the Powerflex bushings pressed into it. I also got the VF front motor mount for it. Here's the front subframe on:

So far I have the non-ABS bracket and brake booster painted and together,

I have a Corrado 22mm brake master cylinder on the way, the pedals will be ready next week, and I am getting a clutch master cylinder, slave cylinder, and line from a Corrado to get the hydro clutch worked out. Once I work out where everthing goes, I'll pull it all out again except for the lower subframe so it can be towed, and I'll get the bay smoothed and painted.

I was referred to a local guy here that lives down the street because I was looking for a someone that could do some welding. He came out to the house yesterday to check out the project and rolled up in a 51 Cadillac with a chopped top riding on bags. Turns out he has a shop called Leet Auto Design and has been building custom cars for almost 20 years. He said he didn't know what to expect when I told him I was working on a GTI, but after coming over and checking it out, he was pretty impressed and said I was doing things the right way. He is going to work with me to smooth and paint the bay, graft the steering columns together, get the dash fitted so it is done right using the metal dash support from the donor car, and get the shifter mounted. He said it would be cool to work on his first VW.


Modified by Batrugger at 11:15 AM 1-10-2010

[Batrugger]

Yesterday I picked up my clutch master and slave cylinder and the line to connect them so I have all I need to connect the clutch to the pedals. I picked up the front crossmember after it had the new bushings pressed in and then installed the VF mount into it.

I got home after dark, but I went ahead and dropped the engine in. This morning I was able to get everything lined up and get some pics:

Front Mount:

Trans Mount:

Everything lined up pretty well. I had to coax the trans mount to line up with a cheater bar, but it was nothing major. I was going to use the MKIV mount on the passenger side to eliminate the rear mount, but it looks like there is not enough room between the engine and frame rail so I'll see if it can be modified later. Unfortunately the SAI pump just barely hits the front crossmember so I am going to have to find a way to make it fit as well.


Modified by Batrugger at 8:13 PM 1-10-2010

[hiawata]

You are missing this part on your gearboxmount.

You will find it on 90`s passats or any other vw`s with 02a or 02c gearbox

[Batrugger]

Thanks for that. I actually have it, I just haven't put it on yet since i am going to pull it out again to smooth the bay and install the clutch and flywheel.

[PhilR]

Looking good, keep it up

[odj]

Looks like this is coming along quite nicely, and makes me wish I hadn't invested in my 8v... Oh well though, c'est la vie.

I like the R53 as well, I read a bit about it a while back... maybe on NAM or wherever. We've got two R56s at home keeping the MK2 company

[Batrugger]

Thanks for the positive comments . I got some axles last night from a 16V Scirocco and they are OE German. I also have the correct flanges on the way so I should be able to get this on the ground soon.

[LovetheA2s]

subscribed

[vrrrrr]

bump

[Batrugger]

Not a whole lot to report on. We had almost two weeks of solid rainwhich forced me to move it into the garage since it has a lot of bare metal and an open rain tray. I didn't want it to get rusted and flooded. I have also been installing Corrado front brakes, stainless steel brake lines all around, new rear rotors, new bearings, and poly bushings on my Scirocco so that has been taking up a lot of my free time. I did have some hoses made for the power steering using the ends from the MK2 hoses:

These will allow me to connect the MKIV power steering pump to the MK2 rack:

I also got some more parts in:

ECS Stage 1 Clutch Kit:

and a used Eurojet upper intercooler pipe with a diverter valve hose. The pipe was cheap and it will save me a lot of fabrication time.

I am at the point now where the car needs to go in to have the bay done. Fortunately I am going to get a tax return for a change, but we have a big MINI meet coming up in Vegas and I really want to get some baller wheels (Schmidt TH Lines) for the wife's car so I may have to back off until April after the show. My goal for the GTI is to drive it to Wustefest this summer.



Modified by Batrugger at 4:43 PM 1-31-2010

[Batrugger]

Got it on some rollers:

It was loaded up and trailered away today to have the engine bay smoothed and painted. While it is gone, I will get the clutch and flywheel in.

[Batrugger]

I went and visited it today. They already have all of the holes filled and the plates made for the rails. Most of it is already smoothed, I have to drop a couple of things off there tomorrow so I will get some pics of the progress. It should be painted next week and Once that is done, I can get the engine in and really start making progress.

[Toffeerado]

Quote, originally posted by hiawata »

You are missing this part on your gearboxmount. You will find it on 90`s passats or any other vw`s with 02a or 02c gearbox

you don't need that part I don't think mk3 VR's even came with it I see a lot of people don't even run that piece, I don't.

[Batrugger]

ok, thanks

[Batrugger]

Well yesterday I was finally able to go by the painter and he had made some great progress. Here is a crappy cell phone pic since I was without a camera:

Also I found out yesterday that I needed to give up the engine hoist I was borrowing this weekend. The bay is now painted and cleared and should be back tomorrow. I got the new clutch and flywheel in today, so I should be able to drop the engine in tomorrow and hopefully I won't need the hoist again. Unfortunately due to escalating costs, I am going to put aside a couple of things mainly an LSD.

[Batrugger]

I got the car back on Monday and here is how it looks:

The panels are in and all of the unnecessary holes are filled. Some of the cool things that were done are since I am not shaving the bay, I made a template of the hole for the lower harness and I had him add these two cutouts for the MKIV harness. The small hole behind the tower will be filled too:

Here are the brackets for the MKIV coolant bottle welded in:

I cut the harness bracket out of the MKIV and had that welded into the rain train so it will fit toght and not leak:

Here it is with the harness run:

Some of the bad is the color is lighter than I intended. I was wanting more of a sandy beige color, but I picked it out so that is on me. It will still work with the color for the rest of the car. Some things that need to be fixed:

Shock towers need to be filled and smoothed as well as the bracket for the coolant bottle:

He made this cutout for the relays and it was good idea, but the wires are too short to run to it from the plastic wire cover and it is in a real obvious place and looks bad so it will be filled:

This area back here needs to sealed and smoothed and the panel edges will be smothed too:

I really wanted to start putting parts on, but it does need to go back for the fixes and he said it was no problem so it will probably be delayed another week. Our big Vegas MINI show is coming up in a month, so I need to divert resources there for the time being. The MINI is almost done with a full respray, new glass, headlights, and trim (sand damge claim) and we got some new Schmidt TH-Lines for it so I am feeling the economic pinch (Got to love the tax return). Should be cool though since I have never seen a MINI with them before. I have all of the big parts to finish the swap except for the intercooler and piping so once it is back and done I should be able to get it running pretty quickly.



Modified by Batrugger at 2:25 PM 2-25-2010

[leroy92]

Very cool build, I really like the direction your taking it.

[Batrugger]

Quote, originally posted by leroy92 »

Very cool build, I really like the direction your taking it.

Thanks I put new Schmidts on our MINI:

which meant I had these to put on the GTI:

So I could pull the wheels off of the GTI to trade in plus $150 for these:

I was going to put the RZs on the GTI, but I think I will leave the Remembers on it for now since they fit pretty well. I am going to just use the RZs on my Scirocco instead for now.

[mafosta]

Quote, originally posted by Batrugger »

unless if I missed something, what about the unpainted areas? are going to leave it like that

[Batrugger]

Yeah, for now. I am concentrating on getting it running. Once all of that is done (and I can afford it) the rest of it will be painted the body color I want for a two tone look. A full paint job is just something I can't afford now so it is going to be a basket case for awhile with a hot engine bay. I am also going to run the cover on the rain tray.


Modified by Batrugger at 2:42 PM 3-2-2010

[Batrugger]

I see after searching that the MK3 tank will swap into a MK2, but has anyone tried to fit a MKIV tank. I would like to use the one I have in my donor car to go along with the engine and harness. If it will fit, then all of the fuel lines and wiring will plug right in with the harness and engine.

[GTi2OV]

There is no way a mk4 tank will fit without MAJOR modifications.

Stuck with the mk3 tank. You can get the mk4 pump to fit with minor modification. Or you can just use the mk3 pump, only downside is your fuel gauge will read backwards.

[halchka99]

any way to fix the backwards gauge?

[Batrugger]

Quote, originally posted by GTi2OV »

There is no way a mk4 tank will fit without MAJOR modifications. Stuck with the mk3 tank. You can get the mk4 pump to fit with minor modification. Or you can just use the mk3 pump, only downside is your fuel gauge will read backwards.

Kind of what i thought. I will just be using the MK2 tank then. Anything i should know about hooking it up?

Quote, originally posted by halchka99 »

any way to fix the backwards gauge?

I thought there was a fix that involved switching the wires from the sender.

[halchka99]

not sure, im on the mk2 pump/tank and my cluster shows backwards.. havent messed with the wires though, i do know that there are 3 wires that go into the intank

[Batrugger]

I remember reading it in one of the build threads, but I really couldn't give you any details or tell you which one. I read a lot of them before I started this.

[GTi2OV]

Reversing or changing the wires on the mk2 & mk3 pump doesn't affect anything. Always will read backwards on the mk4 cluster. I have seen people take apart the fuel pumps and modify the circuit boards(switch them around) and that seemed to work, don't know how accurate.

If want to run the mk4 pump, you need a mk3 tank. The mk2 tank will not work for this as the pump diameter is smaller. On the mk3 tank, you need to dremel out the plastic guides on the bottom for clearance for the taller mk4 pump.

Modified by GTi2OV at 9:46 PM 3-2-2010

[VWless4130]

get that motor in there !

[G60ING]

this might help

http://forums.vwvortex.com/zerothread?id=2928914