My 1.8T Mk1 project

[otti]

jacko, did you pun on those flares yet?

[Russjameson]

I also cleaned up the hole for the shifter cables nicely and tested the grommet for it.

Where did you get this grommet from? I have a MK1 with a 1.8T in it and im thinking about putting my 02J shifter box inside the car also this would be effin perfect.

[grizzlyone]

Where did you get this grommet from? I have a MK1 with a 1.8T in it and im thinking about putting my 02J shifter box inside the car also this would be effin perfect.

Its either the heater core hoses or AC line grommets

[Russjameson]

Its either the heater core hoses or AC line grommets

Effin A Right

[dr770]

I can only work on saturdays and some nights after work, and it seems that my project is going to finish at the end of this summer , if ı work harder. Imust say that İ had so much inspiration from your work. I started to improve the chassis by using 45 mm steel tubes, I learned welding, and ı made a headers manifold (SS) by tig welding , i finished the strut braces. Now I am in the progress of making a subframe that passes between fenders from the inside. I mean from the inside rear fender to the foot rest place near the clutch pedal(LHD) under the fuse box. I have never seen anything like that before but I belive that would be helpful to increase the rigidity. What is your opinion? my mk1 suprisingly dont have bottom pillars like south african mk1's.

[ZiggyB]

All i have to say is that u my man have some skills
keep up the nice work on the Golf
i also got an mk1 full steel widebody gti
that is got a 16v in it but next month after SOWO
im putting a 1.8t in it with 02j tranny with lsd
pic of my bunny



[img=http://img221.imageshack.us/img221/4272/golf2db.th.jpg]
[img=http://img10.imageshack.us/img10/1424/golf3wo.th.jpg]

[GTiSurgeon]

Where did you get this grommet from? I have a MK1 with a 1.8T in it and im thinking about putting my 02J shifter box inside the car also this would be effin perfect.

Its either the heater core hoses or AC line grommets

Yip you guys are spot on, that grommet is from the heater core hoses

[GTiSurgeon]

jacko, did you pun on those flares yet?

Hey Otti,

Yes I have fitted them as a test fit... it's still not finished yet....

I'm getting closer to having it finished, I'll post some updates soon.

[GTiSurgeon]

All i have to say is that u my man have some skills
keep up the nice work on the Golf
i also got an mk1 full steel widebody gti
that is got a 16v in it but next month after SOWO
im putting a 1.8t in it with 02j tranny with lsd
pic of my bunny

Looks good Zig!

[GTiSurgeon]

Finally Some updates worth posting!!

I have completed the heat shield in the engine bay... I know, I know it's way more work than what most would do....










Up next, a typical mounting point to mount the clutch line...



I had to give the intercooler a slight bit more room... (the one boost hose was pinching against the valance... )





General work done in the engine bay... note all the little brackets and things... Goes a bit against shaving the bay...







Clutch reservoir mounting.



Braced the steering rack mountings.... On the right hand drive cars the "floating" rack mounting is on the "wrong" side... on the reinforced mounting...







Two Mk1s next to each other...

[GTiSurgeon]

General pic



You wouldn't believe this.... but this is the third attempt at this bottom brace and I finally have a design that I like!!



Rolled in the garage!!!



Straightening out the sills...



I changed all the brake line and fuel line "hangers" to the new/late model mk1 style... same goes for the exhaust hangers.











Oh, and the fuel lines and fuel pump mountings are also from a late model mk1











Other brackets.



This is where my older update stopped... this was finished quite some time ago...





Frame notching... (I decided to use the whole pipe just to be sure its all lined up... )











And finished...







Other stuff that just consumes time...



This fix was necessary because this valance had a notch at the bottom, probably for manufacturing/assembly - which cause the center bolt hole for the duck bill to have to little meat.



Another mounting point to the exhaust.



Finally a place to put the CO2 sensor




I have also started with the cosmetics of the car, which you all know is very time consuming with very little that you can show others...

That's it for now, hopefully more soon!!

[nnamssorxela]

Wow! Great work! That heatshield!!

[otti]

looks good, lots of work done!

i didnt know ther where a LATER STYLE

keep up the good work

[Vegeta Gti]

i wanna see your cross brace....and what you put underneath the rear control arm attachment that goes further to the rear....whatever brace that is.

[rallydiesel]

[GTiSurgeon]

looks good, lots of work done!

i didnt know ther where a LATER STYLE

keep up the good work

HUH, new mk1s?? who said that!!

i wanna see your cross brace....and what you put underneath the rear control arm attachment that goes further to the rear....whatever brace that is.

The brace to the rear of the control arm is there because the South African mk1s doesn't have the brace that the US and Euro mk1s has... Not even on the late models...

US & Euro



VS.

SA

[GTiSurgeon]

Wow! Great work! That heatshield!!

Thanks!!

I know!!

[lewp91]

so are you a fabricator/panel beater?
because that heat shield looks like its been done old school!

[dr770]

Very nice GTİ Surgeon. You inspire me alot. what do you think the weight of the car be at the end,with so much welding and tubes? I am very obsessed about keeping it light in my project with my little 1.6 liter engine.

[GTiSurgeon]

so are you a fabricator/panel beater?
because that heat shield looks like its been done old school!

I'm a draftsman... but my Dad had a panel beating shop when I was growing up, spent much of my school holidays and weekends in that shop... I picked up a couple of tricks along the way.

The shield will get covered with heat protection material - that's why I didn't go to lengths to get it smooth.

[GTiSurgeon]

Very nice GTİ Surgeon. You inspire me alot. what do you think the weight of the car be at the end,with so much welding and tubes? I am very obsessed about keeping it light in my project with my little 1.6 liter engine.

Yes, I also don't like weight too much, however, chassis stiffness and safety is quite high on my priority list... That said, things like the exhaust even though it has been made from 3" stainless steel, weighs less than a stock exhaust... because of the lack of silencers...

The seats I bought only weighs 5kg each, and the wheels ony 7.4kg each...

I believe there is a golden ratio 4 : 1... every 1kg you save on rotational mass = saving 4kg on dead mass...

I have worked it out roughly at a stage and found that the car would weigh just about what it weighed in stock form, which is around the 830-860kg.

After all that said - I'm sure the 1.8T with the bigger turbo will still pull strong in this car...

[dr770]

Yes, I also don't like weight too much, however, chassis stiffness and safety is quite high on my priority list... That said, things like the exhaust even though it has been made from 3" stainless steel, weighs less than a stock exhaust... because of the lack of silencers...

The seats I bought only weighs 5kg each, and the wheels ony 7.4kg each...

I believe there is a golden ratio 4 : 1... every 1kg you save on rotational mass = saving 4kg on dead mass...

I have worked it out roughly at a stage and found that the car would weigh just about what it weighed in stock form, which is around the 830-860kg.

After all that said - I'm sure the 1.8T with the bigger turbo will still pull strong in this car...

7,4 kg for a 16'' wheel is pretty good! by the way i am an R&D engineer at a alloy wheel company CMS , we work for BMW, VAG group, AMG, Daimler,Porsche,Bentley and the italian and japanese manufacturers.We are OEM supplier. I am using 14'' CMS wheels 5,3 kg . I ligtened the fly wheel about %30 from the outer ring which means a total loss of nearly%50 moment of inertia(not good for turbo engines).I removed every unnecessary thing but i am keeping floor mat, and unfortunately ı used about 10 kg's of gravel isolation paint under side the car. After all that much work done on the car , I could not risk a rust piece . I really need your opinion about the braces I am working on. I am connecting front and rear fenders(may be arches i am not sure about english) with a 45 mm steel bar parallel to the ground . ıt will be connected to rear arch from the inside near the shock tower , and on the front it will be connected to the front arch to the left foot rest place near the clutch pedal(left hand drive).I am planning to stay somewhere about 800 kg's.

[lewp91]

i knew you'd be covering the shield
i will be watching this
only thing i wouldnt have done its the under side protection.. then again im in the uk not sa

[dr770]

I wont be keeping the car in garrage most of the time. the underside protection gives a good feeling, i live at the sea side and corrosion is a really big problem for an old car. After spending my days to clean up the rust and welding sheet metal i decided to use protection with the expence of some kg's.

[lewp91]

sorry by protection i meant the mad max bars under the engine not your stone chip, i too will be rust proofing the chassis of the car i am looking to build

[GTiSurgeon]

7,4 kg for a 16'' wheel is pretty good! by the way i am an R&D engineer at a alloy wheel company CMS , we work for BMW, VAG group, AMG, Daimler,Porsche,Bentley and the italian and japanese manufacturers.We are OEM supplier. I am using 14'' CMS wheels 5,3 kg . I ligtened the fly wheel about %30 from the outer ring which means a total loss of nearly%50 moment of inertia(not good for turbo engines).I removed every unnecessary thing but i am keeping floor mat, and unfortunately ı used about 10 kg's of gravel isolation paint under side the car. After all that much work done on the car , I could not risk a rust piece . I really need your opinion about the braces I am working on. I am connecting front and rear fenders(may be arches i am not sure about english) with a 45 mm steel bar parallel to the ground . ıt will be connected to rear arch from the inside near the shock tower , and on the front it will be connected to the front arch to the left foot rest place near the clutch pedal(left hand drive).I am planning to stay somewhere about 800 kg's.

Well I have done a similar thing on the inside of my car's cage...
Note the bars on either side of the car...



Yeah, my goal is also to try and stay around the 800kg mark, but if I go over then that will have to be it...

[GTiSurgeon]

sorry by protection i meant the mad max bars under the engine not your stone chip, i too will be rust proofing the chassis of the car i am looking to build

Mad Max bars... That thought has crossed my mind also... a couple of times!

But I think that my cage will keep the stuff in place that needs to be kept in place... So I just have to stop myself

[lewp91]

so long as there's no bull bars with spikes on them i'm sure you'll be keeping the weight down

[dr770]

Yes I read the full tread and i saw your bars eitther side , but you also have x's at the doors , İ am trying to combine these 2 by placing the side bar higher at the front and back. at the back i am thinking to fix it some where near the rear seatbelt attachments.By the way what is the wall thickness of the bar u are using? I am using 1.2 mm wall thickness 38 mm ST^37 steel tubing. I know most of you will say it is very thin but i am just trying to increase the body rigidity, i am not trying to survive from a 180 km/h accident. My tubes are under a kg per meter .

[GTiSurgeon]

Yes I read the full tread and i saw your bars eitther side , but you also have x's at the doors , İ am trying to combine these 2 by placing the side bar higher at the front and back. at the back i am thinking to fix it some where near the rear seatbelt attachments.By the way what is the wall thickness of the bar u are using? I am using 1.2 mm wall thickness 38 mm ST^37 steel tubing. I know most of you will say it is very thin but i am just trying to increase the body rigidity, i am not trying to survive from a 180 km/h accident. My tubes are under a kg per meter .

I hear you, I guess most of us do as we think best, I spent a lot of time around production car racing and also rally cars... so most of my cage is based on what I saw there and how it fitted around the rest of what I wanted to install in my car...

I used 2.77 wall seamless tubing in most places 38.1mm OD.

[absentee]

the fab work that goes on in some of these builds just blows my mind. keep it up

[g e o r g e D!]

Wow, this sir is amazing dedication. I cannot wait to see this complete! What color are you thinking of spraying it?

[GTiSurgeon]

Hey guys,

I have again managed to do some work that was worth taking pictures of.

I also had a friend organize some machined parts and laser cut plates + I found some cool parts by accident.



Rear Axle mod..













New brake line engine bay mounting bracket.



The cool parts that I found at a local tuning shop... I've wanted camber plates ever since I started this project....











Start of the new strut brace.





Some more parts... A surprise as to where they are going to be used!!!



Relocated the e-brake cables, had to modify my interior mountings for the gear lever and e-brake...








And lastly, a pic of me that I found when I was visiting my mom - showed an album to my GF moms... I was 13 months old when I was first caught on camera working on a mk1



.... years and years worth of experience....

[GTiSurgeon]

Hey guys, I know most of you have lost interest in this project because it has taken so long - sorry for that.

Well with all the fabrication basically done, the time has come for the car to go for painting - here are some prep pics...

The start of my A-arms:








Brake pedal cluster/bracket - reworked...





So bracing for the brake linkage as per the "late models in SA"



New Shock tops - I have also reworked the strut brace





New interior bracketry - gone is that ugly frame I had in there...







Just before the soda blasting started.







And blasting commenced















Painting will be done soon and then the assembly - I'll get the pics up over the next month.

[nnamssorxela]

I'm sure I speak for not only myself, but for many others when I say I haven't lost interest, and that any update no matter how small or how long it takes is just as exciting as the last! Keep up the good work; this car is truly an inspiration.

-Alex