1979 GLS.. 1272cc Carburetor Turbo Project

[VWinston]

Hello Folks and welcome to my progress thread.. I have been reading this forum for some years now and thought it was time to join in with you guys

I come from a background in Renault 5 GT Turbos and Clio Williams but having spent the last 8 years in the Renault scene it all got abit boring. All my mates are hardcore Veedub nuts so it was only time before i gave in and got a dub lol I broke my current Renault 5 for spares and went on the hunt for a nice Mk1 Scirocco project.

I was straight on ebay but was a fool and bought the first Mk1 Scirocco i could lay my hands on.. It was a Red 1979 GLi & it was in need of quite abit of resto work to get it up to full scratch and also needed quite a few more parts to complete it.. I then bought another Blue 1978 GLS to donor the 1979 GLi... but having picked up the 78 GLS it was just to good to break.. So i was stuck with 2x Sciroccos that both needed resto work. I was torn because I only really need one Mk1 in my life and didn't have the heart to break one.

I was browsing the classified and stumbled across Oli's 79 Scirocco GLS for sale and fell in love... I worked out if i sold both my sciroccos projects and the parts. I could afford to buy Oli's which was a much more soild base to work from and only needed minor niggles to finish it off... Lucky for me a regiester forum member bought both cars and most my parts.

Oli's Classified ad - http://sciroccoregisterforum.c...=3627

So here is the car as she stands now, Ive just got to fit the Mk1 Golf dash or the full GLi Loom and Original Black dash and tidy up a few odds and sods and it will be ready for the road.. I will update this thread as it progresses.

Thanks for reading and big shout Oli and all the other build threads that have inspired me

Cheers
Winston

[G60Jetta2dr]

Gorgeous machine.

[polov8]

Why fit a mk1 Golf dash? Don't ruin a gorgeous car with a hack job dash! You wan't dash? I have dash!

[IronTrap]

I saw that car in person last year when visiting Oli to trade some parts, was pretty dang nice! I'd reconsider the mk1 golf dash as well.. they aren't a direct fit and would be a shame to hack up such a nice example of a mk1! Good luck with it!

-Matt

[Michael Bee]

wow!!

[VWinston]

Don't worry the Mk1 golf dash has already been butchered and its only a quick fix to get it through its MOT as its running with the Golf loom... I won't be throwing my Mk1 rocco dash away, it will go in at a later date

Cheers for the comments


Modified by VWinston at 10:37 AM 5-4-2010

[polov8]

Oh good, I remember that car when it was Grahams and lived in Sheffield, it's a real beauty.

[Rocco_julie]

Thats a pretty color...
drool

[California 16v]

Welcome to the Scirocco family

Have seen this mk1 on the Register and followed it's progress their

[Iroczgirl]

Great looking Mk1!

[VWinston]

Cheers for all the nice comments folks

These Mad'in split rims are my pride and joy and thought it was time to make them something special by giving them a split & polish... Dare i say i love these wheels more than any VW lol

The wheels looked like this when i bought them



I refurbed them in matt black for my 5 GT Turbo which kept them rather stealth and understated


I have tryed to polish them before but I gave up due to an anodized like coating on the wheels (It was the factory colour under the yellow paint).. This picture shows the result of 2 hours in my blast cab.. see why i gave up lol



The time has come to have another go at polishing.. I split the wheels & sent them to the local blasters but he said it would be to much work due to the thick coating on the dishes... So I just left the centres to be blasted

My friend used these discs to eat the rust on his Mk1... They strip like a b**ch and leave minimal damage to the metal below the paint.. Highly recomended tbh





1 hour a piece later and the dishes look like this



I used 80 grit wet & dry to remove the deeper scratches the sanding disc had left



I worked down the grades 80 - 120 - 240 - 360 - 400 grit wet and dry



This picture shows the 3 different stages



I sanded them down again 400 - 600 - 800 - 1000grit and added a few layers of autosol metal polish


At this point i worked out i had not removed enuff of the deep scratches left by the disc, so I had to take them back all the way back to 120grit and worked up the grades back to 1200 grit then added 5 layers of Autosol.. They now look like this...





Ive got over 40 hours in the dishes alone... Im still waiting on getting the centres back from the blasters but they will need much less work to get them shiney hopefully.. leaving me just the bolts to polish

I can't wait to get them built back up and on the Rocco

[veedub_83]

Wow those turned out great! Very good work.

[Makkkan]

Awsome wheels!

[Rocco_crossing]

Those are some awesome wheels! And a beautiful car the well deserves them!

[VWinston]

sorry guys ive not updated this for months..,

I got my wheels finished in time for edition38... but Sadly due to 3 weeks in hospital and then getting problems with my k-jet (after selling my twin 40's, sods law lol) and no time for chassis work to get it sat right it never made it to edition.



It would be just rude not to trail run and see if it matched the picture i had in my head of the car slammed with the Mad'ins.. The stance does need some fine tuning but the exhaust manifold was the limiting factor today. With the new small block engine I plan to fit over the winter and some minor chassis work it will be all gravy.











Can anyone spot whats missing? apart from ground clearance

[VWinston]

After edition38 show I thought i best remove the old engine ready for a new one. That way I could sell all the 8V goodies off to more than fund the 1300cc conversion. maybe even enough to turbo it....



I did have a 1.3 driver engine I had cleaned and detailed for the rocco but that has now been donated to my mates Mk1 Jetta



Another friend was selling an engine that I couldn't turn down. Its a polo G40 engine with a turbo conversion... It is looking abit scruffy and missing a few bits but i just want to get it in and running then it will be removed & cleaned etc.

I plan to use a Renault 5 GT turbo carburetor and Vacuum Retard canister to control the ignition.. It keeps it nice an old skool

[rico_arg]

]

WIN!


I need a set of bumpers.. wanna ship me a set?

[polov8]

G40 turbo! Cool, I built one of those for a friend and put it in his mk1 Golf:




what management are you going to run?

[VWinston]

A member of this forum has already snapped up the original bumpers off this car mid last year.. Sorry dude

Mangament wise.. Im going to run it on a Mk1 Driver 1300cc carb dizzy and use a vacuum retard canister.. Similar to the Kjet turbo conversons

It looks at home in that bay.. I can't beleave how little room there is at the front of the engine with the turbo in etc.. Did it GO some? What was the spec?

Cheers
Winston

[8716vrocco]

Really sick car, I love the direction it's taking. The wheels are super hot, dishes came out really nice. Keep up the great work

[scotttu]

That is a beautiful car!

[polov8]

Mangament wise.. Im going to run it on a Mk1 Driver 1300cc carb dizzy and use a vacuum retard canister.. Similar to the Kjet turbo conversons

OK, we used the G40 management with a custom tuned chip. It initially had a chip tuned by a G40 specialist who's name I forget, but they couldn't tune for sh*t, so it got taken to jabbasport and sorted properly![/QUOTE]

It looks at home in that bay.. I can't beleave how little room there is at the front of the engine with the turbo in etc.. Did it GO some? What was the spec?

Cheers
Winston

It was ridiculously tight on the radiator, to the point where the best we could get with an intercooler in front of the rad was about 10mm clearance. It was a K03 turbo, but it turned out to be bad, so a new K03 was fitted. It ran really well, the lack of weight helped it no end. I was running a mk1 Scirocco with a 1.8t on stock management with a K03 and although the golf couldn't match that, it was probably as fast or a little faster than a mk1 GTI.

With more boost it'd have matched the scirocco

[VWinston]

I was just going to use the G40 management but my setup was missing the ECU so its kind of pushed me in this direction as this was the long term plan.

My mates got a Mk1 Golf van with a 20v on a KO3.. So fingers crossed it will hold its own against it.

Your picture worried me abit so I thought a trial fit was in order





Cheers for the kind replys guys

[VWinston]

Well the engine came back out so the notching of the chassis and tidying up the mount move could take place

My mates dad Glenn did all the welding and im over the moon with it..



After many hours of grinding and sanding I'd had enough! I wasn't 100% happy with the way the notches blended in but thought they looked ok for a first try.. I will get them perfect next year when the full car gets painted.



4 coats of zinc primmer



4 coats of paint and 4 layers of laquer

[d-bot]

Good way Winston. Glad to see this get a bit of power. Keep it up mate.

[VWinston]

Cheer Matt





Now the engine is in I have ran into a few problems

1. The carb fauls the bonnet on the adaptor plate so ive got to drill and tap the inlet manifold and even then it will be tight.

2. My turbo is upside down so the oil feed and drain wouldn't work.. I can't rotate the housings due to it being seized so Im on the hunt for a new turbo.. wish I had noticed sooner before I had bought lots of parts for the current turbo.. Oh well live you learn.

3. The shocks bottom out due to it being to low.. So I need to purchase some balljoint raisers as I can't raise my turrets like the Mk1 Golf boys because I have no room.. Im just waiting on the company getting back intouch on how to pay.

4. Looms are going to be a nightmare.. Its looking like I need to make the under bonnet looms from scratch.

Once these problems are sorted im sure I will have another list of problems to deal with.. Why do I make things hard for myself LOL

[85roccoZ400]

Reading and Watching

[Grig85]

watching this for sure

[VW 16v]

looking awesome!

[VWinston]

The new turbo turned up about a month ago.. Old on the left, new on the right.. The new turbo is quite abit smaller as you can see but its also much much lighter.





I feel like im getting somewhere now.. The bay is starting to fill up.. Ive just got lots of niggly bits to make up etc



After many hours hunting and messaging on ebay.. I bagged this Focus ST intercooler for £27 posted and its a perfect fit.. Ive spent most of last weekend sorting out the hoses that I lifted from a Volvo T4 in the scrap yard, no pictures of the pipe work yet.



Ive also sold most my classic alpine collection to fund this early 80's Alpine.. not quite era specific but it will do :vcool:



Cheers folks

[VWinston]

Ive had no interesting updates, It's mainly been bleeding brakes, messing with hoses and waiting on parts.

But the welder (my mates dad glynn) came up a few weeks ago and spotted me playing with the s/s side exit exhaust from a Renault 5 working out how I could make it fit the scirocco. In short he told me sell it on and just buy mild steel pipe work and he would knock me one up. With this in mind it would be rude not to knotch it up to 3", so I bought a selection of 3" pipe work, silencers and bends from merlin motorsport.

We made a start on it. He thinks im mental but he puts my ideas into metal and we have a good laugh at the results.. Im over the moon with this evil monster dowpipe he has created. Just the back box or should that be front box left to do haha. Im still not sure if I have the balls to cut a hole in the bottom of my wing and have it fully poking out?

[d-bot]

Good joke (hopefully?). Through the wing will be terribly loud I'm afraid. Run the 3" downpipe into the tunnel to a 2.5" with that resonator you have there. Plenty for that motor.

[VWinston]

No joking!!!.. Ive had a 2.5" front exit exhaust on one of my old Renault 5 Turbos and it was not loud at all.



I want it exiting out of the side to aid ground clearance. Ive not got the balls to cut the wing, it will be exiting under the wing TDi turn down style.

[VWinston]

A few long due updates

I had a custom lower gearbox made by a local lad called Arun he has the sickest Mk1 Golf. The ground clearance is most excellent. 8) (Sorry Arun thats the only picture I got due to rushing to get it on for the MOT.. the paint was still drying haha)



I bought these top mounts second hand from the classified. They are very early Mk1 rebuildable top mounts but they have had spherical bearings welded in the top making them Soild top mounts. This gives me just over an inch of extra travel in my shocks and is the final low mod for this years show season.

[VWinston]

Edition 38 updates...

I thought I was on easy street it was 2 weeks until edition38 show and shine, the cars taxed, MOT'd and Insured (road legal). Im left with ironing out the niggles and cleaning....... Nothing is ever that simple haha.

On the first night of testing the engine is shaking the car to bits (I assumed it was the poly engine mounts). It had a loud knocking coming from the off side wheel, it was that bad it felt like the wheel was going to fall off. I fitted a new driveshaft and hub on the offside, this made no difference so I changed the pair on the nearside and the problem was still there. This left me thinking the diff had gone in the G40 gearbox. I fitted a 4 speed 1.3 golf gearbox, the release bearing didn't work with the g40 clutch (doh). I then fitted a Polo GT 5 speed. It still knocked!!!!!

Its now the tuesday before edtion38. I removed my front gearbox mount and the knock was alot better but still worrying. The car had got slower on every outting, the exhaust had got ridiculously loud and it had started running on 3 cylinders. This was down to the plug in cylinder one being covered in oil... Oh no the rings have gone on piston one!!!! Alot of things now make sense!!

Its now wednesday night the car has to make edition 38!!. The only option is to fit all the turbo stuff to the old standard 1.3 engine out of my mates Mk1 jetta and run it on low boost. I phoned my friend Az in the day to see if he still had the saab dizzy needed to run an ignition amp and he did (HERO).. It was game on by the end of the night 5am the new engine was in and mostly plumbed in with only a minor niggle to get it running left.







Thurday afternoon.. I get all the niggles sorted and come to start it. After alot of faffing with the ignition timing it fires up but the inlet is exhaust heated on an early 1.3, I had cut this off the old inlet because it fuled the G40 head. so this left exhaust fumes pissing out the head haha. This was solved with a quick manifold swap. With this sorted I came to fire it up again but with more timing faffing it would not fire up. Morale is very low and thoughts of missing another edition38 are looming....

Its now early friday morning. Ive even got the Haynes manual out!!! This led me to look at the timming marks and they were wrong, the bottom end was a tooth out (this was why it was hard to start in the Jetta) I lined it all up and recharged the battery.... It fires!!!!!!!!!!!!!!!!! Right!!!! I best go get my camping stuff ready and fit my wheels and slam it for its tracking, no sleep for me haha

We pull onto the motorway friday dinner time and the knock is still there but very faint FFS.. A friends engine blew up and set on fire on the M6 Toll so it was towed via A roads the rest of the way. We arrived at the camp site at about 6pm.

Was it worth all the effort?.... **** YEAH!!!!!!!!