£UK Storm Rocco Project

[d-bot]

The original project thread was lost in the move so a quick re-intro then just a lot of pictures to bring it up to date. 1980 Noisette Brown rhd storm w/tan leather interior minus drive train. Plan is a restoration in my home garage doing most of the work myself including a few surprises along the way. I've had the car now for a few years but just started messing with it. Glad I can share, hope you enjoy! Now to bring it up to speed... lots of pictures.

the pickup







mk4 8v AEG bottom end as a base with a 20v head up top. Both will get attention.



11 pence, enough to by me a loaf of bread!





binned the crappy servo and was planning to do something like this.









The trans from my last build. 02J with a tdi 5th. These gears will be coming in handy later.



the "new to me" transmission(s) 4 cyl 02C



cleaning







Some gearing comparisons.
So real quick what is going on. I have an R&P from the CCM VR6 that I picked up a long time ago. The gearing from the 02J EBQ was a bit too short especially with the smaller tire size compared to a mk4 (3.938) in the last car so the plan was to build up a gear set to work better such as the 3.389 from the CCM VR.
CCM VR 02A (left), CBC 02C(02A)(center), EBQ 02J (right)



Yankin stuff off to bin.









built this body cart with some extra material kicking around.



And now the floating scirocco.



More to come as the project progresses.

cheers.

[California 16v]

looks good so far

£ ... will be watching this thread

[polov8]

4wd 20v Scirocco Storm..... Nah, I don't like it! :p

Oh, and that's 13p btw

[theenico]

Nice. Gotta love working out of a normal size garage. Forces you to be more organized.

[IronTrap]

hi. hate your face and your pikey project. moar power

[d-bot]

The first big step of the project was taken care of this weekend. Instead of moving the steering rack and dealing with that can of worms, I decided to raise the motor to allow the prop shaft to clear the steering rack. Starting with the mounts from the previous build, I chopped them up and mocked them up to the proper location and welded em back together. I'll pull the mounts, make some fixtures from them and build some fresh mount brackets.











Next up is some sawzall action. Stay tuned.

[polov8]

Did you raise the engine the same amount all round? How much did it need raising to clear the rack?

Just asking.......

[Falcor]

and is there space under the hood or will that be modded too?

[d-bot]

Did you raise the engine the same amount all round? How much did it need raising to clear the rack?

Just asking.......

I started with my own custom raised mounts already from the previous build then raised them more so it's really hard to say. It was a lot of leveling and making sure everything was where I wanted it to be (hoist, jack and a strap to make it all work). Needless to say once I get the first set done for myself I would consider making more.

and is there space under the hood or will that be modded too?

The FPR on the fuel rail will have to be changed for my application. A lot depends on your intake manifold and how tall your injectors are that will push the rail up (depending how much spacing your stock rail needs). The rail won't hit, it's the FPR that is sitting a bit too proud and will most likely hit under acceleration.

[TheBurninator]

[mr lee]

innit.

[8716vrocco]

Cool project, I'm looking forward to seeing how it turns out

[IronTrap]

is it done yet?

[d-bot]

is it done yet?

Project is on hold until May. Progress is being made for the motor set up though in small ways but nothing worth showing yet.

[d-bot]

Realized I never posted some updates of some more cutting action from last summer so adding that now to keep it current. Cut out minimal material for now to get a better idea where everything will be going.









Rear diff height mocked in place with desired ride height. Planning to raise the rear floor approx 2" and retain the rear seat. So far so good.

[d-bot]

update:
Picked up a tunnel a while back



but more currently looking like this. Been trying to find time to design the rear uprights and suspension in solidworks.

[83mk2scirocco]

One question,rack and pinion?

I want RWD my 83.
Looking good I like the fact that minimal metal was removed.
I often ponder how I would carry out this task.My first thought always what about the rack?
Out of curiosity what are you doing for drive train and engine?
I would like to use a torque tube out of a 944 so the trans and the rear diff would be in the same ball of wax.Then again I dont know what engine would mate to 944 stuff.I would like to do it with the 9A,due its smaller size.
Sorry for the tread jack,but seeing this kind of stuff gets me thinking.

[d-bot]

One question,rack and pinion?

I want RWD my 83.
Looking good I like the fact that minimal metal was removed.
I often ponder how I would carry out this task.My first thought always what about the rack?
Out of curiosity what are you doing for drive train and engine?
I would like to use a torque tube out of a 944 so the trans and the rear diff would be in the same ball of wax.Then again I dont know what engine would mate to 944 stuff.I would like to do it with the 9A,due its smaller size.
Sorry for the tread jack,but seeing this kind of stuff gets me thinking.

Not a problem. The rack is right there in the picture below where the shaft will come past (not sure how clear it is in the photo). The motor is going to be a SC'd 2.0 20v motor which needs custom mounts anyways. The drive train was raised to fit the prop shaft over the steering rack and retain the stock mounting of the rack. There will be more cutting of the tunnel mainly inside the car and hopefully just the top and retain the stock width, but just enough to fit the height of the shifter to clearance over the prop shaft. A marriage of mk4 and mk1 metal. Because the drive train was raised, putting the prop shaft higher as well, the exhaust will still be able to tuck up nicely into the tunnel and not hang low and scrape which is an issue that I have seen with some of these conversions.

For your situation, an adapter plate would work to mount your desired engine to transaxle system. I'm not too familiar with 944 stuff but it seems that there are either kits or if you have the means to do so, adapter plates or bell house plates are the solution for a different motor.

[83mk2scirocco]

I missed this pic.
SYNCRO.....Thats the sh*t too.

It would probably more easy to go that route.

[dub tek]

Lookn good Matt

[TheBurninator]

Somehow this fell off of my watched topics

Looking good so far Matt. Kick Raven in the junk for me next time you see him.

[83mk2scirocco]

Somehow this fell off of my watched topics

Looking good so far Matt. Kick Raven in the junk for me next time you see him.

Good thing's come in time.But I am getting impatient.
I have two S-2 cars,I want to syncro one of them.

[toy_vw]

good stuff man...your only 2 hours from me...if you ever wanna see what i did...

wish I had taken more pics of my setup....oh well.....I did the opposite...angled the engine/trans,raised rack, used 12" struts and cavalier coilovers...didnt touch my tunnel barelly..

also my rear prop shaft is probably at about 10 degree angle from the intermediate shaft...im using toyota tundra hanger bearings...they are AWESOME...and only $70 bucks each..much more heavy duty...NOTE: they will require some "break in"

[d-bot]

good stuff man...your only 2 hours from me...if you ever wanna see what i did...

wish I had taken more pics of my setup....oh well.....I did the opposite...angled the engine/trans,raised rack, used 12" struts and cavalier coilovers...didnt touch my tunnel barelly..

also my rear prop shaft is probably at about 10 degree angle from the intermediate shaft...im using toyota tundra hanger bearings...they are AWESOME...and only $70 bucks each..much more heavy duty...NOTE: they will require some "break in"

That would be great just to meet up and shoot the sh*t and check out your project. I've been over that way for a concert a long time ago but it's not too far.

For the hanger bearings, I was looking at BMW ones but the toyota ones sound like a good option as well. Let me check the schedule and I'll get a hold of you.


As for progress, I've been in discussion with a friend who has done some custom suspension of his own and is giving me some suggestions on how to make it happen. Just need to find some time over here and design some uprights. I may do some more cutting this week to get me going on the body again.

[d-bot]

update. built the rear diff bracket to hang the rear diff.
started with a cardboard template then used some 1/4" plate to make the bracket and welded both sides.
still need to modify some of the rear hanger bracket as I'm not using the stock one anymore. Also will
round the corners when I add in the hanger bushings. Pretty motivated to get this rear diff in so hopefully more soon.

[83mk2scirocco]

[d-bot]

one day this thread will make it to page 2...

now we are movin'
I found the wheel center on both sides and transferred that to the inside while measuring off different body reference points about 100 times...



and figured out where these will sit. 1.5" box tube 1/8" thick. mmm beefy.
the standoffs sit on top of the factory box section. I will further tie the cross brace on either vertical end once I cut more of the old floor from beneath.



welded on the standoffs. B is for BOOM!







prepped the metal



and tacked them in place.





Need to order up some poly bushings and then it will be time to mount the diff.

[California 16v]

thanks for the new pictures & updates to this thread

... can't wait to see this Storm at a future Cincy

[-RalleyTuned-]

MOAR!

[ptrmzr]

D-bot,

Nice project - very inspirational! It's giving me ideas for what to do with the mk1 sitting in my driveway...

Are these cross beams to support the rear of the differential and do you plan to use the original syncro "wish bone" (crossmember) ?

[d-bot]

D-bot,

Nice project - very inspirational! It's giving me ideas for what to do with the mk1 sitting in my driveway...

Are these cross beams to support the rear of the differential and do you plan to use the original syncro "wish bone" (crossmember) ?

Thanks. I actually have read your syncro project thread on TDi club a while back. Very cool!

As for your question, I will be fabricating double wishbone independent rear so it will articulate correctly and not toe & push the wheel forward into the wheel well as the car is lowered and gains camber. The car will be on air so it is important to me for the wheel to be centered in the wheel well at any level. So short answer no, I won't be using the syncro rear beam or parts. I don't have them and won't be using any rear syncro parts besides the differential.

I was a bit distracted the last few weeks with my mk1 1.8t jetta. Installed a front mount on it the other week just to smash & crack the oil pan later that day. Finally got a new pan in today so now I can focus on the scirocco again.

Tonight is the start of the mounting process. I lined everything up, leveled and centered on the bars and then attached a temporary brace to the diff and move the jack out of the way.



Next I started on the rear mount using cardboard to make a template then cut a pair out in steel and finally tacked it in. I'm using 10 GA steel for the main structural sides and plan to wrap the opening/box in with 16 gauge steel. More on that later when it comes time







The front bracket is underway but it was getting to late to cut the steel (too much noise) so had to shut it down for the night. That should be done later this week.

[toy_vw]

[d-bot]

this forum seems to be a bit quiet lately or people don't like this?
Either way the project continues on.

Rear diff mounting done and well hung, (minus boxing in the brackets).

[Meltkamp]

badass glad to see progress on this. Looks like your really planning out how your goin to put this beast together.

[83mk2scirocco]

Very nice.