Kloyvd's Rallye: G60 turbo build

[Kloyvd]

Hi folks! About a year ago I decided to do the Haldex conversion on my Syncro. I finally have all the parts to start working on it. When I work I get so consentrated that I forget to take pictures, so there is a lot that has been left out, but here goes!


Yes, I know the lights are horrible. Gonna change them. Got the car inside my fathers messy garage.






I got the car jacked up and started disconnecting lines and removing the bolts needed to loosen the rear axle. I was met with some really rotten bushings






There she goes!






It was a real struggle to get the trailing arms off. Had to cut one of the bolts off with a thin angle grinder blade to avoid cutting into the arm or the beam. It was rusted so hard, I had to drill out the remaining bit.





Started on the jig.












Not welded yet.






Grinding off the syncro brackets took for ever












Test fitted while I waited for the DutchBuild kit.






The kit has arrived! I must give DutcBuild a lot of credit. The kit fit like a glove.





























I only tack welded it so that my brother could TIG weld it for me.(I'm a lousy welder.) I tacked it real good as I wanted zero warping during the final welding.
























Finished tack welding.

















Got the old paint off and painted with ceramic paint. Good stuff.












Reassembled!






I got powerflex bushings for the whole car. Also got new bearings and hubs. I am betting Norway is the most expensive country in the world, so I am really happy that Ebay exists



There is more to come. Stay tuned!

[thepaintcanman]

subscribed

[cyclops594]

subscribed

X2. Pass the mike & ike's

OP: Good work man.

[Mortal_Wombat]

f*ckin a

[Kloyvd]

Thank's guys!


Just arrived. Going to get some more work done tomorrow. Hopefully I will be able to complete the job. Just waiting for my brother who is going to weld the rear bracket for the diff.

[rawk]

Awesome work man, I'd kill for some AWD in my MK2!!

[Mean 'n Green86]

Sweet!

[tylerlb]

looks good!!

[habitat0789]

do mine next

[Kloyvd]

I got 280x22mm Brembo MAX discs for the front and 239x12(Golf mk1 front discs).






Golf mk4 rear calipers with EBC Yellowstuff pads. Calipers and carriers have to be spaced to fit the 239x12mm disc. More pics and specs on that coming later.

[Kloyvd]

Audi RS2 rear calipers

[FLATBLACKMK2]

subscribed........

[salo mk2]

Subscribed

[Kloyvd]

Custom made G60 head gasket finally arrived. (Yes, the engine is next )






10mm on each side.

Going to get some more work done tonight

[db3ck]

great work man looks like its comin along pretty good

[Kloyvd]

great work man looks like its comin along pretty good

Thanks, it sure is. I was goint to make some new brake lines today, but found out that my brother had stolen my brake line flaring tool.


Some more pics:


























To fit 239x12mm discs, tha calipers have to be spaced by 8mm, and the carriers by 4mm.






After 2 seconds of TIG welding the bushing on the rear beam bracket caught on fire. It was not possible to weld with out melting the whole thing, so I have to press it out and replace it after welding. Since Powerflex does not make this bush, I decided to replace it with a hockey puck. This will require some work with a lathe. I'm also gonna use hockey pucks as engine mounts. More pics on that soon!

[Kloyvd]

It came out pretty good. I put a 18x10mm sleeve in the middle. Found this later: http://www.ebay.at/itm/Differential-...-/220585846359 If I only had seen that a couple of weeks ago...

[db3ck]

looks great when do you think you'll have it all back together??

[Vee-DubbVR6]

awesome, nice work!!

[Kloyvd]

I was finally able to get Golf Rallye brake wires, but they came at a price. 675 Norwegian Kroner (117$)


















Done! Just a few minor things left.

[Wompa]

Ser skitbra ut!!! Skulle vara kul att göra samma sak med min Syncro!


For the english speaking users:
Looks badass! Would be fun to this to my Syncro!

[Kloyvd]

Takk for det! Det var overraskende enkelt.


Thanks! It was surprisingly easy.

[weejunGL]

ang dette greiene med bakbremsene du har gjort


caliperen skal flyte på glidepinnene, ellers vil ikke klossen på utsiden få kontakt med skive når du presser på bremsen


hvorfor kjøpte du ikke 239x10mm skiver som er beregna på syncro? så hadde du sluppet og space caliperholder? så hadde innpress på skive blitt riktig, samt at du kunne brukt glidepinnene slik de er beregna


bare et tips, for ser ikke ut til at stort vil fungere bak der desverre


edit: ser jo nå at du har glidepinnene der, men uten fett og mansjett, så vil disse ruste fast iløpet av noen dager i bruk. og da er du like langt

[Kloyvd]

Bremseopsettet skal fungere helt fint. Hvis du leser litt mer nøye så ser du at jeg har skrevet "Just a few minor things left". Orket ikke mer etter 10 timer med skruing, da var det tid for et par Fullt klar over at jeg må smøre glideboltene, jeg har faktisk litt peiling på hva jeg driver med.

[MÄDDNESSS]

AWWW YEAH!!

here we go again.

looks promising.


are you going to upgrade to motor too?

[db3ck]

looks good man

[AndrewDaniels]

Nice build!!

[Kloyvd]

Thanks guys! Yes, the engine is next. Putting in a G60 engie and swapping for a turbo. Planning to have around 250hp. Should be enough for a while.

[MÄDDNESSS]

Should be enough for a while.

[Kloyvd]

I'm back guys! I have finally started on the project again. I removed the compressor, inntake and a lot of hoses before I washed the engine with diesel first then with an engine degreasing agent. My brothers recipe, works like a charm. Here are a couple of pics


Before:












After:
























Bosch Green Giant 440cc's

[Kloyvd]

Pulled the valve cover off and all looks good.













I also got the head off. There is quite a lot of carbon build up on the valves, just need to get it cleaned up and it should be good to go.













Cylinders and pistons also looked good. Just need to get the pistons cleaned up.









I am taking the head over to the workshop where my brother works on monday. They specialize in rebuilding turbos and doing engine upgrades, so that should be the perfect place to get it cleaned up.

[Kloyvd]

After a lot of nagging I was finally allowed to make a carbon hood at work. Took me 9 hours to make the first cast.









Just needs some minor repairs and polishing.

[Kloyvd]

Progress:

[clove911]

Did you drive it with haldex before pulling the motor? How did you like the feel of the car with the different setup? Curious

[Kloyvd]

I have not tried it yet. Since you have to change gearbox when changing to the haldex diff, I really couldn't be bothered with changing it on the stock engine just to try it. So it's going to be verry exciting when I finally get the engine in