VW Mk2 Golf, AWD big turbo build

savagesam117 · 15 Nov 2020 at 12:44

So, I thought I’d make a thread, because why not!? Although, it’ll be a shortened version.

It’s a 3 door Mk2 GTi 16v at heart, but I’m going to convert it to AWD and strap a larger than normal turbo to a 1.8t as a temporary solution whilst I build a 16vT with an even bigger turbo so it’ll eventually push 500+ little ponies.

The shell is solid, couple of small bits of rust as to be expected. It’s an old golf.

I started at the end of Feb. So I got it up on the rotisserie,

cleaned the underside,

checked for any more rust, mmm no rust!

Then I got the grinder out. I’m a tight git and didn’t want to pay for parts from a 5 door “Syncro” so I made it all. Boot floor cut out for diff clearance

With the diff mounted I could see the tunnel needed to be raised as I wouldn’t have space for a nice big exhaust.

savagesam117 · 15 Nov 2020 at 12:45

Then choppy choppy of the tunnel.

I was going to fit the Syncro stuff then upgrade to halves so I started fitting that.

Mocked up to the height I wanted and then started to fabricate it in.

Almost finished.

This is my new boot floor support.

then got a bit bored of that, so I replaced the battery tray because it had been poorly repaired.

and then welded a new panel in.

Hades · 15 Nov 2020 at 19:50

Nice. Watching with interest. One of my favourite cars was a mk2 GTI 16v. I loved that car and had so much fun it it. This was back when they were fairly new.

Michael Myers · 17 Nov 2020 at 17:00

ill be interested to know the big turbo setup you choose for the 20v, im in the same boat here with a forged engine but standard k04 at the moment.

kaiowas · 17 Nov 2020 at 17:14

Lovely, not enough angle grinder and welder action on this forum these days.

savagesam117 · 17 Nov 2020 at 17:32

Michael Myers said:
ill be interested to know the big turbo setup you choose for the 20v, im in the same boat here with a forged engine but standard k04 at the moment.

I’ve got a Garrett GT2870r or something, but I don’t think I’ll use it. But I don’t know, we’ll see! if I had a K04, which I do in the shed, I’d go for one of them AET380’s. 380+ bhp. Happy days!

savagesam117 · 17 Nov 2020 at 17:33

kaiowas said:
Lovely, not enough angle grinder and welder action on this forum these days.

There’s plenty of grinder & welder action here! I’ll try and update a bit more later on

Bunka · 17 Nov 2020 at 18:10

Subbed - love these kind of builds

dacads · 17 Nov 2020 at 19:29

Nice, how much extra weight will AWD add? Adding AWD and possibly DSG to old cars somewhat intrigues me.

also will engine internals need strengthening?

savagesam117 · 17 Nov 2020 at 19:56

dacads said:
Nice, how much extra weight will AWD add? Adding AWD and possibly DSG to old cars somewhat intrigues me.

also will engine internals need strengthening?

All in about 75kg. Takes it to about 1050kg from 975 to something. I’m tempted by DSG unsure if I’ll make the jump yet. Maybe when the other engine gets fitted.

the 1.8t will have a set of rods and a refresh.

savagesam117 · 17 Nov 2020 at 23:02

So I was away on site and was bored one evening so I bought the running gear off a Mk1 TT.

threw it all in the boot of my car and drove it 120 miles to my dads.

Got the car on it’s wheels

And whilst I was there I thought instead of adapting the subframe to fit, I’ll make it chassis mounted like the TT. So I reinforced the chassis leg and went to town. And repaired the poorly repaired hole in the turret.

I then put the engine back in on its new mounts and mocked up the dog bone.

Tadaaa, need to tidy it up but I’ll do all that before powder coating.

I then set out on making the haldex bracket now I had the engine and prop in place.

Front support

and she’s in!

Flibster · 18 Nov 2020 at 12:07

Ooooh... a rival for Binky.

savagesam117 · 18 Nov 2020 at 12:18

Flibster said:
Ooooh... a rival for Binky.

Care to elaborate please?

Flibster · 18 Nov 2020 at 12:32

savagesam117 said:
Care to elaborate please?

You don't know about Project Binky? It's one of the best things on the Internet. Been going for 7 years and the end is almost within sight...

Take one vintage Mini. Remove all the rust. Remove running gear.
Take one Celica GT4. Remove running gear.
Insert into Mini without making the Mini not look like a Mini.

Full playlist.

https://www.youtube.com/playlist?list=PLGSOZAHg1yQEatqhWza_ae83e313-GLTO

savagesam117 · 18 Nov 2020 at 12:52

Flibster said:
You don't know about Project Binky? It's one of the best things on the Internet. Been going for 7 years and the end is almost within sight...

Take one vintage Mini. Remove all the rust. Remove running gear.
Take one Celica GT4. Remove running gear.
Insert into Mini without making the Mini not look like a Mini.

Full playlist.

https://www.youtube.com/playlist?list=PLGSOZAHg1yQEatqhWza_ae83e313-GLTO

Definitely not a rival, he’s got a workshop and everything! I’ve just got a driveway and a garage full of tools. And it’s just myself and my dad.

It’s really annoying to watch?

Flibster · 18 Nov 2020 at 13:15

More the cars a rival. Also the tools they use most are the grinders(s), welder, cardboard and kettle.

Although the jig Nick made for the Mini is pretty damn cool.

The early episodes are a bit ropey but they get into the swing of it pretty sharpish.

savagesam117 · 18 Nov 2020 at 13:24

Flibster said:
More the cars a rival. Also the tools they use most are the grinders(s), welder, cardboard and kettle.

Although the jig Nick made for the Mini is pretty damn cool.

The early episodes are a bit ropey but they get into the swing of it pretty sharpish.

Maybe I’ll skip a few and get to the fun stuff.

Well I’ve got those tools, and then some. No CNC machine though

Yeah, he’s gone a bit more hardcore than me. They did make AWD golfs so I’m merely recreating it, in a 3 door shell because they only made 75 of them.

Barry Smalley · 18 Nov 2020 at 13:39

savagesam117 said:
They did make AWD golfs so I’m merely recreating it, in a 3 door shell because they only made 75 of them.

can you expand on this a little, please?

savagesam117 · 18 Nov 2020 at 13:43

Barry Smalley said:
can you expand on this a little, please?

They made a Syncro Mk2 Golf, but they were pretty much all 5 door cars. They made a very limited run of the 3 Door 16vG60 Syncro, about 75 of them. And they’re rare as rocking horse ****. I don’t like 5 door Golfs, so I figured I’d build a 3 door version.

Barry Smalley · 18 Nov 2020 at 14:58

savagesam117 said:
They made a Syncro Mk2 Golf, but they were pretty much all 5 door cars. They made a very limited run of the 3 Door 16vG60 Syncro, about 75 of them. And they’re rare as rocking horse ****. I don’t like 5 door Golfs, so I figured I’d build a 3 door version.

I had a Rallye Golf, they were all three door and they built 5000 of them.

And what about the Golf Country - did they not do a three door?