It Begins: The S3 1.8T into my '85 Mk2 GTI

[roccodingo]

You done the homework Wade, so dont expect any suprises...between Joe and yourself you will have it nutted out. Next time i see ya I wanna see it going !

[gareth_oau]

My mechanical background is THIS BUILD!!!!!


Cheers,
Wade

Wade, first MAJOR exercise I did on my S3 was to change the wipers!!

you've got major guts to take on such a huge project and hopefully it will be brilliant when finished.

and why would you want a WRX? hasnt every 2nd man and his dog got one of those?

[GOLFBALLS]

Yea thanks for the inspiration fellas!

Adelaide crew; I am being put up at the Watermark Hotel in Glenelg and will probably have some free time on the weekend of the 15th & 16th if anyone wants to meet up for a quiet lemonade or two...

[tommymac]

Hhahhaha smoker of cock.. thats great!

Wade they are prob nervous. Even with the k03 on my mk2 was able to pick off WRX's on a rolling start

[jayjay]

wade they are definitely nervous. wrxs have been taken in my 8v...

[evorobin]

wade they are definitely nervous. wrxs have been taken in my 8v...

Oh god the trophies are coming out haha

Wade you got my number be sure to catch up when you're in town chief!

[GOLFBALLS]

Ha, cool will do.

I'm getting to the frustrating end now.

The twat who polished the BBS hasn't sealed them properly and the tyres were dead flat after 24hrs just lying on the floor! They'll be going back!

Another problem is the fact that the clutch cable I got was really too long and had nowhere to go in the engine bay, but worse of all the core of the cable itself is restricted by the outer sleeve and there isn't enough thread coming out the gearbox end to make it thru the bracket, so it can't fit on without some dodgy butchering and loads more effing around!

Today i've just really spent time trying to see how the rad and i'cooler is gonna fit. I've had to do a little cutting and grinding to make it fit.

I've run out of fast net MB so I'll upload some pics later on.

Cheers

[h100vw]

I'll measure up the cable I have and let you know how long it is. Coming out for a drink at the weekend shouldn't be a problem.

PMd my number and address but I reckon you'll be on foot, so I'll come down to you.

Cheers

Gavin

[tommymac]

aint you running a 02a? if so dont you use the cable from a Seat ibizia which some models also run the 02a.

[GOLFBALLS]

aint you running a 02a? if so dont you use the cable from a Seat ibizia which some models also run the 02a.

Yeah that's what I thought i'd bought but i've either been given a random incorrect cable, or there are two different length versions for that car. They are also very hard to find.

[tommymac]

from http://www.conrod.co.uk/20v4.html

i used a throttle cable from a 1600 or 1300 too, i got it through VW When i change to 02a i will be using the SEAT set up too.

NEW GEARBOX

After I got the engine running my boost level was peaking around 7psi, not a lot but enough to make the clutch slip on the standard Mk2 box. The original box is known as a 02O, has a rod gear shift arrangement and a tiny clutch! I had no choice but to fit a later Golf mk3 02A box, I could have also used a 02M 6 speed unit but these tend to be quite expensive. The problems with using a later box are it uses a cable gear shift and the clutch is hydraulic, not cable.

You have a choice for operating the clutch - you can either source a manual setup (more on that in a moment) or fit the hydraulic setup from the donor car. You will need the clutch pedal, master cylinder, slave cylinder and a pipe between them. I was put off doing this as the bulkhead requires a little modification to make the pedal assembly fit. I decided to use the manual kit. Around 1998-1999 the Seat Ibiza 2.0 16v was fitted with a 02A box with a cable operated clutch. The parts you need are pushrod assembly, cable support bracket and a new cable. The Seat was fitted with an auto adjusting cable which proved to be a very tight fit in the Golf, I used a cable from a Mk2 Golf 1.3 which is a manual adjust type. The pushrod assembly bolts in the same position as the slave cylinder and the bracket bolts to the gearbox mounting. Simple!

[GOLFBALLS]

Great stuff mac daddy!

I think i will get my std mk2 throttle cable professionally extended. There is a mob in perth who can do it. Although most use that 1600/1300 carbie throttle cable, most also use the 1.8t with the throttle body on the drivers side unlike the AMK!

Cheers

[tommymac]

swap the mani to an AGU you know they flow well! fair enough the 1300 will fit the psng side too there is some length to it.!

[Greg Roles]

Just wanted to say how majorily impressive this thread is. As a MK V type, and diesel to boot, I don't really pay a lot of attention to some of the other sections and only came across this thread today . To have spent all that time and effort AND without any prior knowledge, well, you should be proud of what you've done. Good on you!

You make me feel like an amateur in the mod game!

[Golf Loon]

Just on the throttle cable mate, if you get a motorbike shop to do it, they will do it cheap and easy.
I`d get 2 made as then you have a spare one for if it breaks in the middle of nowhere.