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    1.8 20vt Cupra MK1 Cab project

    Kevin20v
    Kevin20v
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    Post by Kevin20v on Mon Mar 03, 2008 5:12 am

    Thanks guys!

    I'm not sure if I'm going to make it to the uk with this one in '08, had some trouble with the mk4 that cost quite some cash so it all takes a bit longer than planned Sad

    @ Gee: I painted it myself Very Happy
    Geeman
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    Post by Geeman on Mon Mar 03, 2008 5:19 am

    Good work then fella. Looks tops! Cool


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    Kevin20v
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    Post by Kevin20v on Mon Mar 03, 2008 6:47 am

    Thanks! It's not that good but it's no showcar, the only goal I'm setting for this car is that I'm going to have loads and loads of fun with it! Laughing

    JD-engineering told me I could get 210bhp and 340nm out of this little bugger easy (with stock k03 turbo), it has a completely rebuild AYN (longest ratio 02a transmission) with a Quaife differential Very Happy

    with that in mind and the car propably going to weigh 950kg it will have a kg/bhp ratio of 1bhp per 4,5kilo Twisted Evil cheers
    (that's rather sick in a mk1 convertible Laughing )
    sarah
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    Post by sarah on Mon Mar 03, 2008 7:12 am

    hello kevin the cabbys coming along nicely looks like youve done a good job on the paintwork is it the first one youve done?? Very Happy Cool
    Kevin20v
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    Post by Kevin20v on Mon Mar 03, 2008 8:15 am

    Thanks Sarah! Yeah it's been the first time I've painted a car part, for now it's just the engineroom, but I'm currently sanding the other bodypanels
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    Post by Guest on Mon Mar 03, 2008 9:54 am

    looks like your doin a top job dude lookin forwad to seein some mor future links to this project
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    Post by Guest on Mon Mar 03, 2008 10:16 am

    keep us posted on this dude, looks the melons!
    Kevin20v
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    Post by Kevin20v on Thu Mar 06, 2008 3:27 am

    Thanks guys!! Very Happy

    I'm going to post the updates that I haven't posted yet...


    03-12-2007:

    Last saturday I picked up a few nice parts for the project:

    Pictures

    1.8 20vt Cupra MK1 Cab project - Page 2 20vt-015

    1.8 20vt Cupra MK1 Cab project - Page 2 20vt-016

    1.8 20vt Cupra MK1 Cab project - Page 2 20vt-017
    The G60 racing-discs against the vented Golf MK2 GTI discs that were mounted before.

    1.8 20vt Cupra MK1 Cab project - Page 2 20vt-018
    The G60 transmission I'm going to use, got it off a mate for a few cents Smile

    1.8 20vt Cupra MK1 Cab project - Page 2 20vt-014
    de-rusted and repainted these boys, and fitted Powerflex bushings

    and I ordered this set for some serious stopping power!
    1.8 20vt Cupra MK1 Cab project - Page 2 5327
    Kevin20v
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    Post by Kevin20v on Thu Mar 06, 2008 3:29 am

    Bought these engine and transmission mounts, so it should actually fit in quite nice Very Happy

    1.8 20vt Cupra MK1 Cab project - Page 2 18T_engine_mount1

    1.8 20vt Cupra MK1 Cab project - Page 2 18T_engine_mount2

    02A Transmission mounts:
    1.8 20vt Cupra MK1 Cab project - Page 2 02a1

    1.8 20vt Cupra MK1 Cab project - Page 2 02a2

    1.8 20vt Cupra MK1 Cab project - Page 2 02a3

    I don't want to fool around myself with the mounting points of a for me very expensive engine, so I just bought these since they have been used for quite a while in Germany and haven't heard negative things about these Smile

    The combination 1.8t and G60 transmission fits good inside the mk1 enginebay, the only downside is that you need the quite rare Scirocco 16v 100m axles.
    Luckely I had a contact which had a pair that I could buy for a few euro's Very Happy
    Kevin20v
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    Post by Kevin20v on Thu Mar 06, 2008 3:30 am

    18-12-2007:

    Today I received my new brake system for the front! They had to come all the way from Canada Very Happy

    But in the end it was worth the wait!

    1.8 20vt Cupra MK1 Cab project - Page 2 20vt-022

    1.8 20vt Cupra MK1 Cab project - Page 2 20vt-023

    Hopefully the Sebrings will fit otherwise I'll have to find another set of nice wheels (maybe 3 piece)

    Next week the transmission is going to completely checked and i'm going to have a Quaife differential fitted! cheers


    Last edited by Kevin20v on Thu Mar 06, 2008 3:33 am; edited 1 time in total
    Kevin20v
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    Post by Kevin20v on Thu Mar 06, 2008 3:31 am

    28-01-2008:

    The engine is in! After getting the transmission back from the company that rebuilt it and fitted the Quaife diff. I couldn't do anything else but work on to car I love you

    1.8 20vt Cupra MK1 Cab project - Page 2 Itsin

    After a whole saturday of preparations and working till deep in the night, 9 o'clock sundaymorning a pal came to help me! (believe me I couldn't even be bothered and wanted to stay in bed Laughing )
    But after 5 hours the engine, transmission, axles, enginemounts, intercooler, the whole lot was in!! Shocked

    Next week I'm going to play around with loom, and see if I can find a fuelpump of a mk1 gti and just maybe it might run next sunday! Very Happy


    BTW: I painted that engine room myself Surprised Very Happy


    Last edited by Kevin20v on Thu Mar 06, 2008 3:34 am; edited 1 time in total
    Kevin20v
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    Post by Kevin20v on Thu Mar 06, 2008 3:31 am

    11-02-2008:

    Last week we did some work on the wiring! We are using the original management, but with a custom loom.

    Since I didn't want to have all the wires in the loom that we're not going to use.
    We took the complete loom apart and separated the ones we needed from the wires we didn't need!

    That meant we had to remove wires for the airco, side blinkers, outside temperature sensor, airco fan sensor, crash sensor etc. etc. etc.
    After 7 hours of work there was only half left of the loom we initially started with!

    The part of the loom that is used for the lights is going to be made into a separate loom, that way it's easier to hide and when there are problems with the one of the looms there's you only have to check half the cables.
    and ofcourse I don't have to use the 24,5 year old bad wires that were in the cab!

    Some pictures:

    1.8 20vt Cupra MK1 Cab project - Page 2 Motorkabelboom1

    1.8 20vt Cupra MK1 Cab project - Page 2 Motorkabelboom2
    That's the original VAG loom for the 1.8t Shocked (actually it's not that bad they make the loom quite clever so it's not that hard to take apart)

    1.8 20vt Cupra MK1 Cab project - Page 2 Motorkabelboom3
    The mess that we had taken out after 2 hours of cutting Rolling Eyes

    and some more pictures of the engine room itself:

    1.8 20vt Cupra MK1 Cab project - Page 2 Motor-inbouw

    1.8 20vt Cupra MK1 Cab project - Page 2 Motor-inbouw1

    1.8 20vt Cupra MK1 Cab project - Page 2 Motor-inbouw2

    1.8 20vt Cupra MK1 Cab project - Page 2 Motor-inbouw3
    I'm going to remove the pipe you see in the last picture, it's the pipe from the turbo to the intercooler.
    Going to make a custom one for it!
    Geeman
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    Post by Geeman on Thu Mar 06, 2008 3:41 am

    Makes my 16v swap seem like child's play!

    Nice one!


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    Kevin20v
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    Post by Kevin20v on Thu Mar 06, 2008 3:45 am

    @ Gee: thanks buddy!


    That's the progress untill now, wanted to be a bit further along the project now but since I had a few problems with the mk4 I couldn't afford to go on with the cab project!

    Today the Radiator was deliverd so now I can finally go on with the piping and samco hoses for the intercooler and radiator!
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    Post by Guest on Thu Mar 06, 2008 3:55 am

    thats brilliant mate! cant wait to see it finished
    dsmithmobile
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    Post by dsmithmobile on Thu Mar 06, 2008 9:46 am

    Impressive work,keep it up and post up more progress pics when you get some Very Happy

    Kevin20v
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    Post by Kevin20v on Wed Mar 12, 2008 5:01 am

    Thanks!! Very Happy

    I thought I would post some more pics up of things I'm currently running in to.
    They are just small things that need to be resolved before it can run, these are the "problems" most people don't mention but could cost quite some money before you have the right parts.

    1.8 20vt Cupra MK1 Cab project - Page 2 001
    I can't seem to find shorter bolts, the ones I'm using now are the mk1 cab ones. Maybe the 02a G60 bolts are shorter? The problem is that now I can't fit the clutchcable...

    1.8 20vt Cupra MK1 Cab project - Page 2 002
    I'm currently debating if I should weld aluminum ends on the intercooler, that way I wouldn't have to make 2 90degree turns which should help the flow a lot!
    But the aluminum ends would have to be a really sleek shape since there isn't a lot of space in the front.

    1.8 20vt Cupra MK1 Cab project - Page 2 003
    Here you can see there is just limited space in between the airintake and the intercooler, between there should come a radiator and fan (about 4inches thick) and then there's still the engine movement.
    After weeks of thinking I've found a solution for it, there is just one way to postition the radiator and fit a 11inch Spal fan that way I have 1,3 inches off clearance between the engine and radiator.

    1.8 20vt Cupra MK1 Cab project - Page 2 004
    My ecu doesn't run without the electronic gaspedal, so I'd have to reweld the top of the new gaspedal on the old one. Or make new brackets in the car... I'm still not happy with both solutions

    1.8 20vt Cupra MK1 Cab project - Page 2 005
    Since I don't have a secundairy airpump I need to remove the N112 valve and that means I also need to remove the N249 valve.
    It's not a problem, but I still need to work out the proper method and since I don't have internet in the space I work on the cab it's a hassle Laughing


    1.8 20vt Cupra MK1 Cab project - Page 2 006
    I had the transmission rebuilt and fitted with new bolts, but then I found that the custom rear transmission mount needs to have longer bolts then stock... Mad (put it on backwards temporarily till I find the right bolt)

    1.8 20vt Cupra MK1 Cab project - Page 2 007
    These are the ones, they just need to be 1cm longer so that I fit a lugnut on the other side...
    Kevin20v
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    Post by Kevin20v on Sun Mar 16, 2008 4:43 pm

    14-03-08:

    The downpipe I ordered from Quantum Performance Engineering (uk) arrived!

    1.8 20vt Cupra MK1 Cab project - Page 2 Downpipe
    I'm loving it!
    1.8 20vt Cupra MK1 Cab project - Page 2 Downpipe1

    16-03-08:


    I've again done a lot of work over the weekend!


    Since I'm going to paint the car myself I had to sand down the rolled paint that was on the car...
    Still have lots of sanding to do, but I don't mind =)
    1.8 20vt Cupra MK1 Cab project - Page 2 Schuren


    and I did some more work on the enginebay, cleaned it out a bit, removed the vacuumsystem, rerouted the secundairy waterpump and lines, removed the Seat intercooler piping etc. etc.

    1.8 20vt Cupra MK1 Cab project - Page 2 Motor-inbouw4

    1.8 20vt Cupra MK1 Cab project - Page 2 Motor-inbouw5


    Last edited by Kevin20v on Tue Mar 18, 2008 6:56 am; edited 1 time in total
    Bluedub
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    Post by Bluedub on Sun Mar 16, 2008 5:27 pm

    WOW!!!

    That looks great dude!
    It makes what I've been doing with mine look like a very poor attempt!

    thumbs up Keep up the good work - and keep the pics coming! thumbs up
    fleet.arosa
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    Post by fleet.arosa on Sun Mar 16, 2008 6:14 pm

    thats amazing dude.
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    Post by Guest on Mon Mar 17, 2008 2:40 am

    awesome
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    Post by Jezz on Mon Mar 17, 2008 2:41 am

    coming on nicely kevin Cool


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    Post by Guest on Mon Mar 17, 2008 4:49 am

    very nice Very Happy
    sarah
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    Post by sarah on Mon Mar 17, 2008 8:00 am

    gonna look hot when it's finished kevin Cool
    MkIISimon
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    Post by MkIISimon on Mon Mar 17, 2008 8:52 am

    That looks brilliant mate, keep up the top work.

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