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Mk2 2.0 16v Gti Project

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1.3M views 117 replies 35 participants last post by  vr6boy  
#1 · (Edited by Moderator)
Well about 11/2 years ago I bought a MK2 8v gti drove it for a few weeks and then parked it up for a while,
But I always wanted a real nice MK2 16v so I am building it exactley the way I want it LOL

So to cut a long story short Its getting treated to some top notch parts in the coming months
I accquired a Seat toledo that had been treated to a BRM 180 bhp conversion the car was owned by Seat UK at the start of its life,
It was used as a Demo car for the 180 BRM conversion by Seat and BRM and I have a mag feature of this car from way back when they started doing them

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The direction I am planning to go with this project is OEM+

It has a 9a bottom end and 9a head and schrick cams I plan to scrap the k jet management and run the Valver
And widetrack with a 5 x 100 pcd from a VR6 golf and to bring it upto a 90 spec car wiring fusebox and Mk3 VR6 ABS

What I have for it already

Golf Rallye grill kit
Electric recaro interior from an Edition One Golf 16V
Brand new front and rear bumpers genuine
Brand new golf G60 wings and wing liners
Brand new G60 arch kit with sill extensions (missing door trims)
Brand new genuine battery tray repair panel
Brand new full set of OEM green tinted glass
Brand new VR6 hard fuel lines
Power heated mirrors
Power windows
H&R monotube coilovers
H&R Mk3 VR6 25mm antiroll bars front and rear
Eibach front upper strut brace
ARP head main and rod stud kit
Schrick sump and windage tray
Schrick adjustable cam pulley
Schrick 260 cams and followers
Schrick valves and retainers with HD valve springs
Vibratechnics fast road mounts x 3
Vibratechnics front wb rear bush and rear axle bushes
034 motorsport stage 1c 16v management package
50hp shot of nitrous and take it from there
BBM front engine breather plate
BBM Mk3/4 style FPR holder and 4 bar reg
BBM Mk2 16v efi fuel rail kit
255cc's injectors designed for multi valve heads (standard ABF size)
Digifant injector seats
Black diamond fast road clutch kit
50 mm inlet manifold polished
Black diamond 288mm front and standard mk3 rear crossdrilled and grooved discs with predator pads
Mk3 VR6 ABS will be retro fitted
Full powerflex bushes including exhaust rubber mounts (figure 8 shape)
Milltek 4 branch stainless steel manifold
Milltek stainless steel exhaust
Metal gear selector rods with metal ends
Trimsport powdercoated black rocker cover
New genuine Oil pump, Water pump, ABF Metal head gasket, Rings, front and rear crankshaft seals,
1.8T crank and rod shells and genuine water flanges and full gasket set
Valve stem oilseals, Timing chain, Belt and tensioner and Lower temp thermostat and fan switch
Not sure what wheels now but something 8x16 all round maybe porsche design 90's
And a set of BBS RS 16" porsche fitment 8" x 16" for now
New set of German style plates
Beetle rocker cover breather

There is more but just cant think what else i have here packed away
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The engine will be getting a full rebuild over the next few weeks/months
And the gearbox will be sent in to check the quaife diff bearings syncros and just a general check up
And fitting a VR6 fuel tank with a sytec/walbro upgraded fuel pump to increase pressure
Subframe, Rear axle, Wishbones and Front cross member will be getting bead blasted and powdercoated

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And this is a photochopped image of how it will all look at the end Fingers crossed

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*** list updated 30/1/2009***
 
D
#4 ·
that should be another gem of yours.....
 
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M
#5 ·
Busy year for projects Aaron.

Love the parts list, another cracking car from the Aaron Stables on the way methinks
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(worth putting up some pics on the BRM ported head as it looks the dogs - real quality work done on it)
 
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#6 · (Edited by Moderator)
QUOTE (WESLEY H @ Jan 15 2009, 11:50 AM) <{POST_SNAPBACK}>Some list of parts there, nice project

Hopefully it turns out that way
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QUOTE (conord @ Jan 15 2009, 11:54 AM) <{POST_SNAPBACK}>
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as if you don't have enough to be gettin on with.

LOL yeah I have to be kept busy or I will loose interest

QUOTE (draycottgirlz @ Jan 15 2009, 11:58 AM) <{POST_SNAPBACK}>that should be another gem of yours.....

Thats things all going according to plan of course
 
#7 · (Edited by Moderator)
QUOTE (Mike @ Jan 15 2009, 12:01 PM) <{POST_SNAPBACK}>Busy year for projects Aaron.

Love the parts list, another cracking car from the Aaron Stables on the way methinks
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(worth putting up some pics on the BRM ported head as it looks the dogs - real quality work done on it)

I dont have any pics of the porting Mike, Geo should be able to stick one or two up if he gets the chance
But it is top quality alright
I have been collecting bits since the start of 2006 for this one
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#17 · (Edited by Moderator)
Apologies for the lack of updates
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The MK2 is just a rolling shell at the moment

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Them pics were taken late last year plans are to get a new battery tray repair panel fitted and seam weld all joins in the engine bay there is a bit of surface rust starting to make its way in around the bay,
As soon as I have the car painted I can start to reassemble the MK2 with top quality bits
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#19 · (Edited by Moderator)
I just got a more relastic price from a company painting the rolling shell of this mk2 so it will be going ahead over the coming months

Its going to stay the same colour and getting the top of the front panel and the rear of the mirrors painted the same colour as the rest of the car

Also thinking about a set of Borbet A in 7.5 x 16 for the front and 9.0 x 16 for the rear

I will be looking for an Edition one carpet, parcel shelf, and supports they come in Blue and will look really well with the Edition one blue Recaro's
 
#21 · (Edited by Moderator)
QUOTE (Micksheenb @ Mar 22 2009, 10:22 PM) <{POST_SNAPBACK}>Your fond of quality parts anyway..
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LOL yeah I dont do cheap I prefer to do it right the first time

I have stripped the head down, I wanted to check valve guides and stem seals the guides are like brand new the seals have seen bettter days though
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@ Mike I will take a pic or two just for you while its stripped it needs a bit of a clean
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*** post edited 21/4/2009***

The head has been skimmed at lunch time today, The worst part of the job was making brackets up because its an angled head

I dont think I will have the time tomorrow to lap the valves in and reassemble the head but it should be done before the weekend

I will be stripping the rest of the engine in Geo's on friday and going to bring it back down home and prep the block and hopefully get a coat or two of engine block paint onto it

Then its time for a full rebuild and get the gearbox looked over and make sure everything is 100%. Its finally coming together now
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Pics to follow

***post edited 05/5/2009***

I have decided to get the block skimmed over the next few days due to a small amount of pitting on the block face

From being ran with no coolant it could lead to head gasket failure while its all apart it makes sense to get it sorted out now than have to do it later on

***post edited 15/5/2009***

The bare block has been dropped off with Westward engineering in Enfield this afternoon getting the face of the block skimmed should be ready tuesday or wednseday

And going to polish the crank up while I am waiting on the block and have it ready to drop into place with 1.8T shells and thrust washers

*** Post edited 19/5/2009***

I collected the 9A Block from Westward engineering this morning so this weekend will be prepping the block for a couple of coats of engine block paint
And probably going to start rebuilding it then next week hopefully

Pics to follow
 
#22 · (Edited by Moderator)
Ok I am just uploading pics to photobucket now,

I spent a few hours today with a rotary wire brush attached to a drill and went at the block
and this is how it looked after charging the battery of the cordless drill twice and it had been washed both inside and out with petrol
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Its only the first coat of rust sealer, Basically its an undercoat or primer if you will

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It will need sanding down in a few places like where the oil filter housing, front engine breather plate, and water pump mounts up to the block atleast its treated now I will leave it for a day or two before applying another 2 coats of engine block paint and assembley of the engine can commence over the next week or two
 
M
#23 ·
Nice work Aaron. Don't forget pics of the head.
 
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#24 ·
Mike I was too busy running around getting stuff sorted out and left it behind in Dublin

But pics will be up next week
 
M
#25 ·
QUOTE (vr6boy @ May 23 2009, 08:29 PM) <{POST_SNAPBACK}>Mike I was too busy running around getting stuff sorted out and left it behind in Dublin

But pics will be up next week

No bother Aaron, whenever you get a chance before it's all put back together.
 
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#26 ·
I had a free hour and a half today so I made a start on the motor

Pistons, Geniune rings and rods are now in place so the engine build has offically started now
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@ Mike I didnt remember my camera this morning but I will bring it tomorrow just for a few pics for you
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The bottom end should be done just after lunch time tomorrow

Pics to follow
 
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