1985 MK2 Golf VR6 Turbo

[vdubnutz]

"Reihnenmotor sechs mit turbolader!" as my facebook album describes it ;D

I've had this car for about 10 years now, and in that time it's progressed from a stock 8v Kjet to an 8v Turbo(Turbo technics!), to a 2.0 16v, to a VR6, to going the whole hog and bolting a f*ck off great big turbo to the old 2.8 AAA engine.

Here's some pics of her last summer in track form:

[vdubnutz]

So as this is such an awesome forum, I thought I ought to record my build here too

My plan is to run this project in two stages, the first stage being all the gubbins bolted onto the stock block, with a few modifications... And around 350-380bhp. Phase 2 will see the block rebuilt with Wossner low comp pistons, H-beam rods, capacity increase, new mains, shells etc and pushing it up to around 450bhp! Phase 2 won't happen for a while though, as I'm pretty confident it's a strong block and I've seen way more power put through a standard bottom end. Cross fingers!

So work commenced last weekend, as I was on a roll..





Inlet mani off and a few ancillaries..



Back to a bare head and block..



Came apart amazingly well. The only casualty was a snapped exhaust stud. Not bad for a lump that hasn't been apart like this since new





Offered the exhaust manifold up with the 'gate just to get a cheeky idea! The SPA manifold works a lot better than the ATP one, so my spare ATP will be for sale



New Holset HX35 arrived from Ireland!



My eejit brother.. to give you an idea of scale. This is a big turbo, but the compressor map is similar to a garrett GT35. The fact that it's journal bearing shouldn't make too much difference with the amount of exhaust gas the 6-pot will put past the turbine





Clocked the compressor housing and the shaft housing so it sits right, and the oil feed is in the right place.



Dirty curse word!



Front guide looks like it's been replaced... as it's in one piece! First one I've seen like it



Rear guide has seen better days, so that'll be whipped off and replaced when the gearbox is done(can't get it out without removing the lower chain covers which equals box off)



Rusty rusty waterways will be cleaned and treated when the head is back on.



Head studs offered up. Need to clean the threads up a bit with a tap

[vdubnutz]

The plan for this week is:

* Drop the turbo hotside in to get the internal 'gate welded up
* Order a shedload of oil/fuel fittings so I can mount and plumb the turbo up
* Clean and re-fit the head with the decompression plate
* Mount the turbo
* Get an exhaust flange knocked up and fab the first section of the downpipe
* Mount up the short-runner and intercooler + order pipework.
* Remove the front end to make fitting of the above nice and easy!

Plenty to do then!

[vdubnutz]

Some goodies... DG Autotech SRI with speedflow fittings, Helix Organic Clutch, Begi adjustable FPR, New oil filter, Tial 38mm wastegate(in box) - the list goes on. Need to pop to kiddy this week to pick up my new box complete with Quaife LSD!

[10mpg]

YUM!

[broomaround]

Love the little pigion hole on the drivers side!

[waveman1500]

Wow, that is a light car with a big beastly engine in the front! Are you sure this is a track car and not a drag car?! ;D

The plans sound impressive.

[vdubnutz]

Aug 20, 2012 3:11:01 GMT waveman1500 said:

Wow, that is a light car with a big beastly engine in the front! Are you sure this is a track car and not a drag car?! ;D

The plans sound impressive.

Actually I will be dragging it to start with... ;D

[vdubnutz]

Been doing little bits and bobs on her today... The head and chain covers are all cleaned up, and I've had the internal gate welded shut on the turbo hot-side.



Tomorrow I need to fit the head, and the exhaust manifold and turbo! Plus i must remember to order all the hydraulic fittings!

[vdubnutz]

Aug 20, 2012 8:08:06 GMT vdubnutz said:

Aug 20, 2012 3:11:01 GMT waveman1500 said:

Wow, that is a light car with a big beastly engine in the front! Are you sure this is a track car and not a drag car?! ;D

The plans sound impressive.

Actually I will be dragging it to start with... ;D

I see you are from Adelaide! I used to live there

[waveman1500]

Aug 20, 2012 21:54:51 GMT vdubnutz said:

I see you are from Adelaide! I used to live there

Yes indeed, the land of Farmer's Union Iced Coffee and Cooper's Pale Ale.

[vdubnutz]

Bit of progress today! Spent another morning running around finding bits and bobs... finally found some water fittings for the turbo, and found a place that will laser cut me a flange for the turbo

In the afternoon I was mostly installing the head studs with my mate Rhys assisting, and installing the gasket. The head is mounted up temporarily for mockup purposes, but will be cleaned up and finally installed tomorrow. Here's a few pics for the picture diary!

Shiny gasket half!!



Head plonked on..



Ummmm thats a bit tight... in fact so much, it touches the UJ for the steering column



Bit of a wiggle of the head and the manifold and it's on!





Started to mockup the boost pipes...



Chargecooler needs the pipes cut and rewelded but you get the idea...





;D

[The Transplanter]

Once you have had a VRT you wont want anything else

If I were you, at this point and whilst your head is off I would add a gasket spacer and some ARP head bolts.

I know you said you were going to throw some low comps in it later, but with a good map you can get your goals on std internals, the VR bottom end is remarkably strong and responds well to some dirty air

I have been running my VRT for around 5/6 years now and its had some abuse and the standard bottom end is still intact

Keep the updates coming

[vdubnutz]

Already with you mate! ARP studs, decompression plate, and split VW Sharan(AMY engine) headgasket!



;D ;D ;D

[vdubnutz]

Although just noticed that piccy doesn't show the decomp plate and top of the gasket

Ok so no progress today, but yesterday I got a few bits done... Finished mocking up the intake side of the setup, which should suffice for running it in, but will be replaced with either stainless or aluminium mandrel bent tube



So to finish off the mocking up, I thought I'd check the rad fits with the chargecooler rad off the front... it does, but only just. I need to remove one of the bars from the slam panel, but thats only a little minor surgery! Also just need to relocate the oil cooler to the driver side, which is again no big deal.



Happy that it all lines up, and with a list as long as yer arm for additional pipework I need... I then tore it apart! Dropped the turbo with the laser cutters today too for them to knock up the exhaust flange, which should be ready tomorrow

So to be a little productive I thought I'd install the tee pieces into the oil filter housing too, and the micro filter for the turbo feed. I need to order the oil pressure sender which will sit in the other side for the gauge too.



Tomorrow I'm hoping to finish cleaning up the head, lap the valves, reinstall, and finally mount up the exhaust and intake manifold! Watch this space...

[vdubnutz]

Ok, so there's been a little progress over the last couple of days! The weather was pretty reasonable on Friday so I made hay and got under the car to whip the sump off. Gave the sump a damn good clean up ready to weld in the oil return fitting, and while I was digging in there, I thought I'd fit the ARP con-rod bolts Only problem was that I found I was 4 short! So rods 1 and 6 are currently running standard bolts until I can find them... Also, just to be safe I thought I'd fit a new oil pump...



Fitted the sump back loosely into place to protect the bottom end... then moved indoors, just in time for the rain to come down! So I spent some time cleaning up the spare cylinder head so it looked like this



This was off a previous engine of mine, and has already been skimmed and had the valve guides done. Happy days! Only thing was, I couldnt remember if I'd lapped the valves in before... So for the sake of some sticks of wood with suckers and some grinding compound, I dropped each valve and re-lapped them





Nicely seated and theres no wibbly wobbly guides. Happy Days!

Once I'd done that I moved back outdoors and plonked the head on. Tightened the studs down the 30nm which is the first torque setting, and then started bolting some shiny bits to it for giggles!





Rocker cover and fuel rail only on there loosely as I've not reinstalled the cams yet, but stay tuned for tomorrows edition! Hopefully, I can get the cams back in, engine timed, and some other ancillaries bolted up

[miniallsort]

nice motor love mk2

[lemmingzappa]

Bookmarked.

[mattfletcher]

love it, what management do you use?

[vdubnutz]

Been off this forum for a while now but things have progressed somewhat! I'll post up my progress soon