1984 Mk1 20vT Golf Berg Cup Racer - Project Berg Stormer

[Amit]

Hey guys.

Thought I would introduce you to my latest project.



I have always wanted a berg cup car, and just happened across this car on FB when it came up for sale.

I practically bit Jamies arm off and collected the car last weekend. Its looks right at home in my garage


Its flipping awesome.

packing heat in the form of a 20v conversion



With credit to Jamie, he has built a great track car, but there is plenty of scope for improvement to make the car mine.

My plans are to turn it into a show/track car.

That means new paint job and graphics, new interior, and some trick performance upgrades.

Watch this space for some exciting upgrades.

Just to give you a flavor,
watch out for a sequential dog box,
full custom re wire,
50's bomber inspired interior,
custom wheels and much more,
Carbon panels,
power upgrades and much more.

Anyone interested in sponsoring the build, get in touch

Amit

[Amit]

The plan for this car was always to just do a quick tidy up and enjoy it while we gather parts for a major rebuild.

Well my trusty side kick paul came round and got itchy fingers so the car is now in bits

When we bought the car, we new the first job was going to be to sort out wiring. Jamie was let down by his auto electrician so he never got passed the get it in and working stage.

Our eventual plan is to replace all the wiring with a proper motorsport loom and fuse box, but in the mean time, paul decided to have a little tidy and get all the gauges wired up so out came the dash.



He then got carried away with the wire cutters lol



Then decided the best way to get access so install the senders was to remove half the front of the car!. While it was bits, we started looking at relocating the air filter and building an air box for it.



While the front was in bits, Paul riveted the grille in place rather than glue which was coming off



and added some more obvious indicators. The original ones were a little to subtle for london. We also replaced the IC for taller, but narrower IC to give a little more space for better routing of the charge pipes




Then looking through my stash, we found an ally mk1 rad that fits perfectly!



While all that was going on,

This arrived. Is there anything you cant do with cable ties?



mmm dog cogs


and I started working on this. Can anyone guess what it is?

[baggabones]

Hell yeah!!....bookmarked

[penski]

Good stuff.

Will look awesome once it's all sorted and the bonnet's closed

*n

[Xenocide]

May 14, 2014 10:11:30 GMT Amit said:

This arrived. Is there anything you cant do with cable ties?

Make a girl pregnant.

May 14, 2014 10:11:30 GMT Amit said:

and I started working on this. Can anyone guess what it is?

Sequential shift cam?

[yorkebar]

Wow, that's a top notch car!

[TS]

Nice as the car is, your garage is even more impressive.

[Finlay]

awsome !!!!!!!!!

[Amit]

So the wiring tidy up continues

When the new motor was fitted, the original loom was transferred as is. This meant LOTS of excess cable tucked around the engine bay.

Paul got to work pulling it all out, and cutting it to length



Properly terminating the ends with solder and crimps, and protecting with heat shrink



Then covering the lot with nylon overbraid



While the charge system was in bits, it would be rude not give it some love so we went from this



to this



Paul also knocked up a little bracket to support the rad against the intercooler as this was free floating previously,only held in place by the water pipes


While playing with the car, we also made some important decisions. This car is too good to mess with much further than a tidy up, and it would be shame to take it off the road before we got to have some fun in it, so its staying as is except minor tweaks and will act as a test bed.

This now means I am on the hunt for a new rolling shell to build a berg car from scratch with seam welded shell, weld in cage and lots of carbon!

Watch this space

Amit

[Amit]

Update time.

Continuing the improvements on the current car, we decided to tackle the way the fuel lines are routed.

We didnt like that the fuel lines were free floating and secured by cable ties.


So we modified some billet hose separators so they could be panel mounted. Simply be counter sinking the clamp hole



These were then used to secure the fuel lines to the chassis





The next area to tackle was the gear shifter and the shifter tower. The Current shifter was just an OEM O2A shifter and it was a floppy mess with a throw about a mile and a half between gears. Not cutting the mustard in a precision sports car! Also the platform the shifter sits on was a thin folded steel secured by self tappers so more flop there.







So we whipped that off and made a template for a base plate out of poster board. Awesome stuff this for prototyping and pattern making



The transferred the pattern to 5mm Ally sheet and cut it out



We then made a new platform from a folded ally



Added a brace, and then Ally mig welded the lot together for strength. As this is the test bed car, we arent using our best fab skills to make and tig welded skeletal frames, just quick dirty and functional. The clever stuff we will save for car number 2.



The new tower was then fixed to the car using rivnuts around the base of the frame, and the new CROWN put in place for a test fit



The J turn device was then mounted to the tower We had to spin the master cyclinder upside down to relax the brake lines which were tight and twisted before. A quick google revealed that this should be ok, but may cause problems during bleeding time if air gets in the system. It will be fine for now until we can make some new brake lines.



Next we tackled the hardest part of the build. Installing and setting up the CAE shifter. What a curse word!! the instructions are shocking. The cables and ball sockets are all different lengths meaning about a 100 different combinations on how they can go together. We spent a good couple hours installing them, trying it, adjusting all sorts, scratching our heads, taking them out again and trying a different combo, repeat about 10 times, and we eventually got it all in and working. Sweet!!!



The gear change is now magic except for a little bit of slop in the old worn shift tower in the gearbox. In the next installment, we will be looking at uprating that with some needle bearings and bushes for a super precise gear change.



In the mean time, we have also located a 1979 mk1 rolling shell which will form the basis of the new car. There maybe a few weeks till the next installment while we reconfigure the garage and Paul needs to finish his ex Turbo Technics 300bhp BAM corrado and get it sold to make space on the other side of the garage.

Look forward to your comments.
Amit

[Amit]

When fitting the CAE shifter, we broke the battery isolator switch, so a prime excuse for a mini upgrade.

New FIA approved switch fitted in the side of the tower for easy reach



Remote release cable fitted





Then it was time to get her looking pretty for stoner park. The front air dam was all stoned chipped so we decided to repaint that. We pulled out the soda blaster and blasted it clean to get a good clean surface to paint.





All freshly painted



and installed back on the car.



Then it was time for a quick wash before jetting off to stoner park.

Unfortunately, on the way to stoner park, we discovered a couple more jobs that need doing. There appears to be a problem with the clutch cylinders. When in traffic, with the clutch pressed for a long time, the slave cylinder seams to drain back into the resivior releasing the clutch! So looks like a good time to upgrade the clutch release system. New cylinders and lines all round.

Also it gets very HOT in the cabin so need to look at some ventilation.

[Amit]

No mk1 golf fans on retro rides?

[Adey]

Thing looks awesome buddy, keep up the good work. Where did you buy the hose clamps? I could do with the same to hold my fuel lines in place

[Amit]

hose clamps are from ebay. They are just hose seperators available for braided fuel hose

[Amit]

Time for another update.

So last time we went out in the car, we found a problem with the clutch where if we kept our foot on the pedal, the clutch would slowly engage, even with the pedal pressed.

We started to dig and think we found the issue.


Exactly what you want to find the day before heading to Players show!

A quick scramble round london to find a new slave cylinder and we were back in the game



Next day, we set off nice an early for players. Weathers not looking great, but we think we will be fine.

Boy were we wrong. About 30 mins out, we are hit by an Epic thunder storm. In a car with only 1 wiper and no demister, this is a problem!
Visibility is down to about 2m. I am now following the tail lights of the car in front at 20mph! I am sure I was over taken by noahs ark at one point.



First thing on the agenda when we get back lol!

The other issue is the car if full of holes. In the floors, in the doors, in the perspex windows. The car is filling up with water fast!

Well we eventually make it to the players show, carrying about a ton of water. Paul looks happy because all his rollies are soaked.



luckily, the sun eventually comes out and it turns out to be a great show. We meet some great people, and the car seems to go down well.



Mean while back home, some more exciting parts turn up for car two, and we sign up some exciting sponsors. Watch this space

Who can guess what this is


Amit

[Adey]

Air jack?

[Amit]

yep

[penski]

Great work... Bonnet's still open though

*n

[g111mds]

Absolutely love that!!!!

[breadvan]

wow some serious work has gone into that