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Author Topic: GTI version 2.0  (Read 421 times)

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Smokestack

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GTI version 2.0
« on: February 15, 2011, 03:41:27 PM »

To this day I am still kicking myself for getting rid of my old 86 GTI Buffalo Bill. When I decided that I wanted to replace my GLI with something else instead of fixing it I had a weird notion in the back of my head that I would pick up another mk2 GTI. Thankfully, before I bought a mk3 or an old audi, Lovesthedubs (Dustin) decided he wanted to get rid of his 92 GTI project car and I snagged it up. Being an almost 20 year old car it's a bit rough, but not nearly as bad as the GLI it replaces. I can get patch panels to fix the GTI where as with the GLI I was looking at quartering another jetta in order to do it right. For right now I'm focusing on the mechanicals of the car and next year I'll be doing body work and painting (something not red).

To start off with I'm going to put in the ABA that Dustin sourced. It's missing a few pieces (MAF and ignition coil) and Dustin was in the middle of changing gaskets when life called him away from this project. As a result I'm picking up the few seals he didn't replace, a head stud kit to finish out the head gasket change, try to source the MAF and coil at the junkyards, and a general refreshing of the rest of the drivetrain. Once it's in I'm going to get all mad scientist on it and wire it up. I'm even thinking I'm going to go for the challenge of making it smog compliant while I'm at it. It could even make my life easier down the road if El Paso starts smogging again, I move somewhere that smogs cars, or I sell the car to someone in a state like California that has smog requirements. I'll just have to see if I have the patience for it when I do the wiring.

Once the drivetrain is done I'll be moving onto the suspension and brakes. Once again I'll be retrofitting ABS into a mk2. Doing that and retrofitting seat heaters into my Recaros were my favorite two mods on the GLI. Those two mods just made using the GLI as a daily driver oh so nice, and I'm looking to recapture that aspect in the GTI. While I'm working on the brakes the rest of the suspension is getting a complete refresh with new bushings(R32 +OE rubber), strut bearings(VR), tierod ends, balljoints, and a set of FK coilovers like what I had on Buffalo Bill. After that I'll be tidying things up (new shifter bushings) and probably move over the TT exhaust from the GLI since I'm not a fan of what's currently on there. If I get real bored I have a set of projector lenses that I've been wanting to retrofit into some headlights, but we'll see. The overall goal of this car is to make an easy to drive and comfortable daily driver. Hopefully it'll be reliable too.  ;D

And because every thread is worthless without pictures, here's some.


Here's the new car on the trailer.

Some day light shots.




All the wiring going back into the car.


And just for a reference on what I do to GTI's...
This...


...to this.
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greggearhead

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Re: GTI version 2.0
« Reply #1 on: February 15, 2011, 04:41:23 PM »

Nice- can't wait to see what you do with this one Chris.
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Re: GTI version 2.0
« Reply #2 on: February 15, 2011, 04:44:16 PM »

Going to definently follow this thread. Can't wait to do this myself one day.
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Re: GTI version 2.0
« Reply #3 on: February 15, 2011, 06:30:08 PM »

Hey man I looked for the Maf and ignition coil and now that I think of it i dont know that I ever got it out of the donor. I'll try to bring that side skirt by this week but work is crazy busy and it may be saturday before i can get to it.

If you find a multimeter in the hatch let me know cause i think i may have left it in there
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Smokestack

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Re: GTI version 2.0
« Reply #4 on: February 15, 2011, 08:43:52 PM »

Hey man I looked for the Maf and ignition coil and now that I think of it i dont know that I ever got it out of the donor. I'll try to bring that side skirt by this week but work is crazy busy and it may be saturday before i can get to it.

If you find a multimeter in the hatch let me know cause i think i may have left it in there

That's fine. Just hoping that I didn't have to fight all the people at UPAP for them or pay Best Foreign's stupid prices. I understand how work can be so Saturday's fine. I did find the multimeter so that will be there waiting for you.
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Barry

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Re: GTI version 2.0
« Reply #5 on: February 16, 2011, 06:37:26 AM »

Dont smog it Chris...


The car is 20 years old... you wont have to e test it if you have historic tags on it
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Smokestack

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Re: GTI version 2.0
« Reply #6 on: February 16, 2011, 08:36:23 AM »

Dont smog it Chris...


The car is 20 years old... you wont have to e test it if you have historic tags on it

Depends on the state. In Colorado the car now has to be a 1975 or older for classic tags. And like I said, it's the challenge of getting the system to work. Saving a tree is just a byproduct. In the end it should look like a clean, OEM looking bay. If it doesn't then Bambi can suck on some smog with the rest of us.
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Barry

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Re: GTI version 2.0
« Reply #7 on: February 16, 2011, 09:15:15 AM »

Eh... there are plenty of Prius' out there to save the trees....


I remember taking a Mustang in for an e test... no smog equipment... just cat's and a hose. Ran octane booster for the e test, and was good to go!
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Smokestack

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Re: GTI version 2.0
« Reply #8 on: February 16, 2011, 04:39:18 PM »

So it looks like mk3 ABA coils are unicorns because I can't find any in the junkyards. Does anyone have one laying around that they'd sell me? I'd rather not spend $60 on a new one.
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greggearhead

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Re: GTI version 2.0
« Reply #9 on: February 17, 2011, 02:19:51 PM »

Don't think so, but what do they look like vs. a regular coil?  I've got several laying around...
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Smokestack

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Re: GTI version 2.0
« Reply #10 on: February 17, 2011, 02:30:07 PM »

They're square. The big thing is they have the ignitor built in. If I had the ignitor I could just run a standard coil.
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Smokestack

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Re: GTI version 2.0
« Reply #11 on: March 06, 2011, 04:49:00 PM »

Since I don't feel like being a good student and working on my calc homework I'm going to update this thread. I finally got the parts I was missing too.

First and foremost, I hate the color red. Too many times I've shot myself in the foot because I bought something other than the red car and ended up with even more of a money pit. Obviously I sucked it up this time and plan to paint the car another color as soon as I have the time and money. Since it's a serious pain to paint an engine bay with the engine and harness in it I took the time to spray a on the cheap 2 stage black. Black goes good with just about any color choice I may have for the car in the future so I shouldn't have to revisit it. Since it's not a show car I'm not going to go through the hassle of deleting and shaving stuff. I had a lot of clear left over from a past project and I picked up some of that Duplicolor paint in a quart can for ~$20. Unfortunately I had a seal fail in my gun that clogged the sprayer. By the time I fixed it I had wasted a lot of black, but still had enough to coat the bay and fenderwells. I'm curious to see how well it holds up, but for $20 I can't really complain. I would have spent at least that trying to spray bomb it.





And I got the fender wells too.


Finished resealing the engine and installed new belts. I didn't feel like pulling and paying for a MK3 power steering line in the junkyard so I got creative.

There's two main differences between the MK2 and MK3 pump. The first is they both use different fittings for the pressure hose on the pump. The second is the offset on the pulley flange is different (MK3 sticks out more). Most people opt to change to the MK3 steering line, but I like swapping flanges better. You have more room to work and it's generally less greasy.

I used 3 bolts and 3 nuts that were too small for them to thread into to make a puller and pulled the pump flange off of the MK3 pump.You do this to pull off both flanges.


On the pump shaft there's threads in the center of it. To install the flange back onto the pump you thread a bolt (or all-thread with a nut) into it and tighten it to press the flange back on. If you've ever had to change out a power steering pump on a GM car or truck it's the same process.

There's no stop on the pump so you have to be careful not to run it in too much. If so , you can use the "puller" to pull it back out. Easiest way to line it up is to install the pump with the pulley on the flange and tighten it until the pump pulley lines up with the waterpump pulley.



The engine is in. I've started work on the electrical now. Like I said earlier I'm going to try and keep it smog compliant. Really it's not too hard. Smog equipment on the car is the cat, second O2 sensor, EVAP purge valve, charcoal canister, canister valve (not sure of the technical name, but it's on the bottom of the charcoal canister and closes the drain for leak tests), leakdown pump, and crankcase to intake breather valve. Now I'm OCD about cells, so I had a choice of paying $100 for a race file to turn off the smog checks, or spend less than $10 on parts and a little bit of time hooking up the smog parts. Since the smog parts don't really take anything away, and I don't have something like a cam to take advantage of a chip I'm going that route for now. Whether or not it stays depends on the direction I take the car in the future.


Next up is to finish installing the parts I ordered, install the suspension, plumb the radiator hoses and put the AC components in. Since I'm running AC I have to use a G60 radiator. The G60 and the ABA upper radiator hoses are completely different so I have to get creative. The exhaust might have to wait for a different weekend and I know I won't be able to get to the ABS for a bit.
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greggearhead

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Re: GTI version 2.0
« Reply #12 on: March 06, 2011, 04:56:24 PM »

Nice work!
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Re: GTI version 2.0
« Reply #13 on: March 09, 2011, 01:57:26 PM »

looks good man!!!!
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Smokestack

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Re: GTI version 2.0
« Reply #14 on: March 09, 2011, 08:54:30 PM »

Thanks! Been wrapping up the wiring and other small stuff. Also I scavenged the Autotech exhaust off of my old mkv and am in the process of putting it in. Tomorrow I should be finishing that up, installing the mk3 evaporator and a new heater core, doing the suspension, filling the fluids and starting it hopefully.
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Lovesthedubs

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Re: GTI version 2.0
« Reply #15 on: March 10, 2011, 07:27:40 PM »

damn man nice.... I'll get that skirt to you this weekend. its been crazy at work
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Re: GTI version 2.0
« Reply #16 on: March 11, 2011, 12:06:13 PM »

Nice work dude. I may need to get inthe garage soon myself and take care of a few things. :)
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Smokestack

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Re: GTI version 2.0
« Reply #17 on: March 11, 2011, 08:18:55 PM »

Get on it Carlos!  That poor car's attention starved!

Little bit of an update. Put fluids in this morning at ~2am and gave it a half hearted attempt at starting it. No bueno. Probably something stupid that I'll find when I can work on it next. Other things of note; I finished the exhaust and installed it. Really curious to see how the Magnaflow that was on my MKV sounds on a naturally aspirated, non-direct injected motor. It's also a 3" from the tunnel back so it could be interesting. Also tore the dash apart and installed the MKIII evaporator and the new heater core I had just installed and subsequently pulled out of the GLI. Put on the 10.1" brakes with the ABS harmonic rings from the GLI along with the suspension bits. Also found out that the brake MC was bad on the GTI when I tried to bleed it and replaced that. The things left to do is to finish up the interior wiring (hook up the VSS to the MKIII cluster, install the OBDII port, etc), put the front end body pieces back on, set it back down on its wheels, work through the gremlins preventing it from being driven, and get it legal to drive on public roads. Anyways, Pictures!

Heater box with all of the stupid clips holding it together.


Box disassembled.


New evaporator placed.



Reassembled (ended up with an extra clip that I couldn't find a home for. Happens every time I tear one of these apart.)


Exhaust (the muffler is slightly cocked, but I'll fix that after I decide if the fitment of the rest of the piping is good)



...and how I left it this morning.



Eventually I'm going to go back and do a better job on the radiator hoses. Since this was the initial design I used what was at hand. Now that it's mocked up I can plan on some better materials. And yes, I'm using an airbox instead of running a cone filter for now. I'm trying to go for an OE look initially.
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greggearhead

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Re: GTI version 2.0
« Reply #18 on: March 12, 2011, 08:41:06 AM »

Awesome progress.  Don't know how you accomplish so much so quickly. 

A well modded airbox flows as much as a cone filter, so don't let it worry you. 

I don't like the harsh sound of a magnaflow on an NA motor.  I had one on the Dasher, added a resonator to knock it down a bit, and still didn't like it.  For NA motors, my fav muffler is a Thrush or Dynomax Super Turbo. 
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scurvy_bandit

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Re: GTI version 2.0
« Reply #19 on: March 12, 2011, 08:57:27 AM »

I have a flowmaster copy on the caddy right now, like how that sounds. 

Chris if you end up not liking the 3" magnaflow muffler, let me know. I may be interested in picking it up when I get back. 

I looked at your progress yesterday, simply amazing work. I'll have to see what it looks like tonight on the wireless!! 
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Re: GTI version 2.0
« Reply #20 on: March 12, 2011, 09:12:46 AM »

Oh - I was thinking Magnaflow - not flowmaster.  I used a Flowmaster copy on the Panel Van.  They are a bit harsh/blatty, but not awful.  With a resonator to take the edge off, it might be just fine.  Exhaust note is really subjective - what one person likes, another hates, and vice versa. 
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Re: GTI version 2.0
« Reply #21 on: March 12, 2011, 10:13:14 AM »

Wow, That's some fast progress!

When I did my ABA swap in my GTI, I used a Techtonics 2.25" with 2 resonators and a Borla muffler. It wasn't too loud for a daily but had enough noise when you were on it to keep you smiling.
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Re: GTI version 2.0
« Reply #22 on: March 12, 2011, 10:30:57 AM »

workaholic! wish i worked that fast...  :t-up:
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Re: GTI version 2.0
« Reply #23 on: March 12, 2011, 11:06:33 AM »

I guess exhaust is all subjective to who is driving and what you like.  It looks great! I am amazed how quickly you can get a car together and on the road, and then the level of work is amazing.  I thought I was quick, but dang man!!!  lol

Work looks amazing, I like that copper pipe in the coolant. Totally custom I suppose?
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Smokestack

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Re: GTI version 2.0
« Reply #24 on: March 12, 2011, 04:29:18 PM »

Got it running and driving.  ;D Does pretty good too. The exhaust sounds like it did on my mkv gli, so I'm pretty pleased. Sounds worlds better than the TT system with the Dynomax muffler that the 16v gli had. It's non-resonated for now so there's a bit of drone to it, but I can live with it till I get around to buying a resonator. Oh, and the stupid thing I did was plumb the fuel lines wrong. Swapped them and it fired right up.

Dave, the coolant lines are "custom". Since I want to run AC the compressor gets in the way of the lower outlet so I have to use a G60 radiator with the inlet/outlet on the opposite side. Since the ABA and G60 use different locations on the block for the upper hose, and the G60 upper hose is like $80 I had to get creative with it.

I thought I was going slow for taking a week off of work to get this done. Me and the wife will be down to one running car at the end of this coming week so I had to haul ass to have something to drive for work. After almost a week and a half of tinkering with it it should be driveable at the end of tomorrow. Thanks for the kind words! I'll have pics up tomorrow.
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