Most liked posts in thread: My MK2 VW GTI 20V 1.8T Projekt

Yes there is. Finally got the hardware to get the engine on the stand:



I cleaned it a little and got some things pulled from it so that I can start detailing it. I am going to get the the cover, fuel rail, aluminum lines, and intake polished. I also got a powergasket for it. The Y pipe was split so I ordered a Eurojet PCV Hose Kit. Depending on my budget, I may do some other enhancements. I also found a G60 Corrado front cross member to withstand the added power:



Next I got the dash out and did some comparing:






It looks like the height and length are close to the same, but the width on the MKIV dash is a lot wider. I am still not sure about doing the dash swap yet. I will need to use the MKIV cluster and I would need to modify the MK2 dash for it to fit so either way I will have to modify a dash. When i removed the dash, I pulled the wipers to make it easier to get to the nuts underneath the rain tray. Since I am going to be using the newer wiring harness, I checked to see if I could use the MKIV wipers in the MK2:



The MKIV wipers are too narrow to fit in the MK2, but the motors were a direct swap. This picture shows the newer motor installed. Using this motor will give me all of the functions of the MKIV wipers on the MK2.

I got all of the wiring out and stripped the front out of the car:


I also pulled the rack off and dropped in my MKIV steering to see if it would work:



It looks like the dimensions are the same, but the bolts to mount it to the sub frame don't match up. I would need to drill holes to make it work. I would still like to use it because i believe it would the swap go easier by being able to easily bolt on the MKIV column and power steering lines. I also got the bay cleaned a little more and I willl next be dropping the subframe to clean and refurbish:



I can't get that master cylinder off because the 11mm bolts are frozen and only one has come loose. I am thinking about removing all of the lines and then using the lines, master cylinder and ABS pump from the MKIV. I also bought a grinder and some stripping wheels so I am going to start stripping the paint from the bay and getting it all cleaned up before I get the motor in. I'm going to get some G60 pedals this week, but I still need to find an 02J trans. Hopefully I'll sell my six speed soon. My polished parts still aren't done for the engine so I did some detailing and polishing of my own:

 

No, not at all. There have been a few. Here is the guy that inspired me. It is an R32 swap with the dash, headliner, sunroof,pretty much everything:


I got my polished parts finally and set them on the engine to see how it is going to look. i still need to polish the FPR and bolts that hold it all on. I also have a couple more metal lines that aren't on there yet that are polished:

 

Last night I was able to get the subframe off to clean, strip, paint, and rebuild with all new bushings. I got some more paint stripped and I got a friend who is going to help with some welding to smooth the bay as soon as I get it stripped. Once I get the bay stripped, smoothed, and primed, I can start putting in the wiring to see how it is all going to run. The engine is all together now and I found someone to trade transmissions with so things should start happening here soon. I also scored a set of G60 Corrado pedals to do the hydro clutch conversion. So far the weather has been kind to me since I am doing this outside, but it has started getting cold up here in the desert. I just wish it wasn't dark at 5 PM.

 

I have been doing a lot of grinding and stripping on the engine bay to get it ready to be smoothed and painted so nothing much there, but I did solve the problem of getting the MKIV AC lines to work with the MK2:


I pulled the HVAC system from the MKIV and put it in the MK2 and it was too easy. All it took was to drill two new holes where the AC lines go in the car and everything fit perfectly. It will also simplify using the MKIV harness.

I was thinking today about using the MKIV engine mounts with the front engine mount from the MK2 and not having a mount on the back to free up room for the turbo. I figured I could cut out this bracket from the MKIV:



and weld it onto the passenger side frame rail of the MK2. The driver's side would just need some holes for the bolts put into the frame rail for the mount. I t should be stable since the MKIV uses the two mounts plus a rear and nothing on the front.

I still need to find a fabricator to modify the two steering racks, so if anyone in SoCal knows someone or could do it please let me know.

 

Thanks guys for the encouragement. All this really is so far, is swapping parts. I just wish I knew how to weld. The three heavy things on this are going to be smoothing the bay, the steering column because I have to morph the bottom of the old one onto the top of the new one, and the dash because it will have to be cut and trimmed to fit (but the HVAC from the MKIV should help with the mounting of it). I still have no transmission, so I need someone to swap me their 5 speed for my 6 speed. Once I have the trans, I can get the engine in and see where everything sits and where to run wiring and piping.

 

Cool bring the beer, I am off all week, but I am not wearing a bikini :nonod:

 

Yes Jerry, standard work clothes will be worn. It's been getting cold up here.

Today I got all of the brackets, bolts, and screws smoothed out of the bay. I also did some more stripping and am now at the point where my grinder and wire wheel isn't going to reach anymore. I need to research how to get the rest of the bay stripped short of getting it blasted.



I'm going to hit Harbor Freight to see what kind of attachments they have to use. Thanks to Shawn at German Performance in Riverside I was able to get a front cross member, front motor mount, and transmission mount from a VR6 B4 Passat to handle the extra torque:



I have a guy that is seriously wanting my six speed, so I may have a transmission soon. I'm crossing my fingers

 

I would love to get something like that, but I don't even have an air compressor. Believe it or not, I have been doing all of this with hand tools. My father-in-law has one with some pneumatic tools and I have been thinking about hitting him up to borrow it for awhile. I will have to see what kind of pressure it puts out. I think it is only a 20 gal though and those blasters need a lot of capacity.