My 1.8T 924 Project! (Pic Heavy!!)

[JamesLuton]

Got clutch and flywheel bolted on today with sump, also cut inspection hole. Need to just make a plate to cover it now but makes starter motor removal slot easier.

Happy enough, jacked the rear up and turned the crank pulley with it in gear and the wheels move!

So engine mounts next

[Slimchance]

Really starting to come together now, are you keeping the standard ECU? Keep posting your progress.

Bruce.

[JamesLuton]

Yeh plan to use the standard loom and ecu, going to try running everything like evap canister, then remove items when I've got it running. Found a few wiring diagrams for wiring AEB into mk1 golfs so it's quite similar

[JamesLuton]

So, knocked up some tube work to finish the mounts.

Had to remake the p/s one as my notch was pretty shit, first time I've tried lol

But now tacked and off to the shop tomorrow for proper welding and few more pieces of tubing added for bracing, going to have at least another 2 bits of tube on each mount for some triangulation.

[JamesLuton]

Got the mounts back yesterday, just need a clean up and a paint. Bushes back in and the bolt them up!

[JamesLuton]

Gave the mounts a paint today, refitted bushes and bolted it in. Really pleased! Feels pretty solid with the polybushes so shouldn't move that much.

Next up is too pull the motor back out and do all the little jobs, right length bolts etc, tweaks etc. Then it's onto putting the oil return hole and studs into the sump, oil filter relocation, water and boost pipes to make, then the wiring.......

[JamesLuton]

First round out of 6 for the Grass Autotest this weekend, so looks like im missing that, need to get my ass in gear and finish for the rest, next one is 20th Aug so have 8 weeks to get the car ready!

Finished welding mounts to chassis legs and gave them a paint, mounted my 924s header tank, finished mounted bracket for starter, started making up water pipes with offcuts I had lying around, not bad need to buy a few bits but getting there. Made a pickup pipe tonight, looks good just need to cut the holes in the sump for the oil return and that's that done.

Getting there now, bit worried about wiring but everything else should be ok from now!

[JamesLuton]

some more progress on the water pipes, managed to use the old Passat water pipe cut up and rewelded in a different order, it'll prob leak but that's what RTV was invented for! Also nearly finish oil return from turbo to sump, just want to strengthen the inside with another flange and 2 bolts welded in.

Ordered a vr6 slave cylinder today so need to start stripping the hydraulic clutch setup from the white 924s, weld in a bracket and plumb

[Slimchance]

You're flying along, making me feel guilty for not doing more on mine!

[wingers]

Great job, just a thought on the turbo oil return.
With the engine tilt and the modified sump is the return going to be high enough in that position ?

[JamesLuton]

You're flying along, making me feel guilty for not doing more on mine!

Yeh, yours looks pro though, taking your time making a nice job. Im in a rush now and bodged a bit, just want to get it finished and will come back to other stuff. Something will break soon enough, but that's half the battle with making parts and doing engine conversions.......

Great job, just a thought on the turbo oil return.
With the engine tilt and the modified sump is the return going to be high enough in that position ?

hadn't really thought about it, will have to check, cheers wingers

[Slimchance]

Bodged is often the best way, throw it together, see what brakes, then make it better to stop it braking again!

As for your sump and oil drain, it should be ok as it doesn't matter where the oil drains as long as it's below the level of the turbo. Imagine filling a bucket with a hose pipe, it still fills up the same whether the hose is under water or not. If you look at how the air-cooled VW turbo guys plumb their oil drains in as most of those go into the bottom of the sump.

[JamesLuton]

photobucket looks like its ruined the thread, but hey ho.

finish the sump today and swapped over the pedal box and clutch pedal from the 924s, just need to cut a hole in the bulkhead and make a bracket up to hold the cylinder, then plumb It to the slave cylinder which is still to arrive, its a Golf Vr6 Slave.

Started making some new fuel lines up, and removing the old ones from underneath the car, got rid of the accumulator.

Finish making rad mount up, and removed headlight motor and lifting system, still need to find a way to keep the light up all the time, but bolting threw the 'stopper' on the metal bracket at the rear looks the easier option. Gives me loads of room to run an air filter behind the d/s headlight.

Still got a fair list of jobs to do, but no far off bolting it in for the last time before plumbing and wiring!

[Slimchance]

Even without pictures please keep the updates coming! I'm going to stick a Facebook link up for my build thread and keep all my pictures there.

[Pete82]

photobuckets ruined so many people's threads on various forums. They suck hard!

Shame as I was enjoying the thread