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

[JamesLuton]

Had these sleeves made up to fit the bushes, so these will be my engine mounts, luckily I have a friend who works at a engineering firm and he does me a load of jobs for beer tokens......




also had a phone call of another friend on Wednesday, after spotting a rough looking 924 on a driveway 20miles away, he stopped and got me the guys phone number. I called him up and went to have a look, its a 924s 1986, so a 5 stud conversion is now also on the list of jobs to do. Has a few other bits I need, header tank, hydraulic clutch setup and loads more spare parts. Offered the guy £100 and he said yes! Bargin



gave it a wash, came up alright, might keep it now!

[morghen]

omg, 100 ? that guy must be retarded

[JamesLuton]

Yeah it was a bargin, its out of tax by 5 years tho and just been sat on his drive so its no minter, he's half stripped some bits then just left it!



Got my inlet manifold back today, looks good, test fitted it with injectors and rail and fits.

Given the bulkhead a few whacks with a hammer just for some extra clearance, looks terrible but ill just put a bit of filler in there and itll be fine

[JamesLuton]

Engine mount brackets are being made up this week so hopefully get it mounted before next weekend!

Had the coolant flange made now, just need to make a gasket up. Also cleaned up the inlet and painted them.













Test fitted the throttle body and ran a bar over the wings to test bonnet height, looks like im going to have to make up a pipe like this to clear sensors, like the Motor werks 944 conversion cars spacer, the cars look awesome tbf

[Slimchance]

Making good progress. Keep on posting the pictures.

[JamesLuton]

Few more hours, few more little jobs. Mate helped me make up the throttle body extension today, needs corners smoothed off, bit of die grinding inside and painting but looks good.

Sump is next up, then finish engine mounts. Make exhaust and coolant pipes, mount rad and intercooler, remember where all the vac hoses go, sort fuel hoses, make air intake/intercooler pipe work, and another million other little jobs!

[Pete82]

good progress

[JamesLuton]

Managed to pick up a Transit Connect intercooler for £20 so got that mocked up today, welded a bar to mount the rad on so I can get the intercooler pipes round the back, painted the throttle body spacer silver to add some colour, drawn some diagrams so now I know what I need in the way of intercooler/turbo pipe work and all the water diagrams. So just a case of buying some piping and bends for that. Still just mocking everthing up really, motor will back In and out a few more times yet!

[JamesLuton]

Engine mount bracket to weld to chassis legs made, just need to measure from the bush casing to the plates on the block and have a few pieces of tube made.

[JamesLuton]

Cut a hole in the bulkhead today to feed the loom through, still need to cut into interior on the drivers side. Had to cut the cable casing back a bit to get the throttle body connected.

Got the drivers side engine mount tacked in place today. As you can see just need to tube from the bush casing to the plate.

[Prophead]

If you replace the fan and housing with something like a Spal 10 blade fan you will give yourself an extra couple of inches between the front of engine and the fan for the extra pipework qnd general access.

[JamesLuton]

Flywheel Kit arrived today!

The most expensive part of the conversion ha, Valeo Solid Flywheel 826317 cost me £200, its from a MK4 Golf AGU 228mm. Its a 4 piece kit so means Ive ended up with a Mk4 Clutch disc I don't need.

The camper clutch disc fits nicely!

Also ordered sump and windage tray, which should be here tomorrow so can start modifying those next.

[924srr27l]

If you replace the fan and housing with something like a Spal 10 blade fan you will give yourself an extra couple of inches between the front of engine and the fan for the extra pipework qnd general access.

Yes, good point I did just that.



R

[JamesLuton]

Yes, I may well do that. The original fan housing is pretty big.

Sump arrived yesterday, just in from the garage and have fitted the windage tray and cut the sump. Just need to weld in a new piece now, cut hole for turbo return and baffle and then finish engine mounts!

[JamesLuton]

Got round to mocking the sump up, test fitted, needed a bit more taking out, so welded up today. Will sandblast it inside then just need to drill a few holes for the oil return from the turbo.

Also finished starter motor clamp bolt, just needs painting.

Need to finish painting all the brackets and things I have made up, sort out right length bolts etc.

Then I can bolt it all in, finish the mounts and start plumbing/wiring!