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Mk2 20vt

Discussion in 'The Project Room' started by classy, Sep 20, 2012.

  1. classy
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    classy Member

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    [Sep 20, 2012]
    Haven't been on the forum long but it's already becoming a new home with all the info about 20v lumps & stuff for sale so figured I put some pics up of my mk2 20vt [​IMG]

    Started off as a standard 1990 mk2 8v with 2 owners & 83,000 original miles!

    4 years later... It's now a AMK K04'd running mk2 golf on standard management.

    Modifications/notes:

    Massive pipercross air filter
    N249 bypassed
    Forge 007p
    Badger 5 V3 TIP
    Simplified breather system
    Re-manu K04-023
    FMIC & 2.5" piping
    2.5" QPeng downpipe to Jetex SS sytem
    02A CTN (Mk3 Golf diesel gearbox)
    G60 lightened flywheel w/ Vr6 sachs clutch
    G60 bonded transmission mount, solid front engine mount, poly insert for rear engine mount
    Uprated K-jet 5bar fuel pump
    General engine dressing, polished & powdercoated bits & bobs!

    Kw V1 Inox line coilovers
    23.8mm Ibiza cupra R master cylinder
    Running Wilwood 280mm Midilite front brakes
    Corrado hydro clutch system
    Borbet B alloys 7.5x 16 running 205/45/16 Pirelli P-zeros

    Full RAAMmat soundproofing
    Audioscape speaker grills
    TIM boost gauge
    2 in 1 Racetech mechanical oil temp/pressure gauge

    Pretty much everything's been replaced on the car from the ground up right to the full gasket re-build on the engine. Re-sprayed engine bay, wired tucked/re routed, battery, washer bottle re-located to the boot etc.

    Let the pictures do the rest of the talking [​IMG]

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    #1
    Sandra likes this.
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  3. Sandra
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    Sandra MODERATOR Staff Member Moderator

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    [Sep 20, 2012]
    Hi, welcome to audi-sport.net. Good to have you onboard. This has got to be one of the best 1st posts i have come across, i love the car and all the work you have put into it. Thanks for sharing it with us all. Where are you located? Hope you continue to enjoy the forum. :) x
    #2
  4. classy
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    classy Member

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    [Sep 20, 2012]
    Thanks - couldn't fit all the pictures in the first post :laugh: Located in Worcester.

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    #3
  5. Sandra
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    Sandra MODERATOR Staff Member Moderator

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    [Sep 20, 2012]
    ​fantastic. :) x
    #4
  6. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Sep 20, 2012]
    I have seen this in the metal. Nice car, needs som niggles fixing and it will be an awesome car.
    #5
  7. Sandra
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    Sandra MODERATOR Staff Member Moderator

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    [Sep 20, 2012]
    If you want to join the guys in local meets, click on the link below and add your name in to the section that is local to you. :) x

    Smaller (Local) Events
    #6
  8. Lewis583
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    Lewis583 Active Member VCDS Map User

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    [Sep 20, 2012]
    Nice to see another MK2 owner on here bud:rockwoot: (i'm sure i've seen your car on CGTI?)

    What size exhaust you running on it mate?
    #7
  9. ruffrida
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    ruffrida Well-Known Member

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    [Sep 21, 2012]
    Nice motor fella, look well
    #8
  10. classy
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    classy Member

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    [Sep 21, 2012]
    Where have you seen it? Not been out much since it's been finished. What you have you noticed? [​IMG]

    Yeah I have the full build on CGTI, this site is more focused towards the 20v engine though & that's where the attention is at now for me.

    It's 2.5, using the qpeng downpipe & jetex 2 box system (soon to modified because it keeps smacking the rear axle)

    Thanks for the comments [​IMG]
    #9
  11. nightroamer
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    nightroamer Member

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    [Sep 21, 2012]
    Hi mate, I'm in the process of doing a mk2 1.8t conversion at the moment, amazing pictures! Looks like you have done an excellent job.

    Do you have a link to your build thread?

    Thanks
    #10
  12. classy
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    classy Member

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    [Sep 21, 2012]
    Cheers mate. They're`expensive but worth it! I'm having a few teething problems with intermittent lack of power at the moment but when it goes, it goes like a stabbed rat!

    Full build can be found here: Mk2 20v - MOT'd & On the Road!!
    #11
  13. nightroamer
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    nightroamer Member

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    [Sep 21, 2012]
    Excellent cheers buddy I will read this once in back home :thumbup:
    #12
  14. Broken Byzan
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    Broken Byzan Photographic Moderator Staff Member Moderator VCDS Map User

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    [Sep 21, 2012]
    You bought it over to B5 for a smoke test, you have leaks in the PCV system IIRC
    #13
  15. classy
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    classy Member

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    [Sep 22, 2012]
    Ahh, apologies mate I didn't put the username to you :icon_thumright:

    Yup, the breather systems all sorted now - Got rid of all the valves/pipes underneath & used the simple one piece pipe. I found out what the leak was from oil filter housing, the solid 90* plastic breather pipe coming out of it had split at a join from underneath. Replaced the Y piece that was all squidgy - £80 lighter for those two pipes :blink:

    I'll be back down sometime next month for another smoke test just to confirm it's all leak free & potentially some logging as the car's still not running right if I don't sort it myself before hand (lazy)!
    #14
  16. Double J
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    Double J Member

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    [Sep 26, 2012]
    Strong work!
    #15
  17. Fernandes18
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    Fernandes18 New Member

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    [Oct 1, 2012]
    What a beautiful design that you have there.
    See that you had al lot of detail work!


    One HUg From Portugal!
    #16
  18. classy
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    classy Member

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    [Oct 2, 2012]
    Thanks guys :icon_thumright:

    Fitted a toad alarm & kill switches over the last 2 weeks so don't feel as paranoid about leaving it anywhere now. Got a suede sparco steering wheel coming, got to re-trim the headliner this weekend & on the hunt for some decent bucket seats & a serious car detailer.

    Been looking at companies like detail my ride & autodetox if anyone has any recommendations on service, quality of work etc..?
    #17
  19. classy
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    classy Member

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    [Oct 28, 2012]
    Little update. Haven't really done much on it for a while due to the weather (cold)! & generally just enjoying driving it!

    Got 1 seat fitted after having to modify all the subframes for it to suit & fit so I'm comfortable. Installed the harness & the wheel in also.

    Started the headliner, it's pretty much almost finished just needs to be re-trimmed. Needed alot of fibreglassing as it was F*c*ed.

    Also now have it booked in for a 3 day paint restoration with detail my ride, probably going to have the bonnet carbon wrapped to just for something a little different B)

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    #18
  20. JayP
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    JayP Member

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    [Oct 29, 2012]
    Nice work there. Coming along very nicely. Always had a soft spot for MK2's.

    Keep up the good work.
    #19
  21. nightroamer
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    nightroamer Member

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    [Oct 29, 2012]
    Looking good buddy, I'm so far behind you motivates me though :thumbup:
    #20
  22. Prawn
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    Prawn My other car is a MINI!!!!

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    [Nov 4, 2012]
    What a bloody lovey looking car!!!

    nice work mate.
    #21
  23. classy
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    classy Member

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    [Dec 20, 2012]
    Thanks for the comments chaps, keeps me motivated to get her finished. So close - especially hard in the winter months! Still haven't found a replacement headliner & I'm desperate to have it mapped though recently the car has gone completely to the back of the priority list so not sure when it'll get done now :crying:

    Had it detailed recently from the boys at 'Detailmyride' 18 hours worth of a machine polishing alone so I was told, came out looking immaculate.

    Here some pictures shot with their Dslr cam:

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    #22
  24. Burkin
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    Burkin Member

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    [Dec 20, 2012]
    That is one sexy car!
    #23
  25. nil538
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    nil538 Member

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    [Dec 29, 2012]
    Love the car mate looks spot on nices work been done there
    #24
  26. MUSH
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    MUSH MUSH Developments Ltd.

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    [Jan 1, 2013]
    Pretty sure you know my thoughts on this mate... ;-)

    Great to see it all together and lookin fantastic!
    #25
  27. millsy75
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    millsy75 Member

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    [Jan 1, 2013]
    Love the Mk1 & Mk2 Golfs. Great work :)
    #26
  28. RyanJonS4
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    RyanJonS4 Drive It Like You Stole It

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    [Jan 6, 2013]
    Absolutely mint!

    If your looking to sell it drop me a pm, its just what im looking for!

    Ryan
    #27
  29. classy
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    classy Member

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    [Jan 6, 2013]
    Thanks for the comments guys.

    Gave her a good wash & wax today, first time since the detail - came up just as good as she left the place so really happy about that (& how easy it was!)

    Sourced another headliner last weekend & finished off repairing it today, will be re-trimming it next weekend hopefully. I messed the last one up by getting to excited with the fibreglass & repairing the material side so there would have been bumps in the material!

    Took off the original woeful soundproofing on the roof. I've been driving around for a few weeks with no headliner & having temporaily fit the one I got last weekend to drive home - it's amazing how much of a difference it makes being in there to quietening down the car & making the music sound better. Keeping that in mind, the remaining RAAMmat I have left over from the rest of the car & the closed cell foam will now be making it's way on to the roof for more quiet :)

    Also popped the resistor in for the n80 - charcoal canister purge valve as it was the only thing making the engine management light stay on so once I've erased the codes I should be EML Free!

    Should have some pictures next week - Spent the last two hours looking for my vagcom cable that had managed to make it's way under my mrs bed 9 miles away!?
    #28
  30. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 6, 2013]
    As good as VCDS is it won't be able to diagnose faults in women mate... thats something not even god can do ;P

    Love the car... there is a bit of a Mk2 Golf theme at Badger 5 at the moment lol... currently have 3 in for various bits of work... I love my little 1.3 Mk2... bring her up on a weekend next time so I can have a look :thumbsup:

    <tuffty/>
    #29
  31. classy
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    classy Member

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    [Jan 6, 2013]
    Never a truer word spoken ha! Literally turned my house & garage up side down thinking I'd lost it.

    I need to get it back in again soon... Confirm it's all leak free after getting smoked out last time & look at booking a map & sort out the long overdue niggles..

    You guys open on a saturday?
    #30
  32. <tuffty/>
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    <tuffty/> Badger 5 Edition Staff Member Moderator

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    [Jan 6, 2013]
    Yep... :)

    <tuffty/>
    #31
  33. classy
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    classy Member

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    [Feb 26, 2013]
    Car's back off the road again now :(

    I've had an underlying boost fault that I never realised was actually a fault until a month or so ago. Long story short, I had mixed up n249 plug with n75 plug & had being essentially running around in the car with the n75 disconnected as it was plugged into a bypassed n249.

    The reason I never really suspected anything is because it was just slow to build boost, 1.5bar around 4-4.5k (though I've never driven another 20v to of known!). When I realised my mistake & plugged the plugs back into their correct sensors, the car was mental to drive. Boost spiked at 2.0bar++ at around 2.5/3k & pulled 1.5bar to redline - was a weapon to drive that once but very obviously over-boosting.

    Further investigation & understanding, was disconnecting n75 valve, the turbo should run on actuator pressure (6psi, 0.5bar) this evidently wasn't the case as I'd been using the car for months with it disconnected & it was running 0.5 bar to 4.5k, then hitting 1.5bar & maintaining to redline. More faffing & advice from Bill @ B5 revealed the turbo that I'd purchased from Midland turbo was manufactured faulty. B5 had a Chinese copy K04 in recently with similar symptoms to what I described. B5's investigation lead to finding the wastegate port hole was actually TO SMALL. It being to small, means there isn't a big enough hole to allow the air to escape through the wastegate & relieve the boost to 6psi / 0.5 bar.

    When I removed the turbo last weekend to check, I measured up the hole & inspected, called Midland turbo & had them compare. The turbo they had sold me had a 5mm diameter smaller port hole than was actually specified! My turbo measuring at 21mm, rather than 25/26mm. My turbos LIMP MODE was 1.5bar instead of 0.5bar! They also admitted using a chinese hot side, as gen hot sides are very difficult to source.

    Got the turbo back Monday & I'm amazed at the difference in sizes.

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    & How the car looks at the moment:

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    Going to order some valve stem seals this week, I'll put those in when re-fitting the turbo. Hopefully will cure the excessive oil burning on cold startup after it's been sat a while. If the stems are worn, I'll buy some rods & do those at the same time later on in the year when funds are available. I will get this car mapped eventually!
    #32
  34. nightroamer
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    nightroamer Member

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    [Feb 27, 2013]
    Well done finding the fault dude.
    Its pretty awfil they have the audacity to use Chinese copy parts in their turbo builds.
    Is the replacenent genuine or just had the bore size fixed?

    Car still looks stunning.
    #33
  35. classy
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    classy Member

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