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MUSH

MUSH MK2 20VT

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MUSH   

i spend quite a bit of time looking at other peoples cars but never bother me ass to put mine up here. but im off work ill at the min so i have the pleasure of boredom to push me on....

 

Car was originally an 8v but that got sidelined for a 9a 2l 16v. i wanted a 20vt but funds wouldnt allow at the time so the 9a had to do. to be honest i was never happy with the valver lump, it was rev happy and sounded mint but was coupled to a sh it mk3 8v box which had a 3rd gear far too long for the engine and just let the whole thing down. final straw was when me mate thrashed me in his mk2 6a powered car. that was it, i was sick and decided if i didnt do something now id probably just waste time trying a different box to find an extra 2mph....

 

that was all at the start of last year and over the last year not much has happened due to work commiments and havin a 2 yr old but its starting to pick up again now as my job has improved with more money for less time so more time for the motor.

Right, heres the bay after the 9a was taken out...

 

DSC00372.jpg

 

and with a clean up...

 

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the only bit of rot was on the drivers side chassis leg where the airbox had been sat for years as you can see above.

had that cut out and plated then set about getting rid of all the brackets etc that i wouldnt need in the bay...

 

DSC00004.jpg

 

at the time i just roughly sprayed the areas with zinc primer as i knew itd probably be a while til i actually got back to it. Also bashed and cut the bulkhead for the clutch MC.

 

I got a corrado pedal box and had to modify that to fit in place of the mk2 item. The top bracket was 10mm off compared to the mk2 pedal box so i invested in a mig welder (ebay ?50 clarke pro 90) which has made its money back and much more since!! I chopped the top bracket off and welded it back on in the right place. easy as that. Also has to make a bracket for the DBW accelerator pedal id be fitting so that got made when the pedal box was out. Was all a bit trial and error and the pedal box was in and out about 10 times, but now its perfect and sits just right...

 

DSC00007-1.jpg

 

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DSC00011.jpg

Edited by MUSH

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MUSH   

Under the car in the passenger footwells is some drain holes and mine had become a little rotten so i cut them out and plated them over aswell. no pics but you get what i mean...

 

DSC00288.jpg

 

Whilst i was under the car i noticed some of the underseal was looking a bit worse for wear so pretty much a solid month was spent after work stripping and wire wheeling most of the bottom of the car. then a good layer of zinc primer here and there before 3 layers of thick homemade sealant. Now the underside is nice and shiny gloss black with loads of protection. pics to follow on that. All ive gota do is refit the heat shields now (the tunnel shield ill have to weld studs on the undersie to hold it again as they were a bit rotten)

 

Anyway, back to the bay....

 

After many hours spent rubbing down/ filling rubbing down/filling it was starting to take shape...

 

DSC00384.jpg

 

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I cant stand bodywork and have to say apart from the last little bit where it comes together i hated doin all that!!! Id probs do it again in half the time as i learnt about not using too much filler, what to sand with, how to get good results etc...

 

Then it was ready for chris to come, inspect and then paint it for me!!

 

DSC00386.jpg

 

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Bay was primered with a good few coats before final rub down thne painted in original T red

 

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Im probs most happy with the battery chassis leg as i had to drill out the spot welds holding the battery holer on then plate them over. Then i had to plate on top of that to raise the level up before filler to achieve the look as if the battery was never meant to go there...

 

DSC00397.jpg

 

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Drivers leg cam up good aswell tho, as did the bulkhead...

 

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BIG THANKS TO CHRIS FOR THE PAINTING, IT WAS EITHER THAT OR ME WITH RATTLE CANS LOL

 

Battery will be in the boot and the wiring looms will run along the top of the bay but then will got through the chassis legs up to the front of the car. Wasnt too fussed about the looms showing but then seen a car with this done and liked the idea better than having to extend them all and run it in the car then through the legs. ive now ran the looms and only had to extend the battery pos and neg from where they jump off where the battery used to sit. im gona be running a seperate fusebox at the front where these will be able to attach to but more on that later...

Edited by MUSH

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MUSH   

Next, the engine.

 

I got a hold of an AEB lump for pennies that i was gona use but then decided it wasnt worth the hassle so i sold that on for good profit and got back on the lookout. This came up on ebay in dec 07 so i thought itd be worth a look...

 

DSC00441.jpg

 

OUCH

 

DSC00442.jpg

 

but iwasnt bothered, all i wanted it for was its heart....

 

DSC00446.jpg

 

Car was a leon cupra 1.8t 180bhp model with 60k miles and FSH, mostly with the PHIRM. Ive got all the history and no expense was spared. Car was totalled and CAT C written off. I got it for

Edited by MUSH

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MUSH   

Sorry bout the pic orientation, dont know how to spin them... :blush:

 

and because of the change in manifold i had to unpick the wiring loom and pull the relevant cores back over and then re wrap it... which wasnt too bad..

 

DSC000591.jpg

 

Next was a cambelt kit and a metal impeller water pump fitted which again was a doddle.

 

DSC00192.jpg

 

I was about to pay stupid money for a blanking plate for the secondary injection hole in the head when i thought it cant be that hard. Bit of alloy plate a few mm thick and careful re use of the gasket and id done it myself for about 50p!!

 

DSC00264.jpg

 

im chuffed i got a hold of the TT boost pipe also as you see loads of 20v conversions with naff pipe running down the passenger side of the bay. I personally think it looks poo and if theres an oem option which is 100% better then id go for that. Engine built back up and on the stand awaiting fitment...

 

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Got mesel an intercooler too...

 

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Its an ebay uni special but ive heard good thing about them so thought why not!!

 

For the wiring im running oem management with a modded loom and decoded ECU. Im gona be putting mk3 clocks in which will be happening very soon so more info to come.

 

Ive just put the cable in for the battery so thats ready.

 

whilst i was pulling the interior out i decided i wanted a change. I had my mk2 gti seats rebolstered and leather covered a few years ago but sold them on to buy these...

 

DSC00566.jpg

 

Theyre the early ones but i reckon will go well in my motor. theyre also immaculate, theyd have to be otherwise i wouldnt buy them.

 

Anyway back to the mechanicals...

 

For gearboxes...

 

At first i got an 02a AYK passat GT box off a friend but decided thatd be too short gearing so i got a CDA mk3 box which ive still got as a backup in the garage (somewhere). but first prize goes to a rebuilt ibiza cupra box with QUAIFFE lsd fitted. Im still thinking it might be a bit too short but ill just get a longer 5th for motorways. sure ill find out when on the road. The diff will help either way so is a bonus.

 

I fitted the mk4 shifter following the guide on mk2vr6 which is quite good and relatively easy.

 

So the bay is sprayed, all the grommets back in with the alarm sounder resited. Got the engine bay looms back in with the chassis leg portions hidden in the legs themselves. Im gona be making a new heat shield for the rear of the bay to go where the old ones went but mine will be a bit thicker and bigger as i remember the heat soak with the 16v 4 branch was terrible so i dont want the same with possibly even higher temps. The engine is ready and will be bolted to the box with a VR clutch and lightened flywheel as soon as im well and able to do so.

 

DSC00607-1.jpg

 

Got a new brake servo and clutch MC and then painted them all black so they will look good as my old brake servo etc was rusty as!!

 

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New expansion bottle and brake fluid reservoir to follow...

 

Next task was to offer up the intercooler...

 

DSC00417.jpg

 

with the slam panel on the floor, it was obvious what i needed to take out. The upright section that bolts onto the front crossmember at the bottom is L shaped metal for strength. I removed all of this L shape so the intercooler would sit right forward tucked up under the slam panel.

 

I then transferd it to the car to offer up where i hav to make brackets for. was a doddle to be fair.

 

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I then offered up the VR rad im using. The passenger mounting on the front crossmember is the same which is good. All i have to do is weld on a bracket for the drivers side bottom pin to sit in which will be easy also. All that will happen is the rad wont be sitting at quite the angle they nornally do. The good thing about this rad is the water pipes off the 20v lump all mate up perfectly so no bodging there!!

 

I bought a uni ic 2.5" pipe kit off the bay which is good. i mocked these up but need to buy me silicone joiners before i can do it properly. need the engine in also.

 

Next dilemma is where to fit the fusebox ill be mounting up the front?

 

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or

 

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im thinking the 2nd pic. Think it will look/work good there. dont want to hide it and want it accessible.

 

Comments welcome. updates should start to flow now ive got more time on my hands.

 

Well probs not for a week as ive been shot down with mumps, even tho ive been vaccinated, and had it before. explain that....

 

anyhoo....

Edited by MUSH

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MUSH   

cheers for the comments, to be fair that whole progress has taken the best part of a year due to the mentioned work/family commitments but now ive got a lot more time on my hands with my job changing. plus the added desperation of wanting to drive it this summer with the good weather starting to creep in...

Edited by MUSH

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MUSH   

thought id add some pics of years gone by....

 

this was the old 8v engine bay....

 

NEEDSCLEANIN.jpg

 

which i stripped and rebuilt to this...

 

HMMMMMM.jpg

 

but a dodgy earth killed the ecu and flooded the engine with petrol which thinned the oil and ruined the big ends... :angry:

 

which led the way for the 9a...

 

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and heres a few external for yous...

 

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got german plates now tho of course...

 

built the wheels myself, easy job!! got better tyres now aswell lol

 

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updates to follow....

 

fit engine and plumb it all in

porsche scripted handles

bonrath single wiper

skinnier tyres

mk3 clocks

battery in boot

HID lights

 

to name a few...

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dubbuds   

Thats exactly the same intercooler as mine ^_^

 

I fitted mine slightly different thou ;)

 

Looks good!!

Edited by dubbuds

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MUSH   
Thats exactly the same intercooler as mine ^_^

 

I fitted mine slightly different thou ;)

 

 

how then?

 

im happy with the way ive done it but someone else`s point of view is never a bad thing...

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35i-VR6   

Hey Nick you forgot to mention ur early 16v

 

billynmush-1.jpg

 

What a lush colour m8

Edited by oak16v

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MUSH   

didnt want to bring a tear to my eye mate... :( lol

 

didnt mention any of my other motors either, just want this thread to concentrate on the current car.

 

...now that ive bothered my ar se to make one :ph34r:

Edited by MUSH

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MUSH   

...bit of an update, not masses tho as im still ill (weak) lol

 

ordered a load of silicone hoses for the intercooler piping and also got some black conduit to cover all the exposed wiring looms in the bay. They were all wrapped up anyway but think they look better in this stuff. they go nicely into the chassis leg aswell...

 

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the heatshield ill be making will cover the rear of the bay up to the wiring looms so youll not even see most of this when its in. i just wanted to neaten up the drops down into the chassis leg.

 

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The inside of the chassis legs are all prepped and covered in my underseal mix to match the bottom of the car. they do look a bit rough but its all about keeping the stone chips away and if it does get damaged its an easy fix. function over form...

 

also got my brake servo/MC and clutch MC fitted and the brake lines reconnected. might chuck a bit of paint on the lines to neaten them up. Just need to get a reservoir now as the one i have is minging and there quite cheap.

 

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Then as far as wiring goes ive just gota mount my fusebox at the front on the passenger side and get it all connected.

 

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and the drivers side...

 

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Next update will be the heatshield and mounting the fusebox.

 

Anyone know what the 3 core connector is for on my fusebox? (left hand connector in the next pic) its normally mounted on top of the battery? im just gona cut it off if theres no use for it as i dont need it.

 

DSC00609-1.jpg

 

thoughts welcome...

Edited by MUSH

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MUSH   

yep mate, engine will be in in a week i reckon. just gota fab up a decent heatshield then its all go.

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Triple L   

Looking good dude, my only very slight criticism is the intercooler placement, because its only going flow about half it's potential once the bumper is back in place and the grill is back on. Also not loving the CGTI sticker in back window... :P

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MUSH   

update time, nowt massive, just fitted the heatshield that ive made. :ph34r:

 

think the standard items are poor and the cabin heat soak that i got from the 4 branch that used to be on was terrible :wacko::angry: , so time to fab up one myself. got the idea from seeing ceedubyas in his polo which is discreet and works well, mine will work well, dont know about discreet tho... :lol:

 

started with a bit of aluminium sheet from a metal shop. cost me

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Jamesvw   

Cool project chap, very similar to my mk2. Keep up the good work.

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ceedubya   
got the idea from seeing ceedubyas in his polo which is discreet and works well

 

;) cheers

 

the paint work in the engine bay looks very tidy :lol:

 

its starting to look good mate (about time too :D )

 

ya gotta get it on the road for E38

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MUSH   
;) cheers

 

the paint work in the engine bay looks very tidy :lol:

 

its starting to look good mate (about time too :D )

 

ya gotta get it on the road for E38

 

the engine bay paint is immaculate and unscratched, as yet...

 

E38 will be a definate, lump would be in now but waiting on a new clutch mc from gsf. getin that tomorrow!!

 

Heatshield is now sprayed so is ready to bolt it, pics to follow

 

maybe engine sitting in the bay in a week...? :ph34r:

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