Making of a Mk1.6 (slowly)

V6? V8? TDI? Discussion and technical advice for engine transplants inc. 5SFE & 5SGTE builds. Not for N/A to Turbo, or Rev1/2 to 3+ conversions.
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LimeyMk1
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Making of a Mk1.6 (slowly)

Post by LimeyMk1 »

Ok I thought I’d chuck up a thread on the progress of my V6 build, it’s going to be a slow process so bare with me. So far the car’s been in the garage for a year now and due to redecorating the house, lack of money and inspiration things have been going at a snails pace. Things are looking up financially (and motivationally) so with luck and perseverance I’d like to get the damn thing finished this year :pray: (I’m missing driving a MK1).

The plans are to run the engine on individual throttle bodies with possibly a smidgen of porting once I’ve got the whole thing up and running, I'm looking for a responsive drive with a reasonable amount of power circa 250bhp with plenty or torque.

So here’s where we start with a de-engined car:

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And a large lump of V6, VVTi goodness, for the bargain price of £50 :shock: :

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The collection of parts has so far included an HKS Turbo exhaust from Leeroy:

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A Fidanza flywheel and Exedy clutch from Ultrarev in the States, a DTA P8 Pro ECU from Perfect Touch and a Rev 2 Turbo box and drive shafts from Jon at STB. A large number of gauges have also been collected including a SPA digital speedo for a completely custom dash.

I’ve also just purchased a set of stainless exhaust manifolds from the US.

My MK1 is already fitted with KYB shocks, Whiteline springs and a High and Tight rear ARB on the suspension front and a set of hefty alloy Hi Spec callipers and grooved disks for stoppage. So that side of the cars modification is sorted. :thumleft:

The work done on her so far includes:

Painted cam covers with Plasticote, shiny blue for that little bit of bling (woo):

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Removed the old Engine mounts from the Mk1, mmmmmmmm grinder =P~ :

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Flywheel and clutch on (yes I know the clutch isn’t aligned) :whistle: :

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Engine and box mated up:

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Many, many thanks to Stuart (Jaspa), Richard (RedMk1) and Malcolm (Tiamat) for helping heave the lump off the engine stand and onto the engine dolly I’d made up. :clap:

Engine bay degreased, as it was truly manky and covered in metal flecks from the grinding and oil from way back when one of my oil cooler pipes let go:

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Driveshafts reconditioned, new boots and ends were put on (‘scuse the nasty carpet):

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The new ends are required so that the turbo driveshafts will mate up to the Mk1 hubs.

As the long turbo shaft is supported I needed to make up a bracket so it can be bolted to the block, with a huge amount of inspiration from Mr Woods I’ve made one up, it still needs some ‘fettling’ but hopefully I’ll get to do this on Sunday and give it a coat of Por15 too.

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I’ll try and update this as I go as well as my build thread on Twobrutal, next job is to find an engine hoist and get the damn thing into the bay. :pray:
MartG
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Re: Making of a Mk1.6 (slowly)

Post by MartG »

Looking good Chris :thumleft: I think you take nearly as long as me to build a car :lol:
RST
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Re: Making of a Mk1.6 (slowly)

Post by RST »

Do you mind me asking how much the ECU was? I didn't realise they were VVT-i compatible as well, I need a new ECU for my itb set-up next month and thought it was a choice between Link or Motec, a third option would be interesting to see before I settle on one.

Thanks,

Richard
Last edited by RST on Fri Mar 21, 2008 5:45 pm, edited 1 time in total.
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LimeyMk1
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Re: Making of a Mk1.6 (slowly)

Post by LimeyMk1 »

The ECU was £700 I think (bought it a while ago), DTA do other more advanced ECUs which are advertised as VVTi/VTEC compatable. Have a look on http://www.dtafast.co.uk for all the specs. UK made as well. :thumleft:

Dash done: :thumleft:

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Last edited by LimeyMk1 on Fri Apr 11, 2008 11:25 am, edited 1 time in total.
System-G
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Re: Making of a Mk1.6 (slowly)

Post by System-G »

Limeymk1 wrote:

Dash done: :thumleft:

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Now that I'm liking 8) A lot :mrgreen: :thumleft:
85 MK1 MR2 Track N/Ail | 99 528i SE Touring | 01 Mandarin VX220
RST
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Re: Making of a Mk1.6 (slowly)

Post by RST »

Cheers for the info on the ECU's -think I'm sticking with Link XLEM. Went to order one today but everyone's off!
PW@Woodsport
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Re: Making of a Mk1.6 (slowly)

Post by PW@Woodsport »

chris i just realised i forgot to send the mount templates with the jig...im bloody useless! but fear not all you need to do is make sure metal plates hit the holes on the jig,its pretty foolproof bud :thumleft:
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brgbrm
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Re: Making of a Mk1.6 (slowly)

Post by brgbrm »

That is lovely! :)

Limeymk1 wrote:

Dash done: :thumleft:

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utopia

Re: Making of a Mk1.6 (slowly)

Post by utopia »

looks like a very interesting project, will keep my eyes peeled :thumleft:
EarL
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Re: Making of a Mk1.6 (slowly)

Post by EarL »

...any update on this Chris?
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LimeyMk1
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Re: Making of a Mk1.6 (slowly)

Post by LimeyMk1 »

Yup, other than me being a lazy xxxxxx I've finally (just this minute) got my dash all sorted.

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Scuse the legs. :lol:

I decorated my dining room with some tastefull pictures to help with the dash wiring.

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The Mk1 wiring diagrams.

Other than that the engine mounts were sorted a while ago, the inlet manifold has been handed over to Altiss engineering for fettling (www.Altiss.com) and I still haven't rammed the V6 in there as I have some bits to cut out the car and to be frank it's rather scary. :oops: :lol:
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LimeyMk1
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Re: Making of a Mk1.6 (slowly)

Post by LimeyMk1 »

Did a wee bit of fettling to the crossmember that runs accross the back of the engine bay. :whistle:

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I need to put another above it and it should hold things together. :lol:
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LimeyMk1
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Re: Making of a Mk1.6 (slowly)

Post by LimeyMk1 »

Got a bit of power (9v battery) to the gauges yesterday, looks like I'll have to do a dedicated signal wire for 2 of the gauges but otherwise all good. :thumleft:

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Cleaned up and painted (Por15) some of the boot underside. 8)

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LimeyMk1
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Re: Making of a Mk1.6 (slowly)

Post by LimeyMk1 »

Well the damn thing fits (so far). :pray:

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Re: Making of a Mk1.6 (slowly)

Post by Icsunonove »

Looking really good Chris! :D :clap:

Get it finished! :thumleft:
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Re: Making of a Mk1.6 (slowly)

Post by PW@Woodsport »

looking good from here mate,oh lose the lid catch panel,it fouls the plenum.... just cut the bu88er off,im going for bonnet pins.

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i know mine has the charger but the plenum runs in roughly the same place
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LimeyMk1
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Re: Making of a Mk1.6 (slowly)

Post by LimeyMk1 »

S'ok Paul, remember I'm going ITBs so no stock Plenum. 8)
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Re: Making of a Mk1.6 (slowly)

Post by PW@Woodsport »

crap i keep forgetting!
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LimeyMk1
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Re: Making of a Mk1.6 (slowly)

Post by LimeyMk1 »

Yum

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Yum

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:mrgreen:
slipping clutch
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Re: Making of a Mk1.6 (slowly)

Post by slipping clutch »

Yum indeed =P~ cant wait for the next instalment - keep at it - looks fantastic.
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