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Author Topic: Alex Mac's mk2 ABF Turbo track toy.  (Read 297 times)

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Offline alexmac

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Alex Mac's mk2 ABF Turbo track toy.
« on: January 11, 2015, 11:30:56 pm »
Hi everyone, thought I would stick a build thread up. I have copy and pasted all of the text from my thread on club.

I purchased my mk2 golf gti 1.8 16v k-jet 1987 3door tornado red back in January 2010 off my step brother who had it hidden away in a lockup that I accidentally stumbled across when walking the dogs. I payed £600 for it and had around 130,000 on the clock, and it was completely standard. It really needed some TLC so I gave it a wash then got to work on the paint fade, changed oil, filters, rocker cover gasket, gear linkage washers and weight. Took out the dodgy alarm and also fitted a new thermostat so I could remove the dodgy wiring and switch for the fan so it came on when it needed to instead of me switching it on when it got hot.

Can't remember what order I did everything and I may have forgotten a few things I did but ill do my best.


Bought some coilovers, pipecross panel filter and drilled the air box, changed speedo lights for brighter green ones, momo gear knob, momo race steering wheel. I also got hold of a pair of escort rs turbo recaro seats, welded the mk2 rail onto the recaro's.

I then decided to take the plunge and take a trip to TSR to have a custom exhaust made with a 4 branch manifold, that soon livened up the 1.8.

I soon got the real bug for tuning and modding and after a bit of reading on the web I decided to pick up a 2.0 abf. When it arrived I started stripping it down and i soon realized that the oil pump had gone and scored all the bearings and crank. I managed to get hold of a perfectly good second hand crank as well as new bearings and gaskets, new oil pump, baffled sump with gate ways and Windage tray. Fitted a lightened and balanced flywheel and I had the o2o gearbox rebuilt with uprated diff bolts and plates, fitted a black diamond fast road clutch too. I sprayed the block red fitted a new cambelt, new water pump, super 4 spark plugs and red spark leads (can't remember what make now.)




When I had the abf ready for the implant, I started dismantling the 1.8, cleaned up the bay a little bit and fitted new engine mounts ready for the abf the go in. Once I had the abf in the car I connected up the 4 branch, inlet mani off the kr, pipes, cables and set the k-jet up. Got it running and started to check timing with the dizzy, I couldn't get it running right after trying most things so I bought a new kr dizzy and got that fitted. It ran a bit better but there was a slight tapping noise and we couldn't work out what it was, so after a lot of tampering it turned out to be the timing on the cambelt was out by one notch. So the exhaust valves we're clipping the tops of the pistons. After that slight hiccup everything went great it ran like a dream and had good power. I then took it up to gti international and it went on the rolling road and came out with 167bhp.
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Offline Jon Olds

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Re: Alex Mac's mk2 ABF Turbo track toy.
« Reply #1 on: January 12, 2015, 07:56:32 am »
Good work, nice car
Jon
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Offline alexmac

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Re: Alex Mac's mk2 ABF Turbo track toy.
« Reply #2 on: January 12, 2015, 10:21:46 am »
As said I am basically copy and pasting from my other thread. So some stuff might not make any sense :)

I had my gearbox rebuilt with the strong diff bolts and plates.

I then purchased my self a high flow Aluminium radiator, slim line fan and a samco hose kit. I then got hold of a nice set of banded g60 steels that really finished the car off for me. Anyway I drove it like that for some time, until February 2012 when I decided to take the mk2 off the road.



After a lot of debating about selling the car I decided to turn the mk2 into a track car so my plan is to lose the k-jet and go megasquirt. I sold the steels and fitted the original bottle caps back on.

The car was stripped down inside, I had been busy chipping away the floor tar and sound deaden to lose some weight :)
Ported and polished the abf inlet manifold and painted it.

Megasquirt ms1

Wideband lambda probe and a few other little bits, I just need the engine side of the abf loom or the whole abf loom.
I received my abf loom, I stripped all the tape off it and stripped all the plastic casing off my k-jet loom ready to make my hybrid loom :) I started wiring it all up on Sunday.


You can see in the bottom left corner how much plastics and tape came off

started to practice welding so I can weld my feet in for the roll cage and anything else that needs welding.

The loom is almost done at last. I have been drilling the seat rails out for the last two nights.

I do have a few holes to weld :) not to bad though
Got the 4 branch out got the lambda bung welded in, paint the roll cage and wrap the loom.
 
I have put the main loom and light loom back in, I just need to connect it up with all the right plugs :)

Cam pulley and cnc gear linkage kit is fitted.

Lambda probe is welded into the exhaust

4 branch has been wrapped

Brake servo is back in and the inlet manifold is all bolted up. I have finished welding all the feet for my roll cage, and the cage is in the car.
the feet are ready to be welded in and i also have my seat rails now so i can also weld them in ready for my nice new seat :) Loom is basically plugged all up now as well thank god.

I have also up graded my heater fan.
I think I have the loom/wiring all up together now, managed to plug everything into what I think is the correct place on the fuse box. Ran the dash loom in and connected up the switches, dials/clocks. Fitted the fan back in after upgrading the flaps



I was finishing up the welding last night and it ran out of gas, so will need to get that re filed asap. Fitted the HT leads and new speedo cable, kind of mounted my oil catch tank but its sh*t so I am going to weld a bracket on for it instead.

This is when I was running the ABF with k-jet
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Offline alexmac

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Re: Alex Mac's mk2 ABF Turbo track toy.
« Reply #3 on: January 12, 2015, 10:29:21 am »
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Offline alexmac

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Re: Alex Mac's mk2 ABF Turbo track toy.
« Reply #4 on: January 12, 2015, 01:32:54 pm »
Well what a nightmare I have had. And the car is still not running. After flattening out a few issues with it we can not get it to start for no love nor money. It just turns over and rarely sounds like it's going to fire.

We have tried most things in the book now and I'm nearing exhaustion with the damn thing. My mate came around to look at it today (mechanic) and he can't work it out either. I'm getting fuel and spark but it's not lighting at all. It will only go to fire when it's been sat for a while but that's short lived. We have double double checked the timing tried different trigger arms, rotated the dizzy 180deg, changed spark plugs, new coil, bigger earths.

Well at last I think I am getting somewhere with why it won't start. After having a mechanic around to look at it and not having a clue I decided it would be a good idea to send the ecu to toyotec In case there was something wrong with the ecu.

Turned out that the ecu is not configured for my 16V, it also had no trigger signal to detect a hall circuit.

Ecu is all done and on its way back to me :D cross fingers when I plug it back in the car will jump into life ??
No that didn't happen!

Well toyotec came down. Had a look basically process of elimination. It was a real head scratcher to why the engine wouldn't even cough as we had fuel, spark and compression.



Eddie took a look in the oil filler and instantly saw that the cam was pointing in the wrong position with the cam pulley at tdc.

Well it turns out that the adjustable cam pulley was completely out, he suspected that the pulley may have been re assembled incorrectly. We fitted the standard pulley, took the rocker cover off and made sure that the cams were in the correct place. Fitted everything back together and BAM! She fired up :D first time I have herd it running in 2 years.


Managed to get all the sound deaden foam off the floor pan too.

Started tackling the mess of cables behind the dash. And slapped a load of paint on the floor.

Right I got the seat bolted back in and the harness in.

Connected the isolator switch up. I fabricated a carbon panel to stick in the stereo hole. The plan was to have the ms behind the panel with the three led's poking out and a plug, and the isolator switch next to it.

That didn't quite go to plan. When I fitted the iso switch I couldn't get the ms in next to it, not enough room.

I also fabricated a battery box to bolt to the floor and got that all done.
Sorted out an earthing problem with the dash.
And my compomotive ml1581's arrived today :)
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Offline alexmac

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Re: Alex Mac's mk2 ABF Turbo track toy.
« Reply #5 on: January 12, 2015, 01:40:14 pm »


Right pretty much up to date now. I started collecting turbo parts on the 12 November 2013, I took the golf off the road on the 29th December 2013 so everything I post now is what I have done in the last 14 days.
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Offline alexmac

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Re: Alex Mac's mk2 ABF Turbo track toy.
« Reply #6 on: January 12, 2015, 07:18:16 pm »
I started collecting parts on the 12 of November. I bought the turbo and manifold first.
It's a KKK K24 7000 from a audi S2.

I picked up an intercooler off my mate because he upgraded to a bigger one.


I bought a 1.8T inlet manifold and a 16V KR one to cut and weld together.


I test fitted it before I sent it to be welded up.


As you can see it was sitting a bit to high, so I chopped it some more.


New gearbox arrived, 02J.


S2 waste gate


New injector seals



Water hose adaptor


Had to cut the 5th leg off the exhaust manifold and get it plugged.


Inlet manifold welded up


I had some die grinding to do in those inlet ports so I thought I would swap my tiny compressor for a 50litre one, had a really good deal on it too.


The garage that the car is in now is huge but it was full to the brim with crap and my dads old mk1 MR2, so it was a couple nights of hard work and several trailer loads later we managed to get the garage cleaned out. All was left to do was to pull the mr2 out and move to the other garage, and build a big bench to work on.


Received a lightened G60 flywheel
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Offline alexmac

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Re: Alex Mac's mk2 ABF Turbo track toy.
« Reply #7 on: January 12, 2015, 07:49:39 pm »
New shifter


New valve seals. For some reason they sent me two white things.


440cc injectors from America


So on the 29th of December the tax ran out so I thought that it was the perfect time to sorn it and get cracking with it.




Bores were in fairly good condition, there was one slight vertical score but it was to bad. The engine never lost any oil.


The old brake servo and pedal box came out to be replaced by a corrado pedal box and servo so I can run hydraulic clutch.



Squashed the bulkhead in



Had to cut and re weld the top bracket on the corrado pedal box


I made an alluminium plate to cover the whole up were the old gear shifter was, but we decided in the end that it would be better to weld a plate over it, which is what I did in the end but I forgot to take a photo of it.

Brake servo painted
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Offline alexmac

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Re: Alex Mac's mk2 ABF Turbo track toy.
« Reply #8 on: January 12, 2015, 08:33:26 pm »
I made a little stand for my new shifter to sit on.


Nice high shifter and I lowered the steering rack 15mm. The pedal box and servo is all bolted it now.

New brakes arrived. Hi-spec callipers with braided lines and 280mm black diamond discs. Bit of an upgrade from my standard 239mm brakes

Stripped the steering rack out to replace the broken steering column boot.   


Drive shafts out, old hubs, coilovers and tie bars all off

I cleaned the ports out on the head


Block was cleaned and re sprayed.
I then covered the crank with tape and oily rags, taped up the oil squirters and stuck oily rags down the bores.

I borrowed a Flex-Hone off my mate and got to work, 60seconds on each bore.



Picked up a set of 2E rods, thanks Tim.
They really are a lot thicker than the ABF ones.


Gave my Pistons a real good clean up.

Fitted the Pistons to the conrods and the new rings, and voilà.


I did a bit of spraying tonight after work and started painting the newer hubs. I fitted new wheel bearing to the hubs on Saturday as well.

And that's it, all up to date :)
I hope you have enjoyed it so far.

Cheers
Alex
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Offline alexmac

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Re: Alex Mac's mk2 ABF Turbo track toy.
« Reply #9 on: January 17, 2015, 10:31:24 pm »
Went and picked my head up on Thursday


Cupra brake master cylinder


Hubs and tie arms on


Rocker cover done


Today I test fitted everything to see what it sat like

Going to torque everything up tomorrow.
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Offline alexmac

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Re: Alex Mac's mk2 ABF Turbo track toy.
« Reply #10 on: June 03, 2015, 10:47:57 pm »
Been really busy lately so haven't had chance to update this.

The car is running now and running well, I have been running the engine on running in mineral oil. Currently doing the 1000 mile run in and I have 200 miles left.



Cheers
Alex
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Offline Petakerky

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Re: Alex Mac's mk2 ABF Turbo track toy.
« Reply #11 on: December 13, 2018, 08:07:28 am »
Get to know the full without any parts that are well written it.
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