The Mk1 ABF Project

[GOLFBALLS]

Thats the ticket!
Had your bro round for dinner tonight and took him for a spin in my mk2. Put a smile on his face...
He's just told me about the classifieds thing.
Good to see you finally getting stuck in. Try and keep everything categorised or labelled in some way. There's nothing worse than picking up bits weeks later and thinking "what was this bit off?"

[cartertronic]

Yeah good call on the labelling of things.. I bought a set of plastic drawers and am labelling all bolts/nuts as I take them off (plus wires etc), have also labelled all the kjet fuel pipes and wires for the next guy.

A few years have past since my last engine conversion and I'm a little more patient than I used to be. Last time I did enough to get it running, but not much more. This project I'm going to take my time and do a better job

Thinking I'll clean up and spray the engine bay before I drop the 16v in (will do a test drop as I've heard I'll need to knock the drivers side pillar in a a couple of mm with a bell hammer so the belt tensioner will clear)

Can't wait to hear about the Mk2 from Benny, hopefully it might rekindle his passion for Golfs!
(sure he was crapping his daks hahaha!)

Finished taking everything out today... pics below

Engine up and out



Engine and gearbox separated
PS - Engine (Mk2 GTI Kjet 8v) will be posted up for sale soon


Looking forward to a new year & new beginnings


Happy New Year Everyone!

[Jarred]

yay Simon!!

This is finally happenening!

[cartertronic]

Hey guys,

Just thought I'd let you know I'm back from holidays and chipping away at it

First stop is the brakes (pardon the pun!)

I'm upgrading to a Cordoba booster and master cylinder for greater stopping power..
(my thanks to Peter Jones for his useful guide - How to mod a late booster for Mk1.)

Cordoba booster (sans thread that is needed to attach clevis pin)


Using a die to add a M10x1.5 thread..


Finished and ready to be fitted..


EDIT - SORTED - Got another boot on the way!
PS - Unfortunately the rubber boot covering the rod from the brake pedal to the start of the brake linkage has split, called VW (Part# is #172 612 109 B) but it's been discontinued.. anyone have a good one of these?




Other useful brake modding links from Mr Jones:
Installing Cordoba rear drums on a Mk1 (I've already done this)
Mk1 Disc and Caliper Replacement (I'll be upgrading to GTI calipers & discs shortly)

[cartertronic]

Hey guys,

I've heard a few stories about 020 boxes tearing themselves apart when strapped to ABFs.. the diff rivets being the usual weak point.

Valver - I think I remember you saying you went through a few 020 boxes yourself?

So I'm guessing it makes sense to fit a bolt kit... and if I'm going to get bolts fitted, I may as well replace the open-diff with a LSD at the same time.

Traction bonuses aside, am I being paranoid about the rivets (remembering it's a diesel box - 4T 5spd)?
EDIT: For those reading, I'm starting to uncover it's a matter of 'when' not 'if' with the diff rivets going..

PS - Found a good diff bolt kit 'how to' http://www.brokevw.com/020diff.html

[roccodingo]

changing the rivets for bolts is a sinch, You may need to fabricate a puller to split the trans case tho.
If you go the route of installing a quaife, pelo or wavetrack you will need to check the bearing preload on the bearings during installation and re shim to get it correct. ( shims from VW ) See Brian's web pages ( broke)

Bolts are available from ARP also. (204 - 3001)

Rubber brake boot is still available from classic vw ( VW Heratige )

VW Heritage for VW parts and accessories

[GoLfMan]

nice Simon, good to see you're back into it!

[mikinoz]

nice Simon, good to see you're back into it!

I concur!

[cartertronic]

Thanks lads! It's good to be back

Rocco - Have you done this before? From the looks of BrokeVW's site (Opening the 020) it looks like I have to dismantle the entire thing to get to the diff??!

Re: testing bearing preload
I'm not sure if I've got the equipment/experience to get this done myself (and be sure of an accurate job) might be best to track someone down to install it.

PS - From what I've heard only 4spds and pre-1984 5spds need to be shimmed?

[roccodingo]

Thanks lads! It's good to be back

Rocco - Have you done this before? From the looks of BrokeVW's site (Opening the 020) it looks like I have to dismantle the entire thing to get to the diff??!

Re: testing bearing preload
I'm not sure if I've got the equipment/experience to get this done myself (and be sure of an accurate job) might be best to track someone down to install it.

PS - From what I've heard only 4spds and pre-1984 5spds need to be shimmed?

Pics are on the bottom of page 2 and some page 3..
http://www.vwwatercooled.org.au/foru...s-21212-2.html

And yes, all apart to take the diff out.

bearing preloads are explained in the bentley manual along with the part numbers for the shims. While your doing the diff , change the syncro's and any damaged gears etc.

I had to locate a torque meter to do the preloads on the new bearings, cost about $600 from some mtool mob in Adelaide, but then have done Wade's O2A since then and still a pile of others to do.