My Mk1 Golf ABF conversion...

[DognamedElvis]

Fail....................................



I have 'simplified' my original wish-list as the cost was going to be well over $30k NOT including what I've already spent on the Golf and buying the Cupra donor car!



I am planning to do a fair percentage of the work myself to save on costs where possible, however I am not particularly good with my hands, but I have half a clue, give things a go, do lots of reading/research and try not to ask too many stupid questions
Obviously, there are quite a few members on here that have undergone this swap in the past, so please feel free to comment, advise, criticise and offer suggestions as you see fit. That's actually a significant reason for this thread.

The rust, leaks and bodywork I will leave to a pro, as I want to make sure I'm starting with as solid a base as possible. I can't realistically afford to do a full dip/bare metal job all over as my budget for the bodywork is well under the ~$10k it's been suggested to me that may cost. I'm hoping to get away with under $5k...ideally, well under.
Paint/presentation has been demoted well down the priority list (no silky smooth engine bay for me), structural integrity is my main aim.

Not ideal


I was dreaming about a late model hydro 6mt, but have decided staying with the 02A 5 speed makes better fiscal sense. It's around $600 landed for a complete 'crazyquiffs' hydro clutch kit for the 02A, so I'll probably go that way, as I'm no fan of the cable clutch.
Shortening the final drive ratio with a 3.94 Ring & pinion and adding an LSD (*undecided on type/style) are also a priority as is fitting a lightened flywheel (*weight advice req'd) and upgraded clutch (*haven't yet researched this).
I'm budgeting ~$3k for all of the above.



I found some documentation in the SEAT today, detailing a head service at Camden GTi, It appears Matt has added some 'euro spec' cams, replaced head studs, skim/set-up buckets, re-seated the valves, pressure test etc totalling over $2k, albeit nearly 4 years ago, but I'll leave the long motor un-opened at this stage. It's 135k km's young



Again, I was hoping to go ITB's, after market ecu, etc., but the real cost of this set-up is too great for me to justify, so I'll be converting the ABF engine to carbs...hopefully bike carbs depending on cost, availability, manifold etc and making sure the rest of the fuel/ignition system is suitably upgraded. Budget is ~$3k for the carbs, manifold, fuel pump, dizzy, coil, leads, ignition kit etc.

I will be fitting headers/extractors and a catless system (*advice on pipe diameter and header brand req'd) ~$1k

I will most likely need a custom radiator to make all this fit and like the idea of Spal thermos...another ~$1k

Haven't even started on the suspension yet but thankfully, I already have KW V1's, but I would like full poly bushes, Strut braces and a FAT rear swaybar...~$2k



I want a comfortable cockpit, so despite it's weight, I will be rolling out metres of dynamat and getting the dash/doorcards resurfaced or replaced (*looking for info/pricing on dash 'flocking') and my Recaro SR3 will be retrimmed and fitted. I won't run a stereo at all and will probably remove the heater core/fan etc and rep a 12v hair drier for demist duties and a mini fan for cooling
~$2k

No doubt additional costs such as hard lines for the rear discs, electrical upgrades/repairs and other things I've forgotten will crop up, but I'm heading into this with no illusions of a 'budget' build.
If the car is engineered and rego'd for anything less than $20k from here, I'll be stoked.



In the perfect world, this will be up and running by April next year. Can't wait, as I can feel the potential every time I drive the Cupra and can only imagine the difference a few hundred kilos and some added 'eagerness' will make...good times ahead.
Enjoy...
Pete.