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.

[Smead]

Good luck mate. Car looked good at SGAD so ill be following this build with interest

[Stan]

good luck, looks like a cool project

[Jarred]

Great to see.

Seems as you've set a very reasonable price target imo, and some very sensible and well sorted mods.

Should be a ripper car onces done!

Have a look on clubgti (if you havn't already), there's heaps of good info on there, alot of 16V stuff, and bike carb stuff

[zllewellyn]

I'm going to say this again, I LOVE this car!! I'll be very interested to see how the conversion comes together, would love too do the same someday

[DognamedElvis]

Cheers folks

Thanks for the PM's of advice, much appreciated. I've also been made an offer to check out a local ABF converted mk1, will def be taking you up on that Andre

Looks like I'm going to (pretty much have to) go the full hog on the body after all...at the end of the day, it's the only way I can be 100% sure its proper straight, solid and rust free. It really is a mess in the passenger foot well, there is also a collapsed jack point on the front drivers side that has me worried. I am going to strip it back as much as I can myself first (parts etc).

With a full respray on the cards, I will now think about a colour change...probably a Satin Chocolate or Military Green of some description (I have a old VW trends somewhere with a picture of a slammed Beetle Convertible 'Papler' Police car...THAT colour is win!)

It will mean a few extra months of saving before I can really make things happen, but It will give me plenty of time to research every thing else I need properly.

I've been busy reading through clubgti (ta Jarred) and The Mk1 owner's club forums and there is heaps of info to trawl through there.
I have sent an e-mail to BoggBrothers regarding their complete ABF Bike Carb/Manifold kits (car jetted, ready to bolt on/drive to the dyno) as they appear to have been doing it for about 10+years.

Another thing I am going to do, when the spending starts, is list all of the actual costs of all work and parts.
It is something that is, more often than not, omitted (understandably) from build threads. I feel comfortable with this, as it is not really going to be a 'big dollar' car.

I am self-employed, but at this time of year, I have more work than I can poke a stick at (Gardener), so I will be putting in the big days and the odd weekend so I can hopefully get the body under way sooner rather than later It's amazing how motivating these things can get once you mentally commit...

Pete.

[ffoff]

New you'd come round Pete! I'm around to give you a hand if you need mate!

[DognamedElvis]

I'm around to give you a hand if you need mate!

Ditto if you want a hand with your hub conversion

[DognamedElvis]

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.

Sweet news from Bogg Brothers...a full bike carb kit for the ABF including all fittings and delivery is just under $1200Aud delivered, happy with that.

[dubstar]

Cool project. I wonder though whether you would be better going with the Injection/ECU/Fueling from the SEAT. That way you can get access to all the chips/programming available. Wiring it in is very straight forward and straight out of the box you have 170bhp.

You can contact the VASK.org.nz guys as there are quite a few ABF builds there.