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Discussion Starter · #1 ·
Mk1 build / project, for old times sake...

Bought the Mk1 in october; its Hibernating in my driveway for now, but accumulating the needed parts;
On the menu:
Media blasting the whole car
Diamond Silver repaint
New window, scraper sets & misc. seals
Coil overs
Dash overlay
10.1" front brakes
16V rear brakes
22mm master cyl. swap
stainless braided lines
Hydraulic hand brake coupled with prop valve
new carpeting
Short shift kit
Poly mounts
2.0l 16V with 9a tranny (everything to be rebuilt)
Looking for a deal on a Peloquin or a Quaife
Ignition MSD 6Al + 8920/8921
40 DCOE webers
TT swaybars front & rear
wheels (looking out for a sweet deal either on ATS cups or RS's... 15" max.)
A3 fuse box swap
Air dam
Bumper mods for the euro look
Poly mounts
16V engine mounts
16V headers
Borla exhaust system
I'm sure I'm missing a few things, but I guess your getting the picture...
I have to finish my race motorcyles rebuild, before going full time on this one...
I also have an A3, 2dr that I will take as my "track bitch" this summer, so the Mk1, will be a relatively slow process...
BTW I have bought this car, because my first car was a 78' Scirocco, and I just missed having one...
Thread useless without pics, so here it goes:
First Rocco in 1983, doing Auto-X


Picking up the car in Ottawa



Driveway hibernation


2.0l 16V just waiting...


Got my coilovers this week

Weber 40 DCOE, getting rebuilt



Keep you all posted!
Fred

Modified by fredybender at 8:24 PM 2-6-2009


Modified by fredybender at 9:48 PM 2-20-2009
 

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Re: Mk1 getting some glitter back... (Studubbin)

Sounds like it will be quite a project http://****************.com/smile/emthup.gif
Can i get some more info on the parts washer you have pictured on your bench
 

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Discussion Starter · #5 ·
Re: Mk1 getting some glitter back... (LubsDaDubs)

The parts washer, is an ultrasonic parts cleaner
Not good for heavy soiled items, but perfect for carbs & small parts where small holes are present...
Harbour freight tools at about 160$
But it just quit on me this morning

Just bought it in August, and used it half a dozen times...
Hope the thing is still on warrranty...

Does anyone know if I can adapt a 22mm master cylinder, on the Mk1 brake booster :
Is it a bolt on, or mods are needed? If mods needed, would it be simpler to get a brake booster from an A3 ?
Fred



Modified by fredybender at 11:24 AM 1-25-2009
 

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80 Scirocco, 87 Scirocco 16v, 86 Quantum Syncro, 91 318is, 84 230CE, 99 Tacoma PreRunner
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Re: Mk1 getting some glitter back... (fredybender)

Quote, originally posted by fredybender »
Does anyone know if I can adapt a 22mm master cylinder, on the Mk1 brake booster :
Is it a bolt on, or mods are needed? If mods needed, would it be simpler to get a brake booster from an A3 ?

As far as I know, you'd need to use a brake booster from an 85 or later Scirocco or Cabriolet to run the 22mm master cylinder. The A2/3 boosters won't work because they attach to the pedal differently.
The only other issue is that the brake light switch on Mk1s are a pressure switch on the master cylinder. The Scirocco 16v and Corrado G60 that use the 22mm cylinder use a brake pedal mounted switch. You could either fabricate a way to mount a switch on the pedal, or plumb the pressure switch into the brake lines somewhere.
 

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Discussion Starter · #8 ·
Ok, after finding out that the douche bag that sold me the donor engine sold me a piece of scrap (valves hit on all cylinders, shattered #1, bent intake valves on #1 & #4, beyond taking the retainers out...) even the adjustable cam gear is scrap, as the drive key sheared the slot...
Almost nothing salvagable, taking into consideration costs...
Will be looking for another 9A donor engine.. its only money, right?
On a better note; Received my order from Pierce Manifolds. Putting on Webers, is not a totally justifiable thing, but man, they sound sweet, and it cleans the engine bay, big time!
So for my wants; a lot of work, and some $ in the money pit!
550$ later... (Just for small parts, that could fit in the palm of one hand ...

All new internals as per the FAQ's recommendations for the 9A... (plus linkage & gasket sets , etc...)

Pics for your enjoyment:
Started with a pair of beat up DCOE's





Getting them back into shape:





The Pierce manifold os OK, but I must of have 8 hours of port matching/polishing, machining, to get it to my liking: The choke cover has interference, and had to machine top of the head mating plate. Also, I macined the boss for the booster vacuum pick up (Top not level) and also, pressed fit a nipple for a cleaner look than a threaded one.


Starting to look good!


Pretty much finished:



Also got a NOS Kamei (even with the "Kamei" boss on the air dam)

Its winter, so its working time, and parts shopping too...
 

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FV-QR

Is that an ultrasonic? Dayum. I had never heard of one until I started my Dental Hygiene program. You're smart for buying one and using it for car stuff!!! I applaud you!
 

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Re: Mk1 build / project, for old times sake... (fredybender)

I have that same pierce manifold.. Those things are junk, seriously! You should not have to put that kind of work into a piece you pay alot of money for. I messed with mine for several days until I got it right. I was not very happy with it at all!! They do work though with modification http://****************.com/smile/emthup.gif
 

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Re: Mk1 build / project, for old times sake... (fredybender)

Looks like a great project.I think you will have problems with rear brake bias if you run rear discs and 9.4,s up front though. Why not the 16v brakes up front as well?
 

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Re: Mk1 build / project, for old times sake... (So Low 2)

Quote, originally posted by So Low 2 »
Looks like a great project.I think you will have problems with rear brake bias if you run rear discs and 9.4,s up front though. Why not the 16v brakes up front as well?

I am about to do the same thing. 9.4's up front and 16v in rear. Are you saying the prop valves won't do the trick?
 

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Re: Mk1 build / project, for old times sake... (xenergy_one)

Quote, originally posted by xenergy_one »

I am about to do the same thing. 9.4's up front and 16v in rear. Are you saying the prop valves won't do the trick?
Yes.
 

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Discussion Starter · #14 ·
With the 800kg of the car, the 9.4" vented, with good pads are more than adequate. Probably looking to stay with 13's, thus the reason for 9.4" discs.
Will be going with a 22mm master, and I know that stock prop valves (being fixed) even 16v's, won't give me the tunability to set the brakes properly. I will go with an adjustable aftermarket one. Cheap, fast, and clean mod
 

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Discussion Starter · #15 ·
I bought the 9a back in october, and it was just staying in the garage, until I decided to attack it: I wanted to do a refresh: check piston, bearing, and other clearances, and just a hone, and replace what was needed...
Well, got a good surprise when I took off the head!

Valves hit, real bad too...
Piston #1 is shattered, all intake valves are bent! some of the pretty bad too... Valve guides are ovalized, cylinder #1 is scored...
Even the adjustable cam gear is scrap: the drive key sheared and scrapped both the cam & the pulley...
Tried contacting the seller ; can I tell you I can't seem to find him! it was an add placed locally, and he told me the engine was running fine when it was in the car (MkII rocco swap) ... Yeah, right!
So, basically, threw my money in the trash...
Now, I have to find another 9A ....


 

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Re: (fredybender)

Quote, originally posted by fredybender »
I know that stock prop valves (being fixed) even 16v's, won't give me the tunability to set the brakes properly. I will go with an adjustable aftermarket one.
Agreed, but as a heads up I would bet you will need both the 16v and an aftermarket adjustable in series to get the bias right. In my experience neither proportioning valve alone did the job.
 

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Discussion Starter · #19 ·
Re: (So Low 2)

If you had prop valves in series, something was wrong to start with...
A prop vlave will equalize the downstream pressure to a lower one than the upstream... Bear in mind that the volume needed for the front caliper cylinders is greater, than the rear, meaning response time; thats when you have to have enough restriction / pressure drop in the prop valve, to act as a delay.You could even go with an adjustable accumulator downstream from the prop valve to the rear calipers... But I think a prop valve with ennough range should do the trick...
Basicallly I agree with you...
on the principle, not the application of it...

Fred


Modified by fredybender at 3:57 PM 2-8-2009
 

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Re: (fredybender)

Waiting to see with what you come up with that works. The solution I mentioned (16V prop valve before a Wilwood style adjustable) works for quite a few autoxrs locally with the 9.4 front/disc brake rear setup.
 
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