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Discussion Starter · #1 · (Edited)
7/19/17 - I just got the email from Photobucket about 3rd party hosting. Once I find a reliable place to host the pictures I will update the thread, sorry if they aren't working at the time you read this.

Welcome to the build thread for my 1986 Scirocco 16v

I purchased this car 11/07/2009 from the 2nd owner in Scranton, PA. They had owned the car for around 14 years and it had been sitting on and off for 11 when I bought it. Best part about it is that it's 99% rust free and the car is pretty much bone stock :thumbup:

I bought this car on an impulse, not gonna lie. I had not owned a Scirocco for a while and had been just browsing the classifieds when I found this one. My first Scirocco was almost identical, but being much younger when I owned it I lacked the funds to buy the stuff I wanted. With this one I have pretty much set out to make it the 16v I always wanted.

The day I picked it up.


All cleaned up for the first time, turned out really nice. (sorry about the pics, taken with a blackberry)






*Update 2/12: Changed the original thread to include earlier pictures of the car and to make it more of an introduction to the thread. It's amazing to see how different the car looks now compared to such a short time ago.

*Big thanks to Paul for changing the thread name :thumbup:

Enjoy the build, I've had a blast along the way so far and there is always more to do.

:beer:
 

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Discussion Starter · #2 ·
So last night I had some time so I brought it in to check out the situation with my sunroof. The PO converted it to a power sunroof using an Audi motor. I have already had the sunroof apart to replace the seal in the spring, but until now I have waited to figure out what was done with the wiring. Wires have already been run from the fuse box up the A pillar to where the dome light is, I just need to make sense of it all.

Just to show what I'm dealing with, here are the wires coming out of the dome light area.

Now down by the fuse box, the red wires in the top middle are what have been run.


Should be fun! I did find another random wire running behind the radio and decided to check it out since I was already in a wiring type of mood. Removed the center console to find yet again another superb wiring job by the PO. I will say this though, at least the stock connectors for the radio are still in tact!

Here is what I started with.

After about 10 minutes I had it cleaned up to this.


As soon as I can I will be repairing the radio wiring. The actual harness is cut about 8 inches from the connectors and stripped about 1 inch from them. With a little time, heat shrink and solder it should be good as new. Then I can dive into the sunroof. I am hoping to get the wiring done before the weekend. Saturday I will be going to work (on my day off) to install the front wheel bearings, coilovers and perform an alignment. Till then :beer:
 

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Discussion Starter · #3 ·
No real progress to give yet. I swear this week has been moving so slow, Saturday still seems like a week away even though it's tomorrow. Until I do some real work to it I thought I would show off what came in the mail the other day.

Euro Valences, unpainted :thumbup: They have been used but are pretty much scratch free, no broken mounting tabs either.


I also wanted to post some better pics of my Euro lights, the other ones I have were taken on my old blackberry that had a pretty bad camera.


Crack free turns


Now if I could only find some nice bumpers I would have no more stuff to buy for the exterior.

More progress after this weekend :beer:
 

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nice work & nice car to start with!

have you driven on the ST's yet? would love to hear how they are as that's the best deal in coilovers out there.
 

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Discussion Starter · #5 ·
nice work & nice car to start with!

have you driven on the ST's yet? would love to hear how they are as that's the best deal in coilovers out there.

I just got them on today actually. Drove around for a few hours and in my opinion the ride quality is very nice. Yes they have a firm ride but its not over the top like other coilovers I have had experience with. I would highly recommend them to anyone looking for a very nice set of coilovers at a somewhat affordable price :thumbup:

Another update to come shortly :beer:
 

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Discussion Starter · #6 · (Edited)
Over the weekend on Saturday I went into work on my day off to get some heavier work done. It's nice to not have to work fast for a change, I almost forgot what it's like to work on cars for fun.

I started up front and replaced both front wheel bearings, no pictures since it's not very exciting. While I was doing them I also threw in the front coilovers with the new strut tops. The coilovers are from Suspension Techniques, same valving as a KW Variant 1 but with a galvanized body instead of stainless.






I also cut the front rotors really quick, they were rusty and off anyway so why not? All put together up front.


Installed the rears together with Prothane Poly mounts, don't mind the rusty calipers.


Now for the part I was not looking forward to, setting ride height. I was very surprised to find that it's not that bad of a job. I had to turn down the fronts about 3/4 of and inch and only 2 turns out back. Here she is on the ground. The ATS Cups I took off my Mk2 Golf before I sold it, they are by far my favorite rims and look perfect on a Scirocco :thumbup:


On the Alignment rack a little later after some minor height adjustments.


Looks pretty good if you ask me, not too low yet still slammed :thumbup: Here are some more pics I took so you know what it looks like out of the shop for a change :laugh: You can see my other toy in the background in the first one below.







It drives really nice now, alot better then the blown stock suspension I was rocking before. I'm going out of town at the end of this week so there wont be any progress till I get back, I need to order more parts too. Till then :beer:
 

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Discussion Starter · #8 ·
Thanks for the comment :thumbup: The more I look at it the more I agree I need rear spacers, that will have to wait till another day though.

Time for an update.....sorta. I have been going back and forth with my plans for the engine like you wouldn't believe. My choices were 1.8T or 16vT. I chose the 16v for a variety of reasons, one of which is because I already own this.





It's a Zornig manifold and I have had this for quite some time now. This was a gift from a bunch of friends of mine 6 years ago for graduating UTI. I was going to use it on my first 16v but the timing just wasn't right. This is the perfect opportunity. I'm glad the car now has a direction, up until now I have been aiming at a moving target. More progress once I have any to share. Here are a couple more shots of the manifold.





:beer:
 

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Discussion Starter · #9 ·
Plans sometime change

You can completely ignore the above post. Plans changed about a week after I made it. On Thursday I will be making another trip to the east coast for another major piece of the puzzle, a complete G60 engine....with a Lysholm charger :thumbup: This was very much an impulse buy but it actually was an original plan for my first 16v, I just couldn't afford it at the time. I may be asking Paul to rename the thread once I get back from the trip.

Here is the schedule for the weekend:

Leave work around 10pm CST Thursday
Get into Virginia around 6-9pm EST on Friday
Load it up
Drive back to Chicago
Unload the engine Saturday night/Sunday morning
Sleep
Drink/Watch Football

I plan on being back here Sunday morning, who knows what will actually happen though :laugh: I have to clean a space in my buddies garage too so I have somewhere to keep the block until I take what I need and sell the rest. That will happen sometime this week. I will probably the thread from the road to show some pics and stuff. More very very soon.

:beer:
 

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hey, looks great.

just curious about the ST's and the ride quality, especially once you lowered them. did the ride height affect the ride quality a lot? i have some DIY coilovers i've made and the ride quality with 400# springs isn't so bad as long as i don't lower it too much. and then every quarter of an inch makes a big difference in the ride quality, especially the bounciness, so just wondering how it compares to the ST's.

and do you know what rate the springs are?

thanks as i'm still learning what it takes to make these cars handle AND ride decently. BTW mine handles incredibly but still think my shocks need tuning. (bilstein sports but getting old & tired.)
 

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Discussion Starter · #15 ·
hey, looks great.

just curious about the ST's and the ride quality, especially once you lowered them. did the ride height affect the ride quality a lot? i have some DIY coilovers i've made and the ride quality with 400# springs isn't so bad as long as i don't lower it too much. and then every quarter of an inch makes a big difference in the ride quality, especially the bounciness, so just wondering how it compares to the ST's.

and do you know what rate the springs are?

thanks as i'm still learning what it takes to make these cars handle AND ride decently. BTW mine handles incredibly but still think my shocks need tuning. (bilstein sports but getting old & tired.)
I don't know the spring rates off hand, I'm sure that they are floating around on the net somewhere though. The ride quality is pretty nice for being a coilover. Same valving as the KW Variant 1s if you didn't know much about ST. They are firm and not bouncy and I have them as low as I can without rubbing too bad. I think they ride better then the FKs I had in my A2. HTH:thumbup:
 

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Discussion Starter · #16 ·
Success!

Left my work at 10pm CST on 9/23/10(Chicago, IL)
Arrived in Hampton, VA around 3pm EST 9/24/10
Loaded engine into back of SUV
Go to BW3 for some food and a :beer:
Started heading back to Chicago around 5:30pm EST
Rolled into town on 9/25/10 around 6:30am CST
Unloaded engine then went home and passed out at 8:30am CST

Had to remove the downpipe and rear mount bracket off the G60 for it to fit but we got her loaded up in about 2 minutes once the pipe was off.


The hot stuff, Lysholm charger :thumbup:






Pretty good trip overall. Between getting the car and now the G60 I have now driven around 3500 miles for my Scirocco, with more to come I'm sure. Will update once I remove some stuff off the block. Till next time.

:beer:
 

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Discussion Starter · #17 ·
Just wanted to share a few more photos with you. I am going to add some pics of the wiring harness after I take some shots of it laid out at work. I took all the boost tubes off and the engine harness last night, forgot my allen sockets so I was unable to remove the charger and brackets.

Couple shots of the engine




Here is my head gasket spacer, I believe it is a C2 unit but I really cannot remember, I bought it probably 5 years ago.
 

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Discussion Starter · #18 ·
Unfortunately I found out last week that BBM only has 2 16vG60 Integration kits left until next year. After buying the engine I cannot afford to get the kit so unless I find one for sale elsewhere I doubt I will be doing the conversion over the winter like I had planned. Not a big deal though, it gives me time to sort everything out and get everything I need including exhaust and a front cross member brace.

I have been looking through countless threads about this swap and it doesn't look too bad to do. Mechanically I have absolutely no worries about this, it's just bolting stuff on. The electrical is another thing since it's not exactly my strong suit, but I do love working with it. I have an ECU and harness from an automatic and finding info for it is a little tough. I may have to ask elsewhere (probably the digi 1 16v faq) but is there alot of stuff i can take out of this harness? Compared to others I have seen mine looks like I have so much more wiring. Mainly in the area shown here.


Here is the whole thing.


I also pulled apart the ECU to check the chip and found this.


Score there, I'm wondering if the engine has a cam too. More to come soon once all the parts are pulled off the G60.

:beer:
 

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Pull the charger off & cover/plug/protect the inlet, outlet & all oil feed/return lines immediately. those units are notorious for machining themselves into a grenade if the slightest bit of debris gets in them or any torsional stress is put on the casing when warm. :beer:
 
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