Kav1187

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Viewing 15 posts - 1 through 15 (of 48 total)
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  • in reply to: The end of an era #23810
    Kav1187
    Participant

    Hi Chris, long time no see. I’m sorry to see that you’ve sold your Syncros.

    Mine is still in a state of mid-conversion and has been in a garage for the last 8 years 😳 I have just moved to a house with a suitable garage where I can work on it again so hopefully get some traction on it soon.

    I’m glad this forum is still around and it has been a great source of information over the years 👍 I’ll hopefully start adding to it again soon.

    Cheers,
    Kav

    • This reply was modified 1 month ago by Kav1187.
    in reply to: Golf Syncro 20v S3 Conversion #10806
    Kav1187
    Participant

    Sounds like a great project mate. Mine has been on hold for the last year as I’ve been trying to do my house up. Once I get moved in I’ll crack on with the car again :)

    Have you got a thread for your build? I was toying with the idea of plastic welding the fuel pump opening from the S3 fuel tank to the golf one so that I can use the S3 pump but a custom tank sounds much better. Are you making it yourself?

    in reply to: 1.8t, 02m and Haldex into mk2 Syncro #10325
    Kav1187
    Participant

    Hmm…looks like engine needs to come forward by about 1/2 inch. Would the rear engine mount from the 02c be longer than from the 020? I know some passat mounts were slightly longer but not sure they’ll work for the 4×4 setup.

    in reply to: 1.8t, 02m and Haldex into mk2 Syncro #10321
    Kav1187
    Participant

    Thanks for the reply mate. Engine is now fitted and sits nice and square. Only problem is that I tried to connect the prop shaft and the donut is touching the steering rack [xx(] Do I need to raise the engine?

    in reply to: Syncro rear swing arms #10315
    Kav1187
    Participant

    Sold :-)

    in reply to: Syncro rear swing arms #10302
    Kav1187
    Participant

    Sorry forgot…Mk2 syncro ’89

    in reply to: Syncro gearbox and transfer box #10224
    Kav1187
    Participant

    It came straight out of the car…I’m pretty sure it’s the original gearbox from my syncro. I know there were 2 sizes of inner CV joints for the GTIs so maybe this was the same for Syncros?

    in reply to: Mk2 Syncro to S3 1.8t, Haldex, interior, wiring #10193
    Kav1187
    Participant

    With the mechanical stuff mostly out of the way, it’s time to start work on mounting the dash. This is my least favourite part of the process but a necessary one.

    As I will be fitting everything from the S3, the air con unit will need to bolt to the bulkhead. A hole needs to be cut for the air con pipes to fit through into the engine bay.

    20120915_165132.jpg
    20120915_170952.jpg
    20120915_170958.jpg

    These are the holes required for the air con unit to fit. Luckily the coolant pipes fit in the same hole as the golf’s heater matrix.
    20120915_183810.jpg

    Next up it’s fitting the dash support bar. Having done this in a previous project, I found that the only way it was going to fit right was by cutting the bulkhead at the top.

    Dash bar taken from S3
    SAM_6932.jpg[/img]

    Placed in Mk2
    20120916_183857.jpg

    Trimming required so it will fit into the bulkhead
    20120922_155020.jpg

    Now the scary part – trimming the bulkhead…
    20120922_142851.jpg

    And it fits…
    20120922_181527.jpg
    20120922_181536.jpg
    20120922_181550.jpg

    Middle section cut out for screen vent
    20130629_193202.jpg
    20130629_193209.jpg
    20130703_141801.jpg
    20130703_142035.jpg
    20130703_142047.jpg

    in reply to: Mk2 Syncro to S3 1.8t, Haldex, interior, wiring #10192
    Kav1187
    Participant

    I have been looking at different options for the front suspension. I’d quite like to run the S3 17″ alloys as they fill the wheel arch nicely and also it would save me having to recaliberate the speedo. I have the mk3 VR6 setup at my disposal too, however the widetrack on the mk2 gives the front wheels an inwards camber at the top.

    Here’s what I’m trying to do at the moment…

    Audi S3 shock, hub and wishbone
    20120808_125050.jpg

    Unfortunately, with the mk2 top mount, the cup at the top of the strut doesn’t sit in the right place so the suspension can’t pivot round on the mount’s bearings. Some modification is going to be required…

    The S3 strut cup is on the left, the syncro one on the right. The syncro one sits higher in order to fit inside the top mount.
    20120808_135252.jpg

    So I trimmed the syncro cup
    20120808_150545.jpg

    Then the S3 cup
    20120808_151300.jpg

    20120808_151314.jpg

    Then the syncro top with the S3 bottom
    20120808_151322.jpg
    20120902_184659.jpg

    The result
    20120902_190958.jpg

    Strangely the S3 wishbones fitted ok in the syncro subframe. They allowed the wheel to sit a little further forward than the syncro wishbones which meant that the wheels didn’t rub against the wheel arch when turned. The whole lot came together but the car sits quite high at the front now. The springs will need to be cut to size.

    20120817_073309.jpg

    20120817_073323.jpg

    And I will need to raise the suspension at the rear as it is sagging a tad
    20120817_073338.jpg

    in reply to: Mk2 Syncro to S3 1.8t, Haldex, interior, wiring #10191
    Kav1187
    Participant

    With the engine now in situ and the weather getting cold, I decided to focus on getting the haldex bracket built.

    Syncro rear diff out
    20120927_142430.jpg
    20120927_142440.jpg

    S3 Haldex out
    20120901_172041.jpg
    20120901_174511.jpg

    Created a jig to ensure that the haldex fits in the correct place
    20120928_120905.jpg

    20120929_121821.jpg
    20120929_121918.jpg
    20120929_143533.jpg

    I used the metal cylinder from inside the S3 drop link to use as a bolt spacer for the rear bracket…
    20120928_155456.jpg
    20120929_160221.jpg
    20120929_160231.jpg

    20121013_150034.jpg

    Shortened the rear bolts
    20121013_153402.jpg

    I created this extra piece on the jig to ensure that I get the rear hanger bracket in exactly the right place
    20121013_170242.jpg

    WD40 can was pretty much the same size and shape as the rear beam
    20121021_151400.jpg
    20121021_151415.jpg
    20121021_172055.jpg
    20121021_172103.jpg
    20121021_173203.jpg

    20121021_184319.jpg
    20121021_184327.jpg
    20121027_150225.jpg
    20121027_150251.jpg
    20121027_171052.jpg

    Hanger bracket…
    20121028_163501.jpg
    20121028_182148.jpg
    20130106_162745.jpg
    20130106_163124.jpg

    Drilled holes into haldex and tapped a thread for the support bolts
    20130309_151844.jpg

    I sent the parts off to the powder coaters
    20130123_150907.jpg
    20130126_133930.jpg
    20130126_141547.jpg
    20130126_161311.jpg
    20130126_161846.jpg
    20130126_161835.jpg
    20130126_162959.jpg

    Finished items…
    20130414_183633.jpgWith the engine now in situ and the weather getting cold, I decided to focus on getting the haldex bracket built.

    Syncro rear diff out
    20120927_142430.jpg
    20120927_142440.jpg

    S3 Haldex out
    20120901_172041.jpg
    20120901_174511.jpg

    Created a jig to ensure that the haldex fits in the correct place
    20120928_120905.jpg

    20120929_121821.jpg
    20120929_121918.jpg
    20120929_143533.jpg

    I used the metal cylinder from inside the S3 drop link to use as a bolt spacer for the rear bracket…
    20120928_155456.jpg
    20120929_160221.jpg
    20120929_160231.jpg

    20121013_150034.jpg

    Shortened the rear bolts
    20121013_153402.jpg

    I created this extra piece on the jig to ensure that I get the rear hanger bracket in exactly the right place
    20121013_170242.jpg

    WD40 can was pretty much the same size and shape as the rear beam
    20121021_151400.jpg
    20121021_151415.jpg
    20121021_172055.jpg
    20121021_172103.jpg
    20121021_173203.jpg

    20121021_184319.jpg
    20121021_184327.jpg
    20121027_150225.jpg
    20121027_150251.jpg
    20121027_171052.jpg

    Hanger bracket…
    20121028_163501.jpg
    20121028_182148.jpg
    20130106_162745.jpg
    20130106_163124.jpg

    Drilled holes into haldex and tapped a thread for the support bolts
    20130309_151844.jpg

    I sent the parts off to the powder coaters
    20130123_150907.jpg
    20130126_133930.jpg
    20130126_141547.jpg
    20130126_161311.jpg
    20130126_161846.jpg
    20130126_161835.jpg
    20130126_162959.jpg

    Finished items…
    20130414_183633.jpg

    in reply to: Syncro gearbox and transfer box #10190
    Kav1187
    Participant

    No worries, thanks for coming to collect [:D]

    in reply to: brake upgrades #10189
    Kav1187
    Participant

    Thanks Chris. It looks like the Corrado 2.9 VR6 and the golf 3 2.0 gti are the same discs according to this listing…

    http://www.ebay.co.uk/itm/BRAKE-DISCS-BRAKE-PADS-FRONT-VENTED-280-VW-PASSAT-35I-VENTO-1H-/370830959588?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item56573f63e4

    Now I just need someone to make me some custom driveshafts [xx(]

    in reply to: brake upgrades #10186
    Kav1187
    Participant

    Yay my adapters have arrived. They look amazing [:D]

    I am looking forward to fitting them! So I need corrado 280mm front discs? Non G60? [?]

    in reply to: Syncro gearbox and transfer box #10173
    Kav1187
    Participant

    It was sent to my junk folder [xx(]. I have replied [:)]

    in reply to: brake upgrades #10171
    Kav1187
    Participant

    Chris you’re a legend! Thank you soo much :-)

Viewing 15 posts - 1 through 15 (of 48 total)

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