1991 Golf GTi project

natogreen16v

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For the last few years I've wanted back into a Mk2. With the prices of them jumping like crazy the idea of owning one just seemed to get further and further away.

By chance a friend was selling off bits from his show car and I kinda jokingly mentioned buying the car. When he came back with a price I was surprised and it worked for me so we made a deal.

He owned the car from circa 2012 and it started life as a 1991, big bumper, 8v GTI with Recaros in it.

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He decided to change the car up a bit. The plan was to fit a VR6, some 16" RSs and make it nice and tidy.

Things got out of hand and we ended up building a full on car with a VR6 turbo in a wire tucked bay making 400hp, 17" RSs, swapped to small bumpers, air suspension, interior trimmed in Harris Tweed etc etc.

I did all the welding to the shell including any mods so I know the shell is solid thankfully.

It went to Stone Motorsport for the standalone to be fitted, all fab work to be done for the engine and cooling and when there it got a full respray in the original flat black.

I took some pics of it for him in 2019 when it was "done" and it looked like this:
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The car did Dubshed, MLVW and Titanic Dubs on a trailer and that was it. He bought a 911, realised the car wasn't really that liveable with and sold off a lot of it to put a 16v into and enjoy it.

This is where I stepped in and bought it.

So this is how I bought it:
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The spec I got of it:
1991 Golf GTI 8v

Body:
Full respray in OE flat black
Converted to small bumpers keeping big bumper "thin" rub strips
All welding done including new scuttle panel and front wings
Bay shaved
Sunroof fully operational with new seals
All new glass seals

Suspension:
Coilover with camber adjustable top mounts
Polybushed front to back including steering rack mounts
Mk3 Golf wider rear axle
Mk3 Golf wider front suspension
Thicker anti roll bar front
Aftermarket anti roll bar rear

Brakes:
Floor mounted pedal box
Mk4 Golf rear calipers

Interior:
No dash
No seats or door cards
Fully sound deadened
New carper underlay

Engine:
No engine or loom
Track Slag stainless exhaust from downpipe back
Fuel lines changed for braided items
Subframe swapped for Mk3 one
Front cross member swapped for Corrado one

So plans then. With so many long term projects I want something I can get together this winter and enjoy next year.

So I've a 12v VR6 sitting from my mk3 to go into it. I dug it out during the week and this is how it looks.

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Before I tucked it away I ground off all casting from the gearbox, clutch slave cylinder, oil filter housing, intake manifold etc etc, ground off all part marks from the engine mounts and painted and powder coated everything.

It got a new oil cooler, metal crack pipe, thermostat housing, gaskets, plugs, etc.

Before it goes in I'll replace the timing chains and crank seals for peace of mind and that should see it bullet proof.

I had originally thought of going for the likes of some Porsche tombstone seats for the interior but @cauld1 messaged me and did me a deal on a seriously clean early 8v interior including seats, door cards, mint dash and A, B and C pillars.

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Other plans including fitting air ride that I have sitting and some sort of wheels.

I'm really stuck on what wheels to run. And it's made worse by the fact I plan to swap to big bumpers down the line which will probably mean a wheel change too.

Connor
 

natogreen16v

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Great to hear this will be back on the road, I owned that car, matt bought of it me in 2012! Another one of my regretful sales🤣
Ah that's cool to hear. Thanks for saying. He loved the car but I think he pushed himself too far with it. I was still surprised he sold it to me as he was planning to build it a little more mildly.

Thanks for the comments everyone. I'm trying not to get too carried away with this one. I can put it together with parts I have and not stress too hard on the details and have something to enjoy for next year.

Weekend update coming now.
 

natogreen16v

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So I've been keen to get into this project however I need to return some of the bits to Matt that didn't come in the deal.

First was to pull the passenger side wing off and remove the ECU Masters loom which ran the VR6 Turbo he had. A bit shocked and disappointed to see how this was installed. The wiring etc looks well enough done.

However the running of the looms through grommets which had been cut in half rather than having the wiring fed through them and then plastered in some kinda sealer was **** to see. Especially considering a lot of money was paid by Matt for it to be done professionally.

This is what I found. I appreciate it's not a good pic:
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This is an example of what I did to the girlfriend's Jetta last winter with a proper sleeved grommet and a bulkhead pass through for the battery cable:
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An hour or so had the loom labeled up and removed and stuffed into a bag.

I've removed the driver side wing and will see how the headlight loom is ran. I can't remember doing it as it was 5years ago but I'll check it's up to my standards for now.

Next up was to move **** around and get the car on the lift.
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Some shots of the car underneath. The Track Slag exhaust is brand new. Also found out the car is polybushed front to back. I'll change the front arm rear most bush to a rubber R32 one. The air suspension will chew that polybush up but the R32 one is still much stiffer than the OEM one.

With the polybushes and Eibach anti roll bars the car should hopefully handle pretty well.

There's some areas where the OEM floor sealer is failing so I'll wire wheel those back and reapply some. For a 32 year old car though it could be a lot worse. The underside has never been welded and doesn't need it thankfully.

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Connor
 

natogreen16v

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With the car on the lift I removed the turbo downpipe.
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Then it was time to remove the CAE shifter. What an absolute **** show. The cables run through the firewall and have the ends assembled on so I'd to strip them to remove them.

Once out I moved on to removing the shifter itself. A an aluminium plate was bonded over the hole for the OEM shifter and sealed with seam sealer. And of course the bolts were covered in it.
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So I got into the car and Stefan got under it and we fought like **** and finally got the bolts removed. A quick pull with the hammer and the bonded plate was removed too
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I need brakes for the front. I'm a whore for big brakes and have a few OEM options to pick from. I was going to use some 312mm from the Golf 4motion but I dug out a MK4 R32 set in need of a rebuild. They're 334mm with twin piston calipers so should look good behind whatever wheels I pick and also stop good.

I've brand new discs sitting for them and I've ordered a rebuild kit including pistons so that'll be next weekends struggle.

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That's me up to date so far.

Connor
 

natogreen16v

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Cheers @Wayne D it'll be a parts bin build but something I can enjoy.

@Ben P I was surprised tbh. For a car that got well used before he went mad on it it's held up well. I'll sort any rougher areas, give it a good clean and keep it good

@Ian A cheers Ian. Aye although this will be a much quicker build than Otis. And a lot less money lol.

I've done a few bits and pieces to Otis the last few months that I really should update. I just hadn't lol
 

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Are those the MK4 R32 brakes that I sold you many moons ago? Look forward to seeing this put back together, was an awful shame to see it split but glad the shell isn't going to waste
 

natogreen16v

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Are those the MK4 R32 brakes that I sold you many moons ago? Look forward to seeing this put back together, was an awful shame to see it split but glad the shell isn't going to waste
Bingo. The exact ones. I ordered new pistons, sliders and seals for them last night. Once rebuilt and a lick of paint they'll be like new.

Yeah I'd have liked to have seen it finished too but I think life and 911 ownership got in the way. I'll take full advantage though lol. Still seems weird that I own a MK2 again having thought they were long gone for me.

Wheels are my only real killer for the build. I duno wtf to do.
 
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