MK2 20VT (Another one)

[roly]

we don't mess about tris you should know that

we're using a 2000 model cupra as the doner, we will be fitting the pedal box as it will be running full hydraulic clutch setup and the dash aswell as it makes the conversion easier

 

[roly]

couple more pics from today (sorry for the pants quality)

all the wiring loom is out and engine bay is now empty

tomorrow we're going to clean the engine bay up, mod the bulkhead for the hydraulic clutch and start fitting up the new loom and engine parts if time allows

empty looking interior

old engine verses new, nothing in it size wise

MK2 16v in kit form

 

[F2 Stu]

Make it an amphibious craft while you're at it

 

[roly]

20vt powered boat could be interesting

altho the big ones a 5 litre volvo penta engine so think that would be more fun in the ibiza

 

[robbyd]

is the 1.8 engine DBW?
what mods have you got to do to the bulk head?

 

[roly]

the AYP is DBW

the mk2 16v runs a cable operated clutch so you have to cut 3 holes through the bulkhead next to the brake servo to fit the clutch master cylinder, you could use the 16v cable and change the mechanism on the 20vt gearbox but as we're going to the trouble of fitting everything else we're using the hydraulic setup aswell

this part we set about today but quickly found out the bulkhead on the gti 16v is different to the bulkhead on my 16v cupra sport (mine is flat next to the brake servo where as Martin's is raised so made fittment interesting) possibly because the gti runs air con, we had to relocated the clutch master cylinder lower down which then meant brake and clutch lines needed reworking

then to top it off the accelerator pedal mountings are also different between the two (again they wern't on mine ) so the 20vt pedal is going to have to be cut and welded to fit, or the 16v one reworked to incorporate a potentiometer bracket for the DBW

stressful day but all good fun

 

[tris]

Not a good day in the build then

 

[Martin M]

Bulkhead bashing was fun, apart for that i felt like a spare part!

Ben is Mr. Seat so he fixed it all up good!

Hope tuesday goes better.

 

[robbyd]

all sounds like good!
so if i put a 1.8 engine only in my mk2 cupra sport and kept my gti gearbox in there would i have to change the pedal box for a DBW set up?

 

[Martin M]

Finally got a dash sorted today and for a good price. Already fitted, but came across a problem with the front cross member...nothing's ever simple with my car!

Ben's got some pics so i will let him do the update for you!

 

[roly]

Not a good day in the build then

i've had better days mate, today went a bit better but there's always something else to do, you wouldn't think a year could make so many differences between two body shells

all sounds like good!
so if i put a 1.8 engine only in my mk2 cupra sport and kept my gti gearbox in there would i have to change the pedal box for a DBW set up?

depends what cupra sport your doing it to, the 8v box won't work as far as i know but the 16v one should bolt straight up as it almost he same externally as the 20vt box

you could modify the 16v pedal to accept the throttle pottentiometer (bit of cutting and welding) and use the original 16v pedal box, only really need to change to the 20vt pedal box if your going for full hydraulic setup

 

[roly]

todays pics

after yesterdays findings i was ready for another suprise today and as expected i got it

after dropping the engine in we then found out that this 16v has a different front cross member to my 16v again im still to check part numbers to see what model it's from but it means the power steering pipework and secondary air pump won't fit on

we're going to get handy with the grinder tomorrow and see what we can come up with but ultimatly will be on the lookout for a 20vt cross member

on a plus side all the wiring loom is in aswell as the dashboard and i managed to knock up a bracket to hold the accelerator pedal correctly sos not all bad news

 

[tris]

Good luck today boys

 

[andyj]

there was a 20vT cross-member on ebay last week.... will see if I can find it again at lunch time

 

[F2 Stu]

Take it you didn't retain the x member form the donor?

 

[roly]

doner car cross member was bent, didn't look it but when compared to the 16v one was well out

got a replacement coming 2moz so should be back in business, bit more of a relaxed day today rebuilding selector mechanisms and just trial fitting some of the shiney bits

did managed to crank the engine over quickly and it fired up fine so that's a good sign

will be pulling out all the stops 2moz as it needs to be on the road by sunday night

 

[F2 Stu]

4 more days left - plenty of time

 

[Martin M]

4 more days left - plenty of time

Hope so!

Might have that gearbox up for grabs soon!

 

[F2 Stu]

Might be interested in the engine too

Just got the nod of approval of storing it

 

[tris]

How come you want another engine Stu