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My 1.8T 924 Project! (Pic Heavy!!)
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Author:  JamesLuton [ Sun Sep 25, 2016 12:40 pm ]
Post subject:  My 1.8T 924 Project! (Pic Heavy!!)
Hi,

I have an 85 924 2.0 na which I use for Road Rallying and Autocross events and I plan to put a 1.8T 20v Engine in.

Just thought i'd do a thread as many other 1.8T 924 guys have done, to help others, as these guys have helped me.

I've read many threads and can see there are a few ways to do the conversion, but I am many following Steve924's, but I plan to use the engine standard with possibly a Revo Chip because I want to use the standard 924 torque tube/transaxle/gearbox. The reason is as I am on the Isle of Man and there are not a lot of 944's here to strip bits from. I know I can get bits from a breakers yard in the Uk I currently have 3x 924 gearbox/tube/trans so figure If I can get it to work I have a lot of spares.

Things needed for the conversion

AEB Engine
Custom Mounts
Custom Sump - Modified MK1 Golf
Pickup Pipe - From 1.9Tdi
Shortened Golf Inlet Manifold with Custom Throttle Body
MK4 Golf Bellhousing
VR6 Slave Cylinder and Hydraulic Fluid Pot
Solid Flywheel and Cover from Golf
Clutch Plate - 228mm, 13/16 shaft, 24 spline
Custom Starter Motor Bracket
Custom Downpipe & Exhaust

The plan is to get all of the above, get it in the car running and then look at other options such as Emerald Ecu, FMI, Injectors and Ko3s


Anyway here is the car

Its pretty much standard apart from a few mods -

2 inch spacers to lift nose
Full length sump guard
Citroen xsara steelies - so I can use 15" forest tyres
Bucket seats
Half Cage
Hydraulic Handbrake
EBC Yellow Stuff Pads

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Managed to buy a old 1999 Passat with an AEB Engine for £30! Bargin

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The Clutch plate I plan to use will be a Solid Flywheel conversion for the Flywheel/Cover/Bearing from a GOLF AGU as that is the bellhousing I have

Few things to buy and then i'm going to built up the whole setup on the floor using my spare torque tube and transaxle, before transferring it into the car
Author:  JamesLuton [ Wed Sep 28, 2016 9:53 pm ]
Post subject:  Re: My 1.8T 924 Project!
So found out that ARY inlet is from a small port head, so I have managed to get a AGU inlet with the large ports and the throttle body which I think I can get away with just turning it 180degrees on the inlet manifold which is good.

Ordered Clutch plate, and Solid Flywheel to make sure it alls fits before giving the AEB a quick gasket rebuild.

Once all the bits are there I will make a start with some pics
Author:  Steve924 [ Thu Sep 29, 2016 12:22 pm ]
Post subject:  Re: My 1.8T 924 Project!
Nice car, you seem to be very well organised look forward to seeing progress updates.

One thing I do remember is the clearance between crossmember and bonnet was fairly tight to the point where I removed an unused lug from the bottom of the engine block. Also the starter location does require the transmission tunnel to be slightly enlarged on the p/s and where the clutch slave is the tunnel needs raising to allow clearance.

But all this aside even when mine was running the KO3 turbo the mid range torque was so much fun :D
Author:  JamesLuton [ Sat Oct 22, 2016 5:43 pm ]
Post subject:  Re: My 1.8T 924 Project!
So bit of progress, have split the gearbox and got the bellhousing now from an AGU, and started thinking about loom options and ecu

Lots of fun splitting the bellhousing away from the box...


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So just need to make a plate up and cut the bellhousing down and o can start bolting bits together
Author:  Steve924 [ Sat Oct 22, 2016 8:27 pm ]
Post subject:  Re: My 1.8T 924 Project!
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found this and this

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it shows what I cut off, well sort of.
Author:  JamesLuton [ Sun Oct 23, 2016 5:43 pm ]
Post subject:  Re: My 1.8T 924 Project!
Got the grinder out today and cut the bellhousing down, not as neat as Steve's but it'll do.

Cut a little lug of around the starter side aswell so it'll clear the tunnel

Also made a template for the plate i'm having my mate make up

Just need to take the bearings out and nearly done

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Quick run over with a flap disc

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Then cardboard template made

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Author:  JamesLuton [ Wed Oct 26, 2016 8:53 pm ]
Post subject:  Re: My 1.8T 924 Project!
So had my mate make a plate up, don't want to go any further now until I get my spare torque tube to the workshop for measuring up, coming on OK though

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Author:  JamesLuton [ Thu Oct 27, 2016 6:46 pm ]
Post subject:  Re: My 1.8T 924 Project!
So, I found that some people doing mk2 golf 1.8t conversions are using a Seat/VW Clutch actuator which acts like a slave cylinder, but is cable operated.

So this means I should be able to retain the 924's original clutch cable. I could go hydraulic but if I can find one of these it should make life easier. Can buy new for £125

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Author:  JamesLuton [ Mon Nov 14, 2016 11:48 pm ]
Post subject:  Re: My 1.8T 924 Project!
So finally got my spares car to the workshop, I've had it a while, to pick bits from when parts break on the rally car.

I'm going to use the Torque Tube and gearbox to mock up everything

So motor out tonight and just placed the golf bellhousing on to see, tunnel needs a bit of mod to make the starter motor sit in but looks good

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So Torque tube off next and remove bellhousing from engine so I can make a good template for mounting the Torque tube to my adapter plate
Author:  JamesLuton [ Tue Dec 06, 2016 9:19 pm ]
Post subject:  Re: My 1.8T 924 Project!
Some progress.... Had a week of work so spend the last two days stripping the old spares car.

Got the torque tube out, and dropped the transaxle/torsion bar, then mounted everything up on axles stands. Got some stuff drilled like the plate and test fitted, still have to drill my spacer plate so that the input shaft is at the right length.

Need to now make some studs and weld them to the plate so I can bolt the torque tube to the bellhousing next, and 3 dowels to locate it all

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Mounted the gearbox on with a couple of bolts

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Inside bellhousing

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The plate..... drilled my holes at 10mm, wanted to tap the plate and wind some 10mm bolts in, cut heads off and weld thread from the back, but as my template was a bit shit and the holes didn't line up too well I've had to drill the holes at 12mm, I will have to drill out the torque tube now to match, or find a way of possibly welding a counter sunk 10mm bolt in from the back.

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The spacer, need to finish drilling holes but ran out of sharp drill bits. Tomorrows job

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Finally test fitted the bellhousing minus the spacer with some 8mm counter sunk bolts I had

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Hopefully the angle will be right, if not, ill be making a new plate and spacer at a later stage, we will see when the motor is in.......
Author:  JamesLuton [ Wed Dec 07, 2016 10:18 pm ]
Post subject:  Re: My 1.8T 924 Project!
Some more progress made today,

picked up some countersunk m10 bolts to weld in from the back of the plate, and got all my holes drilled in the plate and spacer plate. Didn't take any photos after drilling the centre hole, I had to go to a friends machine shop to get him to drill the hole at 32mm

Also stripped most of the AEB motor apart from the Head/Sump/Mounts. I want to try test fitting it just to see where the O.E mounts sit, then I'll make a decision on if to use the O.E mounts and make up some plates on the chassis legs, or to use the Porsche O.E mounts, and make some new brackets

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Author:  Kas750 [ Thu Dec 08, 2016 7:54 pm ]
Post subject:  Re: My 1.8T 924 Project!
Brilliant work on this. 8)
Author:  jackois [ Fri Dec 09, 2016 9:27 pm ]
Post subject:  Re: My 1.8T 924 Project!
Great pictures.

Nice to see the torque tube laid out on the floor like that... gives an understanding that you don't normally get.
Author:  JamesLuton [ Sat Dec 10, 2016 5:07 pm ]
Post subject:  Re: My 1.8T 924 Project!
So today pretty much finished the adapter plate, just need to weld the countersunk bolts in place.

Also test fitted it to the torque tube and the block so looking good.

Next up is Clutch and flywheel and quick gasket rebuild and tidy up of motor also been thinking of engine mount options and think im going to use the original mount brackets on the 1.8t and make some brackets up on the chassis legs and use e30 mounts.

List of jobs still to do......

Clutch and Flywheel Test
Rebuilt AEB (Headset,Bolts,Water Pump, Cam Belt & Tens)
Cut Inlet Manifold down
Modify Tunnel for Starter Motor
Engine Mounts
Mk1 Golf Sump, and modify
Pickup Pipe
Oil Filter Relocation Kit
Modify Coolant Flange or Bulk Head
Slave Cylinder or Clutch Actuator
Wiring

And probably a thousand other little jobs

Anyway some photos from today

The Finished Plate

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Plate and spacer Bolted to torque tube, now just need to weld the countersunk bolts and grind flat

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Bolted up

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Unbolted it and mounted it the the block to test fit, had a bit of a panic when the bottom bolts didn't line up, but they bolt into the sump which I wont be using, ill have to make a little plate up just to hold the bottom bolts

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You can just see the inprint on the spacer plate from the torque tube in this last photo
Author:  JamesLuton [ Sun Jan 08, 2017 11:56 am ]
Post subject:  Re: My 1.8T 924 Project!
Had a bit of time of Christmas/New Year to get a few more jobs done

Totally stripped the spares car, had as much as I want from it now so time to get the Red car to the workshop and start thinking about mounts, even took the brown dash as I might use it!

Been thinking a little bit about bodywork and I might try and use some 944 front wings and lower valance, a 924 turbo vented front panel and some fiberglass rear arches but along way of that yet!

Also mounted the torque tube to the engine and bellhousing, 924 shaft fits perfect into pilot bearing so really pleased for now

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