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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,
KavSounds 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?
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.
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?
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?
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.
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.
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
Trimming required so it will fit into the bulkhead
Now the scary part – trimming the bulkhead…
And it fits…
Middle section cut out for screen vent
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
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.
So I trimmed the syncro cup
Then the S3 cup
Then the syncro top with the S3 bottom
The result
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.
And I will need to raise the suspension at the rear as it is sagging a tad
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
S3 Haldex out
Created a jig to ensure that the haldex fits in the correct place
I used the metal cylinder from inside the S3 drop link to use as a bolt spacer for the rear bracket…
Shortened the rear bolts
I created this extra piece on the jig to ensure that I get the rear hanger bracket in exactly the right place
WD40 can was pretty much the same size and shape as the rear beam
Hanger bracket…
Drilled holes into haldex and tapped a thread for the support bolts
I sent the parts off to the powder coaters
Finished items…
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
S3 Haldex out
Created a jig to ensure that the haldex fits in the correct place
I used the metal cylinder from inside the S3 drop link to use as a bolt spacer for the rear bracket…
Shortened the rear bolts
I created this extra piece on the jig to ensure that I get the rear hanger bracket in exactly the right place
WD40 can was pretty much the same size and shape as the rear beam
Hanger bracket…
Drilled holes into haldex and tapped a thread for the support bolts
I sent the parts off to the powder coaters
Finished items…
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…
Now I just need someone to make me some custom driveshafts [xx(]
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