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The car is completely naked now and looking a bit rough round the edges, Im having trouble getting hold of new floor pans to replace my holey mess, so it look like some patching may be the way forward.
Up on axel stands
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Originally posted by Trev16vI’ve got a set of VR6 Syncro parts coming my way soon. Was going to use them to build my own 3-door Syncro but I probably won’t now, since I’ve bought a factory one…
Thanks for the words of encouragement.
What sort of condition is your Syncro in?
Got any photos.
Rob
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Originally posted by Chris SPatch it!
btw just out of interest where is the rot in the b/head?
apart from the lower corners the most common place seems to be right in the centre behind the exhaust manifold downpipe, why it should rot there as opposed to anywhere else I dont know, Possibly the exhaust heat? but I have seen three of them that had rotted through in just this position (including my own), as a temporary repair I just folded and stuck a piece of alluminium track plate over the hole using silicon! it actually looks as though it is a VW fitted heatshield, The motor needs to be out to give access for welding on the outside and I would remove also the plastic dash/heater assembly on the inside for as well for safetys sake,
I mean we wouldnt want an under dash fire would we!
not like our local VW garage foreman who was welding a plate under the wing on his own camper van and set fire to his wiring harness, fuse box and various plastic interior trim panels, oops, lucky it wasn’t a customers car eh?LOL
Cheers Chris, will proberbly have some one standing by with a bucket of water as well! [
]and yes it is in the centre behind the exhaust manifold downpipe (perfect condition everywhere else)
Rob
I forgot to mention I also found a small patch of rot in the bulk head. [
!]Any ideas whats the best way to fix this? patch it or replace the bulk head?
Thanks Rob
Had a good day today got lots of work done on the car.
Taken out the engine and gearboxn, no real problems. (pictured below)
Also got the interior completelty stripped so can now see how bad the rust is. (The dash board put up a bit of a fight but we convinced it to come out eventually).
Not actually as bad as we had first thought. (pics below)
As you can see in places the rust has gone all the way through.
Im told you can buy complete floor panels that can just be welded in?
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Originally posted by Chris SOk, after reading your post again, the only extra things you will definitely need are a VR6 Syncro gearbox and transfer box as well as a pair of Rallye drive shafts, optional for the driveline would be a Rallye propshaft and viscous coupling, in my opinion this is a necessity with a VR6 Syncro conversion due to the extra torque produced by the 6 cylinder motor, which will shred the non Rallye donuts in very short order , the rear diff and driveshafts are identical for all models,
For the front brakes you can transfer the complete VR6 hubs (5 stud) and brakes,while at the rear you will need a pair of Syncro Caliper carriers to clear the rear 239mm discs, the smaller brakes wont fit over the drive shafts, you can press standard front 5 stud hubs into the rear swing arms to give you 5 stud hubs all round, you will also need to fit a golf2 16v GTI master cylinder to prevent excessive pedal travel.
The VR6 front suspension is a direct swap into the Golf2
for the rear you will need cut down Passat syncro or VR6 Syncro springs as the standard Syncro springs are not strong enough,
I think the engine mounts may need fiddling with but Im not sure, mind you there are enough people on here who will know though!Thanks for the info. very useful!
Q) I have a VR6 4motion gear box (6 speed) can this be used?
A) The short answer is, not without fitting the full 4motion set up including the rear diff, and also the 02J box is not an easy fitment in the Golf 2 chassis as all sorts of things need 1 off fabricating
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Originally posted by 90vrti have a mk2 golf with a vr6 turbo in it and i will be taking on the task of convering over to syncro. keep us posted on how everything goes. good luck
Sounds like your project will be as complicated as mine.
The link below is from a Corrado being converted to 4 wheel drive looks like a hell of a job (the thread is about 15 pages long but is worth a look).
http://www.clubgti.com/forum/showthread.php?t=36207&page=5
