After carefully researching and collecting parts for almost 4 years, I finally contacted Bill Schimmel (spturbo) about doing a Haldex conversion into my Mk1. I have known Bill since 2009 when he did my first BT install into my MK4 daily driver (currently 2.1L + GTX2867R + E85). That car is an absolute blast to drive especially with my built 02J G-Force transmission. However, there is one thing missing - traction.
That is why I decided to purchase an 02C transmission 4 years ago from a 1993/94 Passat syncro wagon (Canada only). My original intention was to find an R32 rear floor pan and drivetrain and install into my MK4 daily driver along with the necessary components to make it work (FEX center differential, etc). However, I couldn't bring myself to cutting up such a nice car. Fast forward to last January when I jumped on the opportunity to purchase a 1984 Rabbit GTI from a fellow vortexer in Lancaster, PA. The car is almost perfect for being more than 3 decades old. After seeing the Boba Motoring MK1 video, I decided that I want to build an American version of that car using the MK1 Rabbit GTI built right here in Pennsylvania ('Merica man. LOL). So, it will retain the square headlight and DOT front and back bumpers.
I decided to weigh my MK1 Rabbit GTI on an industrial scale last week before the project started (see below). Even with all the American-only extra parts, it still only weighed 1,980 lbs! That included the spare tire and tools which I forgot to remove from the trunk. Those weighed 17.2 kg's or about 38 lbs. I also plan to use a lightweight Lithium battery same as in my MK4 daily driver. Removing the spare tire, tools and heavy OEM battery brings my weight down to about 1,900 lbs.
With the added Haldex drivetrain, bigger brakes, roll cage etc. I am hoping to come in less than 1000 kg's or 2200 lbs. That is about 1,200 lbs. lighter than an MK4 R32 or MK1 Audi TT quattro. I will try to post more details about all the parts I collected along with some graphs and analysis. I will also try to post some progress pictures as the donor Audi TT quattro is already at Bill's shop in Warminster. Please feel free to comment here as your feedback will help guide this project.
EDIT: Build details
ENGINE
BOTTOM END
Audi TT 225 engine block
Eurospec 4340 billet 95.5mm crankshaft
IE Tuscan connecting rods
IE Ultimate Crankshaft Girdle Kit
IE Dowel Pin Kit for TDI Crank
IE Billet Timing Belt Drive Gear
Fluidampr Crank Pulley
Mahle PowerPak+ 9:1 CR pistons
Mahle Race Main Bearing Set
ARP Hardware
CYLINDER HEAD
AEB largeport head
Ferrea Complete Valvetrain Kit (valves, springs, seats, Ti retainers)
Catcams 3660 Intake/Exhaust camshafts with adjustable sprocket
PPT Adjustable Camshaft gear
PPT Manual Timing Belt Kit with Gates Racing belt
SEM largeport intake manifold
Custom short-runner unequal length divided exhaust manifold (Pat @ Pitt Soundworks).
Dorman VVT solenoid
ARP Hardware
DRIVETRAIN
TRANSMISSION ("Kleiner Felsenbrecher")
02C transmission/B3 Passat G60 Syncro
AP Tuning (G-Force Transmission) race gearset
CTN 3.157 final drive
Clutch Masters FX725 ultra light clutch and flywheel kit
Clutch Masters hydraulic throwout bearing for 02J/02A
DIFFERENTIALS/COUPLINGS
Peloquin 02C limited slip differential
FEX angle drive/Typ 1U Škoda Octavia
Haldex rear center coupling/Audi TT 225
Peloquin R32 rear differential
BRAKES/SUSPENSION
FRONT
Stock MK1 lower control arm and spindle
Epytec 5x100 hub for MK1 spindle M14x1.5
Epytec Porsche brake adapters
Porsche 986 Boxter 4 piston front brakes
Eurospec 280mm vented slotted 5x100 Corrado rotors
Front Coilovers
Just Engineering Lower Control Arms
H&R 22mm front Anti-sway bar
REAR
Syncro beam and 191 trailing arms/B3 Passat G60 Syncro
Dutchbuild Haldex Kit
5x100 hub for B3 Passat G60 Syncro M12x1.5
VW Mk4 rear calipers
239mm vented slotted 5x100 rotors
TUNING
Ignitron ECU
Ignitron EGT Amplifiers (x2)
Eurowise Plug and Play Engine Harness for 1.8T
BOSCH 4 Bar MAP sensor.
That is why I decided to purchase an 02C transmission 4 years ago from a 1993/94 Passat syncro wagon (Canada only). My original intention was to find an R32 rear floor pan and drivetrain and install into my MK4 daily driver along with the necessary components to make it work (FEX center differential, etc). However, I couldn't bring myself to cutting up such a nice car. Fast forward to last January when I jumped on the opportunity to purchase a 1984 Rabbit GTI from a fellow vortexer in Lancaster, PA. The car is almost perfect for being more than 3 decades old. After seeing the Boba Motoring MK1 video, I decided that I want to build an American version of that car using the MK1 Rabbit GTI built right here in Pennsylvania ('Merica man. LOL). So, it will retain the square headlight and DOT front and back bumpers.
I decided to weigh my MK1 Rabbit GTI on an industrial scale last week before the project started (see below). Even with all the American-only extra parts, it still only weighed 1,980 lbs! That included the spare tire and tools which I forgot to remove from the trunk. Those weighed 17.2 kg's or about 38 lbs. I also plan to use a lightweight Lithium battery same as in my MK4 daily driver. Removing the spare tire, tools and heavy OEM battery brings my weight down to about 1,900 lbs.
With the added Haldex drivetrain, bigger brakes, roll cage etc. I am hoping to come in less than 1000 kg's or 2200 lbs. That is about 1,200 lbs. lighter than an MK4 R32 or MK1 Audi TT quattro. I will try to post more details about all the parts I collected along with some graphs and analysis. I will also try to post some progress pictures as the donor Audi TT quattro is already at Bill's shop in Warminster. Please feel free to comment here as your feedback will help guide this project.
EDIT: Build details
ENGINE
BOTTOM END
Audi TT 225 engine block
Eurospec 4340 billet 95.5mm crankshaft
IE Tuscan connecting rods
IE Ultimate Crankshaft Girdle Kit
IE Dowel Pin Kit for TDI Crank
IE Billet Timing Belt Drive Gear
Fluidampr Crank Pulley
Mahle PowerPak+ 9:1 CR pistons
Mahle Race Main Bearing Set
ARP Hardware
CYLINDER HEAD
AEB largeport head
Ferrea Complete Valvetrain Kit (valves, springs, seats, Ti retainers)
Catcams 3660 Intake/Exhaust camshafts with adjustable sprocket
PPT Adjustable Camshaft gear
PPT Manual Timing Belt Kit with Gates Racing belt
SEM largeport intake manifold
Custom short-runner unequal length divided exhaust manifold (Pat @ Pitt Soundworks).
Dorman VVT solenoid
ARP Hardware
DRIVETRAIN
TRANSMISSION ("Kleiner Felsenbrecher")
02C transmission/B3 Passat G60 Syncro
AP Tuning (G-Force Transmission) race gearset
CTN 3.157 final drive
Clutch Masters FX725 ultra light clutch and flywheel kit
Clutch Masters hydraulic throwout bearing for 02J/02A
DIFFERENTIALS/COUPLINGS
Peloquin 02C limited slip differential
FEX angle drive/Typ 1U Škoda Octavia
Haldex rear center coupling/Audi TT 225
Peloquin R32 rear differential
BRAKES/SUSPENSION
FRONT
Stock MK1 lower control arm and spindle
Epytec 5x100 hub for MK1 spindle M14x1.5
Epytec Porsche brake adapters
Porsche 986 Boxter 4 piston front brakes
Eurospec 280mm vented slotted 5x100 Corrado rotors
Front Coilovers
Just Engineering Lower Control Arms
H&R 22mm front Anti-sway bar
REAR
Syncro beam and 191 trailing arms/B3 Passat G60 Syncro
Dutchbuild Haldex Kit
5x100 hub for B3 Passat G60 Syncro M12x1.5
VW Mk4 rear calipers
239mm vented slotted 5x100 rotors
TUNING
Ignitron ECU
Ignitron EGT Amplifiers (x2)
Eurowise Plug and Play Engine Harness for 1.8T
BOSCH 4 Bar MAP sensor.