Meet K.A.T. MK2 Golf VR6T

Drilled the holes and beat the bulkhead flat to allow the VR6 Clutch master cylinder to fit to pedal box

Engine bay

Inside car


Also made a start stripping the accident damaged engine to see how badly damaged it was! Turns out its way more foobared than i thought!

Top part of Inlet manifold



Lower part of Inlet Manifold



Vibratech Solid front engine mount



And.....................

Block cracked




But wait, theres more.................

Oil Filter housing



Also water pump pulley and shaft are buckled so need to buy new ones, the rear gearbox mount is cracked off, the studs have sheered on the Exhaust manifold and downpipe, and also the Alternator and tensioner pulley are smashed off.

BAD TIMES

ouch.... sure you'll sort it tho
time for the pub mate!

this is a real interesting thread....was thinking about going vr6 power in the rocco so its good to see how its done!

Impy Mcdub wrote:

this is a real interesting thread....was thinking about going vr6 power in the rocco so its good to see how its done!

Im sure theres prob better ways and easier ways of doing the VR swap but im kinda learning as i go along. Best thing to do is not be scared and get on with it. Whats the worse that can happen?!

geeeez not for the faint hearted

Ok, Sump is off, and all broken parts are also off engine. Ordered new replacement parts.

Also rubbed down and painted Radiator support bar, and front cross member and fitted them along with the Custom made front Solid Engine mount to allow engine to sit lower (so bonnet will close) and also reduce engine movement,



Also got delivery of these adjustable coilovers yesterday



Fitted Brake fluid resevoir and topped up with fluid for now just to stop rubber seals from drying out.

Finished fitting VR6 pedal box and fitted pedals. (what a bitch of a job!!!)

Started to rebuild the smashed Engine Block!

Left this to my expert old man to weld this up as i want it done properly 1st time!

The Gap missing from my block!



Used gas torch to burn all the crap off the area needing welding
(The orical himself! lol)

Moi





Then the hard bit.... welding inside the block





Once its cooled down over night (cast needs to cool slowly) thenm tommorow i will Braze it with Brass to make it double as hard then wash out all the Crank area with Parofine, make sure its all gleaming and no swarf etc left inside. Repair Sump, refit then rub engine down with wire wool and paint it black.

F@@king ell very nice work fella

Top job dude...

Nice work dude

Cleaned and sprayed engine Satin Black to match the engine bay. Should also help my polished goodies stand out a bit more!




Engine will be fitted on Saturday morning!

dude, you and jamo are both amazing with these projects, very outside the box and making awesome threads! keep up the great work.

you said the block was cast?.......iron or ally?

nomates wrote:

you said the block was cast?.......iron or ally?

iron!
The Head is Alley

vwbeetlebum wrote:

dude, you and jamo are both amazing with these projects, very outside the box and making awesome threads! keep up the great work.

Cheers Olly. Im hoping to have it in for MOT by 2 weeks! Then the fun starts!! Me and Jammo were chatting about when both our cars are finished we should cruise into weston chav central on a sunday night and mix it with the boyracers. Would be a laugh to show a few cars up!

Aaahhhh maaaaate!! That would be so funny!! I'd be keen to ride shotgun that'd be mad banter. MOT in 2 weeks, unbelievable!! You are both too hardcore.

Yeah mate your welcome to ride with me or jammo!

I think tbh me and jammo are inspiring each other to get our cars done! We both finish work, work on our cars till 9pm then off down the pub to talk about how much we got done today! lol

lol, yea it takes it out of you though. plus me being a lazy student i can throw a few more daytimes at it as well. si you coming on sunday|?>?

slammervan wrote:

lol, yea it takes it out of you though. plus me being a lazy student i can throw a few more daytimes at it as well. si you coming on sunday|?>?

What we doing sunday?

im playing f ing bowles with james.! not happy
what u doing later tonight?

oh yeah haha gutted. I may pop down for a few pints and watch you all make a tit of yourself.

Im out in bristol tonight mate on a work P*$$ up!

Bit tight but it should be ok




It was only meant to be a trial fit but i cant see any reason to take the engine back out again so its staying in there now!

Decided there just wasnt enough room to play around between the pulley and chassis leg



So... out came the engine AGAIN
I marked up where abouts i needed to cut the chassis leg



Then cut top and bottom



Re-fabricated chassis leg and re-welded




Gave me an inch more gap to play around with



Also hand polished upper part of inlet manifold by hours of wet and dry. Eventually came up well and painted detailed areas matt black

Top work Si, nice extra fab work too. Everyone could do with an extra inch!!

Looking good there Si nice work