Meet K.A.T. MK2 Golf VR6T

Slowly getting there......

Tonight after i finished work i started to make some gaskets for the inlets out of Gasket paper. (couldnt be arsed to try and order the proper ones). So after i made them, i fitted them and the lower part of inlet Manifold, new fuel rail, sealed and fitted new injectors, connected fuel lines, fitted upper part of Inlet manifold, throttle body, secondary electric water pump, connected most of the water pipes and made a start sorting and plugging in the engine bay loom.

ok seems like i havent posted on here and also feels like im making no progress...

Started sorting the wiring looms



Was hoping it was going to be just a case of plug and play the engine loom only into the old 16v GTI fusebox, until i found out the car has an early 8v fusebox and looms which means replacing the fusebox with a 16v one, replacing the whole interior loom, engine loom, and lighting loom with 16v and VR6 ones.

an hours job turned into a weeks work!

Ohter than that, i had to remove the Clutch master cylinder again, aswell as the Brake Master Cylinder, all to remove the Servo and flip it round 180 degrees and fit it all again! (i mounted it upside down by mistake so vacum hole was ontop left instead of bottom right) DOH!!

Bloody Hell!! If I had seen that pic earlier I might have knocked up a spag bol!!!
Good luck with that lot.....

Mr Scoops wrote:

Bloody Hell!! If I had seen that pic earlier I might have knocked up a spag bol!!!
Good luck with that lot.....

Yep, just when i thought the worst part of the build was over. I look at the looms and cry! What makes it worse is i labelled every single plug before i put the looms into an empty dustbin before storage. Now that i have got them out the dustbin, half the labels have fallen off!!!!!

Made massive progress today.

All looms are now run in their correct places, had to splice the rear interior loom with pre 90 spec plugs as my car is a 1986 and all plugs are diffrent Spliced front Lighting loom with later plugs, sorted and stripped all the Engine loom and removed loads of wires i didnt need to tidy loom up a bit (i.e ABS wiring, etc) Re-wrapped loom and extended a load of cables so that i can hide most of wires. I hate seeing wires everywhere i wanted to make the Bay look as minimal as possible.

Changed the Fuel Tank sender unit for a late spec 4 pin, as mine was an early 3 pin type, Connected all looms into the MK3 VR6 fusebox.

I had to cut a small section from the dash as the Mk3 clocks wouldnt sit right, and also moved mounting bracket 1cm wider as mk3 clocks are wider and deeper than mk2. I wanted to use mk2 clocks to give it a factory look but im still yet to work out how i can use a 4 cylinder rev counter with a 6 cylinder engine. (the amount of pulses will be wrong with a V6 as it will pulse approx 1.5 times more than a 4 cylinder)

Not really much left to do before sh'll start...

- finish connecting all plugs, pipes, hoses, etc
- Finish re-assembling dash
- Fit Exhaust
- Buy and fit a Corrado VR6 radiator and twin fans
- Buy and fit a Corrado VR6 throttle cable
- Fit drivers side driveshaft and brakes
Then........... VROOOOOOOOOOOOOOOOOOOOOOOOOOOOM

(I hope!!!)

Regarding your tacho......why not replace the marks on the face??
ie put 1000 where 1500 is, 2000 where 3000 is etc etc

Mr Scoops wrote:

Regarding your tacho......why not replace the marks on the face??
ie put 1000 where 1500 is, 2000 where 3000 is etc etc

How would i replace the numbers? i would have to work out exactly how much the diffrence would be and it would never be accurate enough. My mates Mk2 VR6 is using Mk2 clocks but when the engine hits the limiter the rev counter has actually gone right round and is reading nearly 1500rpm!!

Im sure if i add a resistor somewhere i can reduce the pulse down 1.5 times a second. ideally need to find a circuit diagram of the mk2 clocks

Shit me Si you don't half get stuck in fella

I had some awesome, yet annoying news last night.
The original owner who built my red Mk2 VR6 sent me a PM on another forum, he explained that he was a VW technician and built the red VR6 as a toy for the track.

The car in question......



Anyway he gave me his number and said give him a bell and he'd be happy to give me details on the car and everything i need to know. Bargain i thought, as there has always been something not quite right about that engine, numbers dont match up, bits are diffrent diameters to what they should be etc.

So i rang him last night, we chatted for over an hour and i explained to him the engine was now sat in K.A.T.

The red VR was the 1st ever Mk2vr he had built, he is now just finishing his 12th!! And he says the red one was the most powerful N/A VR6 he had ever built, he is emailing me a copy of the rolling road print out to prove its 232bhp (180bhp standard) and nearly 200 Ib ft of torque!

I told him that i had recently replaced the inlet manifolds with new 2.8 ones and that when i fitted them the ports on the old manifold were a lot bigger than the new ones. He told me that it was originally an OBD1 2.8 early VR6 engine from an unknown car, which some1 had put into a passat before finding its way to the red car. The engine owes the guy well over £5000.

Its now a 2.9 OBD1 Corrado block (not 2. which are really rare and hard to get bits for. Also reason manifolds were diffrent sizes is that i replaced them with 2.8 ones and the old ones were 2.9 that had been enlargened further, then polished and ported. The car also has hardened valves, etc etc, and to top it all off a rare as fooook OA Motorsport gearbox and clutch with short ratios in 1st 2nd and 3rd gears.

All explains a lot to me now BUT it means getting parts is a pain in the arse!

if you think thats a pain in the arse to get parts for you should try and get parts for my mk1 jetta

need to change it to 1989 mk2 golf 2.9 vr6 turbo . looking good so far dude

Its annoyingly close to running now (without the turbo) but i had an operation yesterday so kinda put me outta action for a while. Although im still hoping to get out on the razz tonight!

Bought a genuine VW oil pump which cost me £104!!!!!!)
plus the VR6's are renowned for snapping the drive shaft rod that runs the pump so i bought a new one of those aswell just be safe. Also bought a new pipe that ges from the oil pump to the block, as im at this stage i cant see the point in putting old stuff back on as the oil pump is prob the most vital part in any engine hense i got genuine VW items not cheapo stuff from GSF.

Bought some 15" VW G60 winter wheels (steels) from a mate whos had them powdercoated matt black. Will fit these instead of the red Compomotive alloys i think till i decide what to do with them. Also been thinking about how loud i want the car..... ive got a 2.5" Stainless exhaust with a De-Cat pipe, and one silencer half way down the system but i need to get a backbox, although im thinking of just extending the 2.5" pipe from the silencer straight out the back with no rear silencer backbox.

Dont know how loud it will be though and if it will pass MOT having only 1 silencer?!

Me and dad have been talking about this for a while now and how th best way to do it is.....

VR6 are a cross flow engine (inlet manifold goes other side of head to exhaust manifold - thus creating a cross flow head) - sorry if that is obvious to some, but the way a VR inlet manifold enters the head means it has to cross the engine...

see pic...



This is pretty good for a non turbo car as they run better when hot, but with a turbo'd car it helps if intake temps are low as possible as the turbo does the warming instead. So we have thought about doing this.....





Would mean relocating the throttle body to the right hand side, along with airfilter, etc but would give me loads more room at the back of engine for a bigger turbo, more cold air into engine, more space for maintaining it, and also give me more room to run my intercooler pipes, etc.

Gonna make a template soon and make myself one up!

Finished product should look similar to this...... (prob not as good tho! )

Looks nuts

Top idea dude...


How about a custom rocker cover??? The stock one looks abit crap really..

thecrewkid wrote:

Top idea dude...


How about a custom rocker cover??? The stock one looks abit crap really..

Yeah i thought about polishing up the rocker cover but i hear what your saying about looking a bit crap. I dont know what i can do with it tho tbh, who knows what will happen in the future!

I think this is going to be awesome when you are finished fella.

Mr Scoops wrote:

I think this is going to be awesome when you are finished fella.

i hope so! Just wish i had the enthusiasm to get and finish it! Even just to get it on the road without the turbo would be alright for the moment! lol

Considering i had a massive hangover from hell today i still cracked on with the car and got a bit done.

- Bought and fitted new Battery
- Fitted Coilover suspension
- spent bloody ages trying to set a nice ride height (still need to lower front another inch)
- Fitted 288mm G60 brake disks and Audi S2 Calipers
- Fitted drivers side driveshaft
- Put tyres on my G60 steels and fitted them

Really taking shape now Si'...............good work.

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looking really good with them steelies on is that the munster mobile poking out your garage ??

type25 dan wrote:

looking really good with them steelies on is that the munster mobile poking out your garage ??

haha! its a 1920 rolls royce in the middle of being built.

looks sweeeeet.proper sleeper

Little update - got myself some plastic G60 wheel caps to go on the G60 steels (hard to come by) and look so much neater than having the bolts exposed.

Also got some reclining bucket seats, in fairly good condition but are red and black (which looks cack with the green car). So im gonna try and get some black spray on fabric dye. It will either work or it wont!

Just got to buy some full harnesses to go with them now!

Oh and i got my paper work through from the VWDRC. Apparantly if my car runs a quarter mile in 12.99 secs or faster i need a 6 point roll cage to meet the race regulations