I stumbled across this incredible build thread over on
VWvortex.com recently, and decided it would be an appropriate thread to launch our new series of blogs dedicated to automotive build threads. So what's a build thread exactly? Well it's essentially a way for automotive enthusiasts to share their progress on whatever car they are building, posting updates along the way to showcase their work. Some are updated more often than others, and some are much more involved, however the end result is a documentation of your project, something any enthusiast can enjoy.
So when I saw this thread I just had to share it with everyone here on Forzamotorsport.net. From reading the comments on my own personal AE86 project, I've noticed that you all enjoy this sort of content, especially when it's as sick as this one. This 21 year old dude from Norway, known by his Vwvortex forum name “bikkjaa” has been documenting this ridiculously clean custom build since June 2007. Since then his thread has reached over 50 pages, all filled with compliments and suggestions from amazed readers. The scope of this project is quite impressive, along with the custom work required to convert this Volkswagen Golf Mk2 to a mid engine rear wheel drive set-up, especially considering he is doing all the custom work himself in his home garage!
Needless to say this build thread has reached legendary status within the VW community, and I want to share it all with you. The fact that this guy started his build with a fully gutted shell and has managed to get it where it is today is incredible. Of course sifting through pages and pages of comments can be pretty tiring, especially for those of you who are more casual enthusiasts, so I decided to gather all the main updates from Mr. Bikkjaa to post in one place. His entire build (so far) is documented below in chronological order. So grab yourself some popcorn and kick back with this incredible project.
"bikkjaa's" VW Golf Mk2 Build Thread - Mid Engine RWD ConversionView the entire thread on VWVortex here.
Post 1 - Page 1: 6-8-2007 This is my racecar build wich i am working on.
Spec. Engine:
2l 9A bottom and head.
83,5 bore
Pauter rods
Ross pistons 8,5:1
Sputter bearings
Arp Studs
Shcrick oilpan
Ported head
Race valve springs and titan retainers
Autronic Sm4
Gt2871R turbo
Tial 38mm wastegate
Home made exhaust manifold
G60 transmission with peloquin limited slip differential
The car has been totally stripped down and all paint removed before priming. Then I built the rollcage before making the chassis and engine mounts. Right now I am working on the wheel arches and front and rear bumper plugs for molding it in fiberglass.
I have most likely forgotten manythings about what I have done, as you might read/see my English isn't the best in the World! But what can a norwegian do?
Post 2 - Page 2: 6-14-2007 Here are some more pictures a few new ones of the front fenders. Hope to start molding the fenders/bumper/rear panel in a month or so. For now it is just bondo and sanding.
Will say this is as close you can get the fenders like each other in a hobby-garage
Some of the rollcage/frame. Also made a frame that goes from the front subframe to the rear subframe, and are bolted to the org. frame under the floor.
Post 3 - Page 4: 7-2-2007 Now I am finished with my part of the sanding on the front, the rest is up to the painter who is gonna take the last "fine-sanding".
Like I have said earlier in the post, I am gonna make molds of it to use. Don't you agree that its a little stupid to do massive weight reduction and then slam on 20 kilos or more off filler?
And NO, I am not gonna mass produce this kit and sell, how cool is that when there are others who have a Mk2 looking like yours when you have spent ALOT of hours making the body kit, to be the one and only? The molds are for myself to use. Much easier to just make a new bumper or fender instead of repairing the other ones when they get smashed..
Post 4 – Page 5: 7-3-2007
Had the car out of the garage today to have a little clean up, think it was on its time...
Some better pics of the front end. Running LOW
Post 5 – Page 6: 8-4-2007 Now I am finally done with my part of the sanding on the plugs for the fiberglass molds. So its now up to the painter for the rest, only bad news is that he is sick at the moment But I have other things to do, like for example a "little" cleaning job in the garage.
Post 6 – Page 7: 9-5-2007
Intake manifold starting to take shape.
Post 7 – Page 7: 9-10-2007
Today I finished the intake manifold, and assembled the rest of the engine. Everything, like exhaust manifold, intake manifold, throttle body and so on are match ported to each other.
Post 8 – Page 8: - 9-27-2007
The engine should be capable of producing 350hp. So I am planning on running between 300-380hp. Some new bits has been made for the engine like this support for the turbo.
Post 9 – Page 8: 9-28-2007The temperature was nice outside today so i found out that I should take use of that and sprayed the first coat of filler on the panels.
Post 10- Page 9: 10-12-2007I am finished fine sanding the panels and the first coat of paint is on. And there is also a change in the plans, instead of just making half of the back quaterpanel in fiberglass I will make the hole quaterpanel around the window in fiberglass.
Pics for you my friends!
Post 11 – Page 9: 10-14-2007
Yesterday I wet sanded every thing and gave it a second coat of paint. Just put on the fenders and bumpers to see the result.
Post 12 – Page 10: 10-21-2007
Made the mold for the roof this weekend. Here's a little explanation how its done.
After waxing everything 6 times it was time to start molding. After masking where I didn't want polyester/fiberglass, it was time to put on the release wax and let that dry.
When that was dry it was time for the gelcoat. Before the gelcoat was completely dry, still a bit sticky I put on the 2 first layers of fiberglass. After that had dried a bit it was time for the 2 next layers. Used a total of 4 layers on the mold, and molded in some reinforcements
After it had dried it was time to release the mold, witch went pretty easy. And the result was excellent! Pretty amazed about the result of the mold, having in mind that I have never done this before..
Post 13 – Page 11: 10-25-2007
Then some more molds are molded stiffed up and released.
Post 14 – Page 12: 10-30-2007Finished the left rear quarter yesterday. Started on the left front fender and finished the first part of it.
Post 15 – Page 16: 12-5-2007 Had some good hours in the garage today and so you can tell from the pics I have got something done to the rollcage too. The new rollcage setup, Nice??
Post 16 – Page 18: 12-30-2007 Then some more work is done! Finished both frame rails in the back, and engine mounts. Didn't make the front mount because I don't know if I am gonna make a new mount for the engine also.
The hole for the driveshafts, they didn't come completely in the center
of the hole but they do not hit the body with full compression or
decompression of the coilovers.
Post 17 – Page 25: 3-6-2008 How The suspension travel is setup now.
Post 18 – Page 26: 3-11-2008 New parts arrived today:
Ford Escort Mk2 quick steering rack(2 1/2 turn side to side), that I think will work perfectly, it a bit shorter then the stock golf rack. This will give me a lot of space to work with the adapters to the golf steering shafts and room to prevent bumpsteer.
Also some other parts:
Camber plates from corolla ae86 to be used in the rear and reservoirs for the brake and clutch fluid.
Post 19 – Page 28: 4-6-2008 I have just cut it out roughly with an angle grinder for now, but will fine cut it later and glue in the roof. The split between the fiber roof and body will be under the rail gutter. Today I molded the front bumper and left quarter so now the only thing left is the left front fender.
Also released the panels I molded yesterday. And they look great!
Post 20 – Page 29: 4-8-2008 Have now finished all the fiberglass panels and cut away all the excessive fiberglass today and took a test fit of everything.
Post 21 – Page 30: 4-18-2008
Today I finished the new control arms.
Have also been a visit to the junkyard and cut
out some new strut towers. So today I started modifying and raising the
struts in front got the first one done with the 034 motorsport
adjustable strut mount. The strut is raised 60mm and have adjustable
caster from 1,5 to 3 degrees and 1,5 to 5 degrees camber.
Post 22 – Page 34: 6-24-2008
So for an update. Have finished the rear strut towers today and lined up the rear control arms.
Post 23 – Page 35: 7-1-2008 So for the project. I`ve spent a couple of days figuring out the front suspension geometry, and have finally got it right. Figuring out the geometry/bumpsteer issues. When I got the placement of the steering rack where I wanted it I started on the sway bar, and now the front suspension is nearly done, need to weld everything up and stiff up the mounts for the steering rack.
Post 25 – Page 36: 7-25-2008 LADYS AND GENTS! Finished up the rear swaybar and tie rods today, and that means. I got a rolling chassis. Finally the car is down on 4 after nearly a year on jack stands!
Post 26 – Page 37: 7-26-2008
Then the engine is in the back and weight numbers are ready.
Post 27 – Page 38: 7-28-2008
Today I started fitting the front fenders, they need some more fine adjustment, but that I will do before it goes to paint. Also started fitting the radiator.
Post 28 – Page 40: 8-24-2008
The wheel wells are starting to take shape, have a couple of hours left with welding and grinding before its done. Also cut out the old mounts for the roll cage in the wheel well.
Post 29 – Page 45: 10-5-2008 Yesterday I finished up the mounts for the harnesses. The bars in the roll cage are just tacked in, will weld them when I take out the engine. Then I finally got my self to make the last pieces for the firewall. So now that is starting to get done.
After that I started on the expansion tank for the engine coolant. The tank itself is just a regular box, but the welds I am really satisfied with, since this is the FIRST time I have ever tig welded aluminum. So now I am looking forward working with aluminum, which is the plan to use more on the work that's left, like firewall in the back, dash ++
Post 30 – Page 49: 11-4-2008
Well guys, been a while since a update, so here is
something for ya guys! The rear wheel well is done, finally! Yesterday
I got the rear tow hook in place, and started on mounting the bumper,
molded in the brackets.
Today I started on the new manifold, this time in SS316, still work in progress:
Post 31 – Page 50: 11-9-2008Yesterday I made the exhaust system and got everything welded, and acid washed. And I will have to say I am pretty happy with the outcome.
Post 32 – Page 52: 11-17-2008
Took some new better pics today.
Post 33 – Page 53: 11-23-2008
Started to practice some aluminum welding to get the feel for it, its a totally different task welding aluminum instead of steel, but starting to get some small feel for it. First thing I got done after getting some feel for the welding was to mount the intercooler, everyone prefers FMIC, I make it RMIC.
Post 34 – Page 55: 12-1-2008
So today I made the intercooler tubing, didn't have any 3" tubing for the intake so, need to get that later, hopefully a friend got the stuff I need for it.
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