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gazzag60 80q build on a budget. big turbo s2 conversion

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  • gazzag60 80q build on a budget. big turbo s2 conversion

    guys its been a long time coming for me this. im not really a thread person and im sure itll raise some eyebrows when i say build on a budget.

    the reason its build on a budget is simple. most parts i already had.

    a little history. Mid 2000's i bought a 95 s2 coupe. i have been a vag man before and in search of more power following a scirocco and a corrado g60. both went well for what they were with a few mods here and there. the corrado i intended to install a mega 16vt. unfortunately the corrado was written off before the engine was ready.

    when the s2 arrived home i already had a set of BBS rs2 wheels waiting for it. a couple of months went by and an eboost 2 was purchased. then with my 16vt collection i got a wagner tubular manifold for my sc6152e to fit on and dropped the car off with quattronics for a week to install and have a 3" system made. all went very well tbh. gt2 6pots wer next and then vems........the list goes on.

    soon enough another write off. hit by a stolen car this time. rip s2.

    3 years later im in the hunt for a car. bmw was a gonner and i was looking at mazda 6 mps. up pops a 1991 80 16vq saloon in very nice condition, under 100k on the clock and no rust in sight. project on! looked more or less like this when i got it.


    i drove it for 7k before an issue stopped it working properly. never solved it. kjet, wiring whatever it was, in back of my mind was fit the lump and move the car on.

    what i wanted was clear to me. the benifits of the saloon shell over the pretty poor coupe and the benifits of the s2 coupe running gear and setup i had. win-win in my book. in summary i want as close to an s2/ factory look 80 saloon as possible except for externals. i also wanted the almost 80's look to the b3 saloon.

    so there it started nearly 2 years ago. since then ive been diagnosed, treated with chemo and made redundant from work. still the project rolls on. 0 funds lots of parts and help from friends and fellow fanatics.

    ill stop rambling on. heres a basic list to start with of the points ill cover, the hardships and pitfalls and the simple bits. some of this may be fact, some opinion whichever way you see it its as it was for me. ill add more as the project becomes a runner.

    so heres a brief list of my "doings". ive tried to put them in order.

    car stripping
    trim - leather from coupe installed into saloon
    procon removal, cables and brackets
    battery relocation - boot install
    wiring loom changes - remove dash and engine
    install dash loom
    install engine loom
    install s2 gauges, clocks mods to not alert on autocheck
    s2 subframe swap, full running gear change
    brake master, bomb, line change.
    steering rack swap including column
    mount fitting and brace fitting.
    ghetto front bumper cutting, x member swap.wagner ic fitment
    throttle body fix.
    gauge install and ebc install.
    gt2 6 pot change, rear brake upgrades
    wheels, narrow arches and offsets. wishbone differences and camber bolts
    fuel pump install
    exhaust modification
    mount weld and brace weld.
    engine install, clearance
    single mass install.
    ghetto throttle cable mk2.
    cental locking mods. installing and wiring.
    vems setup and testing including firmware changes and megatune versus vemstune.

    next installment soon.
    Attached Files

  • #2
    Very nice Gazzag60 look forward to watching your progress. Miss my 80 16v Quattro in red now after seeing your picture. Think I need a barn!!

    Comment


    • #3
      About time Gazza..

      Sorry to hear about your health. Hope you make a full recovery!

      What a bummer.. two write off's.

      80 is a clean looking car. Appears to have had a loving owner. Some nice mods your doing there.

      Any pics of the wagner tubular. Didn't wagner stop production on them?
      Stuart
      B2 90 quattro with boost

      Comment


      • #4
        cars not as clean now. hope to return it to that glory once its a runner again. its still looking nice though imo. previous owner really looked after it. i have used it more and unfortunately it lives outside now.

        i bought a wagner when carsten was little known from ebay where he was trading. he may have been trading elswhere but not over here at time. that was about 2005 ish
        i ran it till it cracked a couple years later. testement to the great service of carsten he replaced it foc with the slightly updated version. i have that still now. ran that unit til the car got wacked. carsten stopped making these before the evo units were available. i expect demand and the usual tubular issues meant they were not really viable business.

        today is downpipe test day. a friend spend quite some time cutting out a squashed flat part of my exhaust and welding in a new section for me. not sure how the fit is yet. the accident squashed the downpipe more or less flat against the engine. quite evident on it is the shape of the steering arm hole and the main front chasis shap where the exhaust goes. this systm will run open dump wastegate. at least for now. ill update later with some pics. seems already im not going to do this thread in order of install. having said that the plan changed many times too.

        Comment


        • #5
          Good to see you got a thread up Gaz, looking forward to seeing this when you've got it running (notice I didn't say "finished" as they never are )
          I guess you had to cut the front bumper to fit the intercooler? Are you going to run the same Precision turb?
          Panthero Coupé quattro 20vt
          Indigo ABY coupé
          Imola B6 S4 Avant

          Comment


          • #6
            the car is more or less together now.
            left to do is exhaust fitment, clutch install, oil return hose, brake bleeding with a temporary stock brakes till I can find the calipers I lost for the 280mm.

            spec briefly is

            aby, skimmed pistons, skat rods
            stock head. 7a cams
            wagner tubular manifold, sc6152e turbo, stock wastegate, 3" system no cat.
            wagner ic, inlet and piping
            650cc injectors, vems, 044
            eboost 2 defi.....

            tunes up to 2 bar boost so far. front bumper is chopped, a massive task in itself due to the construction.

            there are so many little bits to the project to be honest that I feel are important to help others out. mine will be a bit yeeHaa to some out there but I feel the total cost of the project , although an arguable figure as at one time I had to buy the parts is like 3.5-4k including car.

            Comment


            • #7
              well its been a long time. still got all those gaps to fill in the post but a very quick update.

              the car runs and drives. its not looking too nice at present as i dont wash it when works in progress.

              a quick engine pic.


              not seen a road yet. still work to do but should be ready very soon.

              really is a mix of s2 primarily and some 16v where s2 wont fit like water and pas bottles abs unit. oil cooler is mocal 13 row.its behind the grill. bumper is ghetto chopped for now.

              after not running for over 5 years i got her to start on new years eve. sounds good.

              its uber small budget. well under 3.5k including car. im not working at present and am basically pennyless. when i work ill do a few more things.

              ill update the thread with more as time goes on.
              Attached Files

              Comment


              • #8
                Someone needs to donate you an s2 bumper

                Comment


                • #9
                  Great idea comfort and speed all in one, good luck with the build and your health fella

                  Comment


                  • #10
                    healths going good cheers.

                    it runs s4 rims with 6 pots up front. the koni springs from the s2. s2 whiteline roll bar at the back. s2 coupe leather.
                    dash is 80q with s2 clocks and wiring.

                    one thing that was very noticeable even as a 16v is how much better a shell the saloon is to the coupe. so much more rigid.

                    gonna run a bar boost to start to see how it fairs. then wind it up again.
                    its basically an s2.

                    you got a bumper vas? it took quite some cutting to get the wagner cooler behind the stock bumper.

                    exhaust is 3" straight through. 1 box. thanks to a friend for fixing my downpipe and hangers as the saloon has different hangers points.

                    flywheel is 7a lightened with a exact replica of the aby timing piece. so far so good. clutch is sre which I bought about 7 years ago.

                    ecu is of course vems. still on 1.1.23rc lol.boost control is still eboost2.

                    Comment


                    • #11
                      I really like this , great project

                      Gav
                      S2 Cabriolet.........

                      Comment


                      • #12
                        thanks, the installs nowhere near as straight forward as a b4 would be or even a 5 pot b3 that's for sure. and I want it right so to speak. I know its not a right as some might say but im more than happy with how its turned out so far. I know the paint comes up well.

                        things to do.

                        test the fan
                        tidy the wiring up.
                        fit a new starter switch.
                        wire up the alternator.

                        id expect a fair few more things will pop up but ill update again in a week or so.

                        Comment


                        • #13
                          Looks a good job so far to me, well done!

                          Comment


                          • #14
                            Good job Gaz, glad you have it running after all the problems you have had
                            Looks like a nice install, you just need that bumper as above.
                            The saloon has the rear bulkhead which must make a big difference the shell rigidity.
                            Panthero Coupé quattro 20vt
                            Indigo ABY coupé
                            Imola B6 S4 Avant

                            Comment


                            • #15
                              not sure the bulkhead makes too much difference. its not that thick but the construction of that and the shelf which is metal and the fuel tank bolted between the rear turrets must be a factor.

                              actually had to pop the ski hatch panel out of the panel to fit the coupe seat.

                              anybody know the best place for a ignition switch. cheap.

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