VW Mk1 golf RSR

[Puglife]

Only a small update i'm afraid... The strut top plates i sent off for profiling are done. Fronts are near perfect fit... Rears I misjudged and needed to be 5mm longer in overall square dimension but this doesnt matter as I can probably adapt them once the wide track is test fitted. I did a mock up of the suspension just to see whether I need to use the longer or shorter rear driveshafts from the quattro setup (diff is mounted central unlike the Quattro which is offset by 2"). The pics are with the longer shaft fitted and the wheel is a 6J et45 14" ronal. I'm running 8J all round and with the offset in mind (ET12) it should be spot on for fitment with berg cup archs. (currently the rim protrudes 2" from stock arch...)

Pics...

[DJ-ROY]

Badass Golf :mischeif:

[pixsaudisex2]

another awesome golf.

[Puglife]

Cheers baz, sent them an email.. the profiling isnt complex and i'd like to keep costs down although its not been an expensive build so far! But cant hurt to try save every penny here and there!

Any news on your Golf?

[gnutz2]

http://www.kjblaser.co.uk/

This is a company local to me, i think they should be competitive.

[Puglife]

Baz - Doing it macpherson... I know double wishbone would be a better setup but I'm trying to keep it fairly simple with readily available parts. I've converted 4stud CQ struts to coilover and will make up some tubular wishbones. Phoning around today about lasercutting my top mount plates, done the CADs for them but just wanna find a good price for two fronts and two rears.

Anybody do laser or waterjet cutting on the forum who can do 4mm steel plate?

Cheers

[gnutz2]

I'm enjoying this, vory good work.

How are you doing the back suspension double wishbone or mcpherson?

[volcano rs]

at last some progress jay

[Puglife]

Then cut down the lines going about 1mm into the sheet (halfway) to create a channel. with a block of wood near this cut (on the opposite side of sheet) folded it back aginst itself to open up the channel and create the box shape. The line was cut by eye but its pretty straight although the photo looks way off!





Then welded the channels either side to fill them and strengthen the fold. Penetration was ok but not continuous so i'm doing 1 inch stitch welds on the inside fold to strengthen further.






On a flat surface i used the iPhone to check the angled top to make sure they were around 7degrees... Came up close enough for me!




Finally test fitted in the car although need to clean up some of the fitting area to get them sitting spot on. Cut out the O/S inner arch too but didnt get round to finishing that today.






Also made up and tacked in a new section for the inner arch... with the raised turret the inner arch would get grit and **** coming through it so boxed it off with a piece of 1mm sheet... once turret is welded in place i'll trim the lower section to follow arch curvature.




And finally a sodding great hole in the N/S inner arch h34r: Going to have to do som serious reapir work once turrets in the get it all flush!



I'm busy for next two to three weeks so updates will be scarce but i'm going to try get component designs finished and sort out booking cage bending in! Cheers!

[Puglife]

Update time! Cameras now semi fixed....

Finished welding front panel ready to get a mould of it when i get free time.



Engine mounts was next on the agenda, Need to finish the O/S as i've only welded in the side tabs and not braced it yet.











Next up was get the diff mounted... simple job and just a matter of aligning it to gearbox output and getting height and centred correctly... Alot of measuring and I had it chocked up where i needed it. On to making the read mounting plate and brace frame and the two side mounting plates. Had to do all cutting by hand with a 3" air grinder but the lengths and angles i cut with cut off saw. Need to clean up some welding as i had to fill a gap i'd overcut by h34r:











And todays work which wasnt as much as i'd have liked but everyday life apparently takes preference to car building :unsure: So I decided to cut out the audi rear strut and make up some box turrets for the rear... They're 2mm steel and quite bulky, but As everything is solid mount I'd like it to be sturdy! Designed some 4mm thick custom top plates for front and will use same design for rear but without the curved inner face. 2mm steel is hard to bend, and my sheet folder only does 22swg which is 0.71mm So had to be cunning in my fabrication methods! Marked out the design on the sheet incorporating the 7degree camber angle of the audi strut design and cut it out.

[Puglife]

Group H is the Berg cup kit.... Although i dont plan to run the flat valance with ducts... Just arches for me! Looking at 15x8 up front and 15x9 in rears. Need good brake clearance but dont want to go to 16" wheels...

[Gompa]

Nice work how wide is group h kit? Is it as wide as a berg cup kit?

I used arch repair panels and new wings to widen my mk1 arches and they swallow an 8" alleycat with a -6 ET

[Puglife]

Blanking the bumper holes off. Will grind these smooth once fully welded and sort dents on panel so it can be moulded. The indicators are in front bumper which i'm obviously not fitting so i have smoked black ones to fit in the centre of these blanking plates... Will be less visible till you turn them on!





Also began checking diff fitment again and getting that level and mounted at correct height (will practically touch bootfloor...) The diff will be mounted into a frame with three plates (one where each mount would normally bolt onto diff). It'll be solid!




So thats now up to date! Will try keep adding to this as and when i make progress...

[Puglife]

The roadcars have coloured trim on the swage line... but i've welded up the holes and will use 8mm coachtape to recreate this line in red.


Fitted the AAN and 016 gearbox to try get an accurate alignment so i can start making the mounting tabs on the chassis legs.







Good old iPhone came in handy for once.... its useless as a phone but brilliant as a workmans tool, and timewaster!



I've decided how to make the front panel removable and set about cutting up front panel and welding in sections to support the headlight section. Headlights dont need to be removed to access anything now thank god. Just need to finish the welding in places and clean it all up.






Made up two mounting tabs, one either side. Will use a Dzus fastener on each to retain panel, they follow the shape of the slam panel so are a snug fit without stretching anywhere.







Take lower front panel...... cut cross brace out and voila a lightweight front panel! Althoguh i've decided to mould this and make a composite one.

[Puglife]

Test fitted my Carbon Fibre bucket seats to get an idea of fitment and height/position i want. Also a chance to measure clearance where i plan to fit rollcage.





Cut front panel off so I can modify it and make it completely removable now. Did some weight loss to inner archs.. Will tub the arch with a composite liner once i get wings and Group H extensions.




Made up some inner arch bracing... i may remove this is the new frame i'm making is sturdy enough.




Blanking plate for the heater cover hole