*** MK2 Rally Build with ALH TDI ***

Proper.
Nicest build I've ever seen.
No joke.

scubagli said:

lookin good any idea when you will have it together?

Click to expand...

Thanks, hope to have it together in the next couple of months so we can use it at the Mt Washington Hillclimb (Climb to the Clouds) http://www.climbtotheclouds.com/

http://www.youtube.com/watch?v=4BZh-7hkNe4

scubagli said:

Also you are using the mk2 steering rack, welded adapter to the end of the mk4 column?

Click to expand...

Yes. We welded the lower universal joint from the mk2 column to the mk4 steering column lower link.

scdevon said:

Proper.
Nicest build I've ever seen.
No joke.

Click to expand...

Much appreciated. We are as eager as anyone else to get it finished

Great hope to see you there, I'm trying to make it. If your free May 7th come to our show here's a link http://www.facebook.com/event.php?eid=190971124270718

Holes in firewall for mounting clutch:



Firewall reinforcement plate for clutch--Outside


Firewall reinforcement plate for clutch--inside


Also added a vertical strut and backing plate




Added a throttle stop


Built a hard/soft line from the Willwood pedal & master to the clutch slave and bled it.


Here you can see the Stainless braid flex section in the middle.

[IMGhttp://quantumrallysport.files.wordpress.com/2013/03/204616_10150179258724601_4270279_o.jpeg?w=740][/IMG]

Built an aluminum block off plate from the bottom that is sealed here with silicon



View of cover plate from the bottom




Holes for the shifter cables outside/Inside view

Hydro Handbrake bracket & install:

Looks good! Can't wait to see this thing in action.

What is the bore size of the clutch master cyl?

i have the same shifter in my scirocco, its fantastic.

foxracer1 said:

Looks good! Can't wait to see this thing in action.

What is the bore size of the clutch master cyl?

Click to expand...

Thanks, the bore is 0.75" which is the same as the stock mk4 unit 19mm

andrew1984 said:

i have the same shifter in my scirocco, its fantastic.

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You running an 02J cable shift trans?

Car looks almost like a car....




Carbon Door cards installed



Wrestling with wiring harness






Sunroof delete panel installed




Rear end-plates from mk4 beam for future rear brake project. Might get some of these laser cut so people can adapt mk4 rear stub axles, wheel bearings, hubs, etc... leaves the potential to go to 10"+ VENTED rear discs from the 337 & R32 cars.

Thanks for the updates.. I don't envy the wiring harness job!

manual_tranny said:

Thanks for the updates.. I don't envy the wiring harness job!

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Things that make the wiring harness a pain:
1) I hate wiring
2) I hate wiring
3) The mk4 harness is truely a piece of utter ratsh*t from the factory. As my first ever experience with a car newer than 1993, I can't believe the construction quality on these things.

I just hooked up most of the wiring just to reinstall an ALH. It doesn't look like much, but with everything else going on in there it is a serious pain.

Why do I hate VW wiring?
1. Everything plastic breaks.
2. Most of the clips are designed differently and open differently, but for no reason whatsoever.
3. I hate wiring, I hate wiring, I hate wiring

That's my wiring mantra too, for some reason it keeps me going.

All the best!

What we have been up to besides attending yet even more weddings

Spliced in the mk2 tailight harness to the mk4 chassis harness




All the lights are on but nothing caught fire, melted, or sizzled



AC Delete requires new serpentine routing and a custom tensioner. Thanks to Justin Carven at Greasecar for this one



Replaced the rain gutters and all new weatherstripping for the doors and windows





Gold foil for extra speed! (Zipties to keep the wires from flapping in transit on an open trailer)




And, videos from Mount Washington Hillclimb last weekend in the Gasser (took 2nd place in class)

Fog at the top


[video]http://youtube/NIR5QbcIDgw[/video]

Exciting moment on the bottom of the mountain
[video]http://youtube/1KQS1Cq06Mk[/video]

REALLY EXCITING moment on the top of the mountain leading to a flat tire
[video]http://youtube/yJQHjsrP95I[/video]

Thanks for the updates!

I've actually got an A/C delete on my ALH but it's not as smart as your timing belt tensioner/bracket invention! I've just got a bracket where the A/C lives with a free spinning pulley...

manual_tranny said:

Thanks for the updates!

I've actually got an A/C delete on my ALH but it's not as smart as your timing belt tensioner/bracket invention! I've just got a bracket where the A/C lives with a free spinning pulley...

Click to expand...

We considered that too but the low-hanging pulley is vulnerable in rally so this is a better solution.

One other thing that needs to be done is to change the alternator pulley to a non-freewheeling one because we are now spinning it backward.

I like wiring. Pairing down harnesses is kinda relaxing to me. But i have to say- The ALH/MK4 harness is pretty cheesy

Still moving on this. Took a break for a few months to buy a house....

House buying is good!

Keep us updated.

Just found this thread....


WOW!

congrats on the house. Hope it does not hamper the build.
That is going to be one solid rally Car when you finish.

You got the driving and the fabrication skillz down. lets see this thing race!

I already wanted to buy a second Chevette to do this with... This thread makes me want to do it soooo much more now. May not work quite as good as a FWD chassis car, but at the same time the RWD can hang it out a little bit more haha. Awesome work, definitely want to see it finished!

Sorry about all the dead pictures and a year of silence. Last year, I spent 27 weekend either traveling or at weddings so not much got done other than running the old car at Rally West Virginia.
Without further ado here are some update pics.

WRC Replica roof scoop from my buddy Scott Williams at USRT


Another picture also showing the VW Motorsport Shifter from Scott @ USRT



Plumbing & EVO FMIC in process thanks to Chad @ NGP Racing






Misc little bits







NGP Racing article I saw on the wall there featuring the rally car.

Pics have been restored!!!!!

Intercooler plumbing looks good!

scubagli said:

b3 correct? I'm planning on useing them in my project.

Click to expand...

So what control arms will Quantumrallysport be using??

Kristofk said:

So what control arms will Quantumrallysport be using??

Click to expand...

we are using the passat control arms for now but we are fabricating a stack of tubular control arms with Eric Langbein racing for both of our cars. Should be testing them soon (by soon, i mean after a few weeks working in Kenya and Somaliland and then after my wedding.... Soooo.) pictures will follow

More info on the intercooler?

What intake manifold is that? Stock?

what size clutch master cylinder did you use? Bore and throw?