Project 1.8T Rabbit

[Paul]

Hey everyone, I know I haven't been on here much in the past, but I really want to work on changing that. That said, some of you may know about the Rabbit that has been in the works for god knows how long now. I have a 1984 Rabbit GTi that has been stripped down and taken apart. I am currently rebuilding it with hot rod parts from other VWs (which takes a bit of fabrication). As far as chassis parts, I have replaced all the rubber bushings with poly bushings, using H&R coilovers, and possibly some Eurosport camber plates. I also have a set of BBS RM wheels which are 15x8, 2 piece wheels. So my project is finally going public!! So I will start from the beginning to get everyone up to speed!

First task on order was to build the pedal assembly and bracket for the clutch master cylinder. Rabbit's stock have a cable actuated clutch, and rod linkage shifter assembly. That trans is designed for an engine that produces less than 100hp stock. Well considering I was looking to produce around 300hp wheel I didn't think that trans would get along with my new engine too well. The trans I opted for is a unit out of a VW Corrado which has a stronger gears and a larger clutch. Only thing is, it has a hydraulic clutch and shifted via cables. So here is what I came up with:


This is the pedal bracket with the steering column and mastercylinder bracket that I fabricated bolted together outside of the car. This took some trial and error to get the geometry right.


This is the completed bracket, which has been cleaned up and painted.


With the brake booster installed, tight squeeze but it all fits. Note, Scirocco 16v booster/master to compensate for Corrado brake swap.


Interior view of clutch pedal linkage. Note that steering column goes through the middle of the linkage.


Lone engine bay waiting 1.8T. Radiator support changed to euro spec (the way these damn cars are supposed to come), these cars have square lights stock. Color is BMW Urban Green which the entire car will be sprayed after it runs.


G60 front brakes, 11" of stopping power on ATE slotted rotors. Car has 9.4" rotors stock!


Rear disk brake swap.


Dropping the engine in!


Engine is out of a 2001 Audi A4 1.8T with just under 30k on it. Mated to the 1990 Corrado G60 trans.




The stock KO3 turbo just wasn't going to cut it. Garrett T3/T4 hybrid, 57 trim, .63 A/R.


Progress!! Flex-A-Lite slim fans installed to Scirocco radiator. Intake manifold from VW GTi 1.8T, Audi one will not work on transverse applications. Throttle body and alternator is from a 2 liter VW engine that came in most 93-99 Golfs/Jettas. Simens 62# injectors and Eurospec adjustable FPR. Note, this is a newer picture, I have done a lot of work and didn't take pictures for a while.


Remote mounted filter and external oil cooler installed!!


Putting together stainless steel hoses with AN fittings.




Working on the wiring harness.




Intercooler installed!

That is about where it stands right now. All of the wiring in the bay is pretty much finished. Just need to connect everything inside the car. Inside the car, it has a dash from a MK2 GTi (mine is a MK1), I have a roll cage but I'm not sure if I am going to install it, Corbeau fixed back seats, Scroth 4 point harnesses. The car will be using an SDS EM4 system for engine management. So even after everything is finished there will be tuning to face. I still have to make intercooler piping and the downpipe.

[.RJ]

Cool project Good luck!

[CaptainHenreh]

Cool project Good luck!

+1

[PDenbigh]

Cool project Good luck!

+2!

Nice fab work. I feel your pain (and sense of accomplishment) of combining parts that were never intended to go together!

[Paul]

Thanks! Some of the parts are a direct fit, but others do require fabrication. I have been working on VWs for nearly 10 years now, so I have been learning what works and what can be made to work. I'm 1 upping it with the Truck next. VR6 swap and air bag suspension!!

[.RJ]

Do you have any ideas planned to get the power to the ground? I had a '03 GTi 1.8T for a while, with a K04 turbo and a bunch of other upgrades and it was real tough getting traction in 1st/2nd gears - I imagine your rabbit will be quite a bit lighter than the Mk4 too.

[Paul]

Traction is going to be an issue. As Thayer always tells me "that's cool, but it's wrong wheel drive". I plan on running a Pelequin LSD, after I get it on the road and get the money for it. Also want to utilize a 2 stage boost controller, to use less boost in the lower gears. My friend has a Rabbit with comparable power to what mine will have and his doesn't do all that bad. Yeah, you're right though, my Rabbit weighs about 1800lbs where a MK4 weighs in around 2800lbs!

[Goodspeed]

Hell yes! For anyone who didn't know, Paul does work, as evidenced above. I'll never forget how scary fast Jake's turbo VW was with the same power goal you are shooting for...especially sitting in the cage where the backseat used to be, it was a wild ride.

[Evan]

very cool.

for some reason i really like how it looks without bumper or even grille

[Sijray21]

i LOVE vw projects

awesome project man, i have a soft spot for mki's and mkii's

[Paul]

Actually, a lot of people run these without bumpers at all. VW had to attach these huge boat anchors they called bumpers when they started importing these to meet US crash standards. I planned on running European bumpers which fit the car nicely and are light weight. No bumpers though would increase airflow through the intercooler!!!!

[PDenbigh]

Oh - as for the cage, I would highly recommend it. A cage might be a bit much for a DD car, can you turn it into a rollbar?

They do a lot to stiffen everything and with that much power I imagine distortion will occur...unless that's only a RWD thing.

Regardless, you'll go fast in that thing and it'd be nice to have that extra bit of safety.

[ScottyB]

very cool! love the color.

any plans for the engine or are you just going to leave it internally stock for now? that thing will move once you get the tuning sorted.

[Jeff]

Makes me want to get an Omni even worse then I already do... looking good Paul.

[WRXtranceformed]

Do you have any ideas planned to get the power to the ground?

Good suspension setup + LSD + DR's and he'll hook nicely

Cool ass project man!

[Dave]

That looks awesome, what a beast!

[Mike]

Do you have any ideas planned to get the power to the ground?

Good suspension setup + LSD + DR's and he'll hook nicely

Cool ass project man!

riiiiight, because those negate physics.

edit: oops, my first post in here! paul, looks like you're doing some stellar work. keep it up!

[Paul]

any plans for the engine or are you just going to leave it internally stock for now? that thing will move once you get the tuning sorted.

The 1.8T's are normally good for up to about 400hp on stock internals. I want to get a nice tune on it so it will have good driveability. I'd like to be able to make the trips to some of the shows as far as Florida. The price of Audi TT drivelines have come down, can get the quattro set up for around 2k now....hmmmmmm

[ScottyB]

let me know if you're interested in a set of AEB rods. i still have mine from my A4 and just need them gone.

[V1GiLaNtE]

oh man.... i've been dying to try and get my hands on one of those vws...... there is just something so awesome about old skool vws.... nice project mate!!