betenoir
Part of things
Afraid of the Light
Posts: 163
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The next job I did proved eventually to be a blind alley, but I will not leave it off here just because I have the benefit of hindsight. The original plan was to use DBW throttle control as on the mk3 Ibiza Cupra. With that in mind, I sourced a throttle pedal and shaft from the later model. In the photo the mk2 Ibiza part is at the top, with the mk3 part underneath.  I had the throttle position sensor bracket from the mk3 pedal shaft welded onto a mk2 shaft, and chopped the cable mounting off the end. This picture shows the standard mk2 shaft in the front and my modified shaft behind it.  I even got as far as fitting the modified pedal shaft into the car, before I decided to go with throttle cable operation, so I swapped back to the original shaft. |
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betenoir
Part of things
Afraid of the Light
Posts: 163
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The track rods and gaiters were replaced with new, and the steering rack was bolted to the sub-frame, along with a Powerflex mounting bush. The standard anti-roll bar was replaced with a Neuspeed part I bought used, but which I managed to source new polyurethane bushes for.  Putting the sub-frame assembly and front crossmember back into place made the engine compartment look only slightly less empty, but it was a nice feeling to be bolting things back together.  |
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betenoir
Part of things
Afraid of the Light
Posts: 163
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Whilst the engine compartment was comparatively unoccupied, I took the opportunity to clean, prime, and paint some of the areas that were showing their age.   As the Kiwi paint was open, I did a pair of OMP strut braces with it too.  |
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betenoir
Part of things
Afraid of the Light
Posts: 163
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The front dampers I took off the car were Bilstein units, but they had clearly seen better days.  The front suspension components which will be reused were all cleaned-up and given a lick of paint.  The new and freshly powder-coated front wishbones had Powerflex bushes installed.  The replacement front suspension parts are from a SEAT Sport kit marketed for the mk3 Ibiza. The dampers are Bilstein while the springs are Eibach. The more obvious choice would have been to go for coilovers, as this car is intended for track use, and I will be very surprised if I do not change it to coilovers in the future, but having picked-up this kit very cheap on eBay I am keen to at least try it out.  The purple top mounts are more Powerflex parts. The front suspension was bolted into place, with new hubs and bearings, so the front end could sit on some wheels for the first time in a long while.   |
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adi
Posted a lot
Posts: 1,426
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I had an earlier 8v GTI (with the half bumpers) that I put a full polo estate front bumper and a later rear on. Even had standard 3 spokes on it until I put mk3 cupra wheels on it. About 12 years ago it was a rare car then, you just don't see them anymore. Merely a polo with a golf gti engine, it was a lot of fun
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olduns
Part of things
Posts: 326
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Nov 10, 2020 17:02:34 GMT
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I think every man and his dog has had one of these at some point  mine was Kiwi Yellow, surely the only colour, but an 8v. daughter 'borrowed' it and after standing on the drive for 12 months...'i'll fix that one day'..i never did!  front bumper hanging on , just..both headlight mounts broken etc etc plus the state of the body panels... I scrapped it, wish i'd have kept it but hey ho slightly OT, betenoir, is RobT's track weapon still around? |
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betenoir
Part of things
Afraid of the Light
Posts: 163
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Nov 10, 2020 21:52:04 GMT
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I had an earlier 8v GTI (with the half bumpers) that I put a full polo estate front bumper and a later rear on. Even had standard 3 spokes on it until I put mk3 cupra wheels on it. About 12 years ago it was a rare car then, you just don't see them anymore. Merely a polo with a golf gti engine, it was a lot of fun The pre-facelift GTis you do not see at all now, you are dead right. As I think was mentioned on here previously, the mk2 Ibiza is actually Polo from the firewall back, and Golf from the firewall forward. I think they are a cracking piece of kit. |
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betenoir
Part of things
Afraid of the Light
Posts: 163
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Nov 10, 2020 21:58:39 GMT
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olduns Kiwi is definitely the best colour, although as your picture shows it does like to fade. My son had an 8v GTi for a while, and I liked that engine more than the 16v.
IIRC, RobT traded-in his track Ibiza for a Radical. Last I knew of the Ibiza it was on the dealer's website for big money, with the description claiming it was an ex-works rally car.
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adi
Posted a lot
Posts: 1,426
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I had an earlier 8v GTI (with the half bumpers) that I put a full polo estate front bumper and a later rear on. Even had standard 3 spokes on it until I put mk3 cupra wheels on it. About 12 years ago it was a rare car then, you just don't see them anymore. Merely a polo with a golf gti engine, it was a lot of fun The pre-facelift GTis you do not see at all now, you are dead right. As I think was mentioned on here previously, the mk2 Ibiza is actually Polo from the firewall back, and Golf from the firewall forward. I think they are a cracking piece of kit. Which definately makes them ripe for a 20vt, when you consider what a pain in the  it is to put one in a mk4 polo! |
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olduns
Part of things
Posts: 326
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Nov 11, 2020 15:04:54 GMT
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IIRC, RobT traded-in his track Ibiza for a Radical. Last I knew of the Ibiza it was on the dealer's website for big money, with the description claiming it was an ex-works rally car.now that does ring a bell with me, too long ago obviously. I had some OZ's off Rob fitted with used 'legal' trackday tyres on them, very sticky and hard work on the road, tramlined like hell Looking good so far  |
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betenoir
Part of things
Afraid of the Light
Posts: 163
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Nov 12, 2020 21:58:09 GMT
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Attention now turned to the rear suspension. The rear axle beam was removed.  It was dismantled, cleaned, and given a lick of paint.  |
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betenoir
Part of things
Afraid of the Light
Posts: 163
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Nov 12, 2020 22:04:04 GMT
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Another of my eBay bargains was a Safety Devices roll cage. It was listed by Safety Devices as being a NOS item for a mk1 Ibiza, but the answers I got to a couple of questions suggested it was much more likely to be for a mk2. It came compete with a mounting kit, which was all in place after I paid for a day of a welder's time. At this stage I only left the main hoop bolted-in to the car to make access easier.  This was primed,  and painted Kiwi  More people seem to choose to paint roll cages in a different colour compared to the car, but I love the way it looks with everything being Kiwi.  |
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betenoir
Part of things
Afraid of the Light
Posts: 163
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Nov 14, 2020 23:40:03 GMT
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Clearly as this is planned to be a track car, being clean and shiny is not top of the list of priorities, however I realised that Hammerite Zingy Lime looked, in the shop at least, quite similar to Kiwi. I bought a tin and tried it out on a rotten wing.  Side-by-side the difference is clear, but that is not to say that it is of no use. I spent an unpleasant afternoon with my head inside each of the wheelarches in turn, giving them a good clean, followed by a couple of coats of paint. The outcome is very satisfying. Before  After  At the front end I removed the freshly fitted uprights, and I took the wings off, so I could do a proper job.   |
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betenoir
Part of things
Afraid of the Light
Posts: 163
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Nov 14, 2020 23:44:02 GMT
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Lying under the car with the rear axle out of the way, it was obvious that one of the exhaust heatshields had seen better days.  I cleaned-off the surface corrosion, and riveted aluminium patches into place in the areas needing repair. A couple of coats of silver Smoothrite had it looking more like it should again, not that anyone but me will ever see it.  While the exhaust mounting brackets were off the car I replaced the mounting rubbers with Powerflex. Lacking a Powerflex of the right width for the rearmost mounting, I used two thinner parts instead.   |
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betenoir
Part of things
Afraid of the Light
Posts: 163
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Nov 17, 2020 22:07:04 GMT
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With the rear arches now looking clean but empty, I was motivated to get on with the rear suspension. Powerflex bushes were fitted to the rear beam.  The rear uprights were assembled with Powerflex top mounts, and bump stops from the same company. I had to cut the bump stops down, although whether that is because I bought the wrong parts I do not know.  I struggled for a while to get the rear axle back into place, before I sussed that it is easier if you attach it to the struts first, and then attach the front mountings, rather than the other way around.   |
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betenoir
Part of things
Afraid of the Light
Posts: 163
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Nov 25, 2020 21:09:19 GMT
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I bought a set of Black Forest Industries engine mounts. When I opened the box it was not at all clear what went where, but a quick comparison against standard items soon had them sorted out.  All assembled and ready to fit.  |
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betenoir
Part of things
Afraid of the Light
Posts: 163
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Nov 25, 2020 21:16:43 GMT
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Anyone who has read this thread from the start will have seen that I sold the 16v ABF engine when I removed it. The reason for this is (as predicted earlier on the thread) that I am going 1.8T. I realise that I am years behind the times, with most mk2 Ibizas with 1.8T transplants having long since been built, enjoyed, and broken. I took advantage of this trend by buying parts that were removed from these cars, which have been stashed waiting to make their way onto this or another of my projects. The engine I am using in this is a low mileage AYP from a mk3 Ibiza Cupra, which will be coupled with an 02A gearbox fitted with a Peloquin LSD. I have done very little to the engine, apart from giving it a lick of paint. The sump will be swapped for a baffled item for track use but is standard for now. While I had the engine on a stand I did the timing belt and water pump, and replaced the auxiliary belt pulleys with alloy parts which should give me slightly less power steering assistance.  The SEAT Sport manifold on the engine in this picture will be swapped for one with an offside throttle body before it runs. When I sold the ABF engine I kept the solid flywheel, which I subsequently had machined to lose some weight off it. This was then fitted onto the AYP engine, along with a nice new VR6 clutch. The engine and gearbox dropped into place in the Ibiza without too much trouble.  |
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betenoir
Part of things
Afraid of the Light
Posts: 163
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With the 1.8T engine in the car, I started thinking about the wiring for it. The plan is to use the Emerald ECU which was previously fitted in my 'other' mk2 Ibiza 1.8T. The transplant into that car was done prior to my ownership, by Parsons Performance, so I started from zero in my knowledge. The other Ibiza had not been boosting properly when it was last running, and it had been suggested that this might be down to a fault with the ECU. It had not been protected from water ingress and was looking a bit suspect. I sent it off to Emerald M3D for them to test it, and to upgrade it from M3DK to K3 specification if it got a clean bill of health. Happily for me, it came back duly upgraded. My approach to working-out the required wiring started with buzzing-through the engine and ECU loom removed from the other Ibiza, and it was quickly apparent that it was this loom which was more likely to be the cause of the poor running. This picture was taken more recently, but it is illustrative of the quality of workmanship throughout the loom.  At this point the project stalled for a couple of years. The Ibiza was on the driveway (under a cover for the most part) with wires dangling everywhere under the bonnet like an automotive version of Mary Kelly. Part of the reason for the pause was that I was struggling to work out my best way forward, and part of it was that I was having my garage / workshop built and then fitting it out. In January of this year, I finally got the Ibiza into the new garage. This was a very big day!  As can be seen (just about) in the above photo, the Mattig mirrors have gone, to be replaced by a pair of DTM style mirrors. I liked the look of the Mattigs, but the adjustment on them was insufficient for them to be of any practical use. After much faffing about whilst the Ibiza was on the driveway, I finally settled on an approach for the engine and ECU loom. I decided to use the AYP engine loom, mostly because it connects to the vehicle loom via a 27-way and a 14-way connector, rather than being hard-wired. I had to modify the engine loom to use a cable throttle valve on the offside, amongst other things. From the two multi-way connectors, with known pin-outs, and the Emerald ECU, also with known pin-outs, I 'just' had to make-up a loom between one and the other, and which also connects to the vehicle loom where required. The theory is pretty straightforward, but I still spent a while with it looking like this.  I worked my way through one wire at a time, and after a long few days of soldering and crimping, and not a little head scratching, I had a loom between the engine and the Emerald ECU which had all of the connections I had identified as being required. It then took a little bit longer to sort the connections into the rest of the vehicle loom. This is mostly power supplies, but also includes the tacho output from the ECU to the rev counter amongst others. I have decided to locate the ECU inside the passenger compartment, so all of the wires between the ECU and the engine have to go through the bulkhead. To achieve this I cut a new hole and fitted a grommet which was supposed to have a home on a mk2 Escort. By now it looked like this under the bonnet. The 27-way (round) and 14-way (lozenge-shaped) connectors are at the front of the engine, and the new hole in the bulkhead is visible to the right of the bellows on the clutch cable.  Inside the car, the new ECU connector is hanging through where the glovebox would usually be.  |
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Last Edit: Dec 2, 2020 7:47:20 GMT by betenoir
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dikkehemaworst
Club Retro Rides Member
Posts: 1,636
Club RR Member Number: 16
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scary curse word, wiring...
all the luck!
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betenoir
Part of things
Afraid of the Light
Posts: 163
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I had been putting-off getting underneath the car to fit the exhaust. There was a perfectly good Milltek non-resonated system waiting to be fitted, but working in my garage rather than on my gravel driveway unexpectedly presented a new problem. Whenever I jacked a car up on the driveway, it was straightforward to put the jack on a board, chock the grounded wheels using a plastic chock or a piece of wood, and know it was not going to roll away before or after I got it onto axle stands. My garage floor has been done with two-pack resin, which is very hard, and very smooth (compared to gravel, anyway). The chocks I had been using before just slide across the floor, which resulted in the Ibiza falling-off the jack when I first tried to raise it. When that happened, it trapped my fingers between the tailgate and the garage door, which gave me enough of a scare that it took me a few days before I tried it again.
Using different chocks I got the back end up in the air, and put two pairs of axle stands under it, before I gritted my teeth and crawled underneath. The Milltek exhaust system is non-resonated, which means the section from the downpipe (also Milltek) to the bend before the fuel tank is just a straight section of pipe. When I trial-fitted this, it was clear that the bend was going to foul the fuel tank. I checked and re-checked that the pipe was fully located in the joint to the downpipe, then measured and re-measured how much I needed to cut off the centre section. I then cut-off about 10mm less than I had measured was needed, just in case I had got it wrong. Back underneath I trial-fitted it again, and confirmed that there was still more to come off, to the tune of about 20mm. Now finally convinced that I could cut that much off without finding I had an exhaust that no longer met in the middle, I cut the centre section again, and this time when I fitted it back in place the bend was exactly in the middle of the space designed to accommodate it. Getting the rear section to hang on its mountings was a little awkward, but only routine and nothing unexpected.
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