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megaw.co.za - MK1 Build Thread

Welcome to megaw.co.za

Introduction My car was originally a stock 1996 Golf Citi Shuttle 1.6 model and looked like these Citi Shuttles :

Before

I don't have old pics of my Citi Shuttle but I took pics of other Citi Shuttles below:

vw mk1 golf citi shuttle frontal

vw mk1 golf citi shuttle aerial

vw mk1 golf citi shuttle rear

vw mk1 golf citi shuttle side



































































After


vw mk1 golf citi shuttle modified drakensberg

vw mk1 golf citi shuttle modified drakensberg side

vw mk1 golf citi shuttle modified zwartkops trackday back

vw mk1 golf citi shuttle modified zwartkops trackday open bonnet

vw mk1 golf citi shuttle modified zwartkops trackday front

vw mk1 golf citi shuttle modified zwartkops skidpan gymkhana launch

vw mk1 golf citi shuttle modified zwartkops skidpan gymkhana launch 2

vw mk1 golf citi shuttle modified zwartkops skidpan gymkhana mid-course

vw mk1 golf citi shuttle modified 1

vw mk1 golf citi shuttle modified 2

vw mk1 golf citi shuttle modified 3

vw mk1 golf citi shuttle modified 4

vw mk1 golf citi shuttle modified 5

vw mk1 golf citi shuttle modified 6

vw mk1 golf citi shuttle modified 7

vw mk1 golf citi shuttle modified 8


















































































































































































































































































Engine: Before (1800 carb, It looks the same as my 1600 carb motor)


vw mk1 golf citi shuttle modified engine

vw mk1 golf citi shuttle modified engine 2





































Engine: Now


vw mk1 golf citi shuttle modified engine 4

vw mk1 golf citi shuttle modified engine 5






































Modifications (parts are OEM where applicable) :


• 2.0 ADY 8v motor
• Head, intake manifold and throttlebody were gasflowed
• Estas 276 degree cam
• Intake and exhaust ports matched
• Valve guides and seals
• 3 angle valve seats
• 3 angle and swirled valves
• Gotech MFI / Mini X fuel management system
• 210mm SACHS Power clutch kit
• VW Mk2 GTI 210mm flywheel (balanced)
• Wildcat 4-2-1 branch / header
• Febi Bilstein struts
• KONI Sport shocks / dampers, adjustable (front)
• KONI Sport shocks / dampers, adjustable (back)
• KONI Sport springs (front & back)
• Powerflex bump rubber on KONI Sport shocks / dampers
• Front lower strut brace / bar
• Front upper strut brace / bar
• Brospeed ff exhaust
• Endless S - Four brake fluid
• Powerbrake braided brake hoses (front)
• 280mm ventilated disks with Ferodo Platinum brake pads
• Michelin Exalto 2 Pilot 195/50/15 tyres
• Modern Citi clutch cable and mechanisms
• 15 inch Stride Racing Hart Concept alloy wheels
• Clear front indicator lenses with new sockets
• Clear fendor indicator lenses
• MP9 airbox (de-trumpeted) with adjoining induction pipe and air filter
• Radiator cover panel
• New fenders with indicator lights (shorter wheel arch overhang and no aerial plug)
• Custom Inner CV heat shield
• Quad light grille with big badge
• Fuel injection fuel tank and 8mm fuel lines
• Fuel injection filler pipe and petrol cap
• Bosch (Kombi) fuel pump
• ADY dizzy with MP9 4 window trigger plate
• Semi-clear crystal tail lights
• MP9 throttle body (no MAF sensor hole)
• Engine block, dizzy, spark leads and master cylinder painted blue
• Modern mud guards
• Engine bay re-spray
• Large rain tray
• Door handle recess plates
• Painted calipers






Performance:

• Gotech MFI / Mini X was installed by Domingo from Gotech and tuned by Shane from K.A.R. Performance
She made:
113,6hp / 84,7 kw ATW and 140nm ATW - on the K.A.R Performance dyno, 20th January 2010.


VWCSA Gymkhana '10: 2nd place in Class A (2.0litre, naturally aspirated and above) - 44.19 second run.

http://www.vwclub.co.za/results/2010/Th ... ficial.mht
Results from the day.

http://www.youtube.com/watch?v=r5bXg8MsE-U

http://www.youtube.com/watch?v=RsALTbS-yTE

http://www.youtube.com/watch?v=50SQ_4L2VQk

Videos of my car in action on the gymkhana track.

VWCSA Night Gymkhana '11:

Results from the '11 Night Gymkhana:
http://www.vwclub.co.za/results/2011/Ni ... na2011.htm

My car was the Class A winner with a time of 22.30 seconds.
My car came 4th overall on the day.

http://www.youtube.com/watch?v=ZQXllJSfhXg

My car (current setup) vs. modified Evo 8.

All parts (OEM) that were replaced on my current setup:

• Windscreen
• Front bumper
• Valance / cradle
• Hatch rubber seal
• Hatch (not glass)
• Rear ball-bearings
• Starter motor
• Bonnet
• Boot hatch
• Radiator
• Oil cooler
• Radiator pipes (OEM / Topran)
• Oil cooler pipes
• Water pump
• Pressure plate bolts
• Flywheel bolts
• Serviced original AEN gearbox (Similar to the AUG, shorter 2nd gear than the aug and ffz (2.12 vs. 1.94)*
• Engine gaskets, o-rings, seals and engine mounts
• Coolant bottle and cap
• Oil cap
• Back wheel arch guards

*Info courtesy of Killerwatt

ICE modifications:

• Bee - sting aerial
• 200W Sansui Amp
• Sansui 6x9’s and 6x4’s in the back
• Pioneer 6x4’s and Sansui tweeters in the front
• Panasonic MP3/WMA HU

Future modifications:
In the future I would like a 280mm race -spec disc upgrade, racing harness (4-point), rear strut bar, ARB's and semi-slick tyres. When my car is no longer my daily drive I'll get an AEG x flow head with a low boost T3/T4 turbo setup.

Image

My previous 1800 carb engine (someone through a hand grenade inside it :cry: ) -
Engine Modifications:

• 1.8 Golf mk2 8v GTI HM block
• New internals components (KS 81mm pistons etc) built by Racer Rob
• Gasflowed head by Van der Linde Developments
• 272 VW motorsport cam
• Engine block decked (Engine compression increased - 10.2 :1 )by Racer Rob
• Bottom end has been balanced







In memory of Mark Sandmann
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