Mk2 Rocco G60 Turbo

So, basically this was in the daily rides section, but as with most things, i fell in love with driving it every day and ended up deciding that my mk1 project was never going to go anywhere.

so, instead of letting the g60 turbo engine go to waste, i thought i may aswell put it, into the rocco.

car has had several sets of wheels already in the space of 6 months. just at the finishing stages of installing the engine. i will let some pictures do the talking. got a build thread over on edition with many more pictures, but here's a brief explanation of what's gone on so far

brought the car in february '10



loved the way it looked for a while. has a few dents and patches of rust, but all of that will be ironed out over the next few months

sold the wheels to a mate and now have a set of o.z turbo's which will be going on next year once they have been refurbished. definately wont be running them over the winter



then ended up buying a set of g60 steels from phil on here



however this all changed when i decided to put the engine in. with more power, means decent brakes. and i was swayed into keeping my audi S2 calipers with 280 mm brakes. this meant that the g60 steels wouldn't fit over the brakes due to the offset being all wrong

so i will be running on some porsche d90's (boring i know) over the winter as they will sit over the brakes





so then it came to the engine side of things. old one out, with the new one in the background waiting to go in.



first thing in was the intercooler and oil cooler



then the block went in. waited ages for the mk1 g60 engine conversion mount to come, so in the mean time the whole front end was poly bushed and cleaned up. treated the old girl to some new lower arms aswell








all the car needs to run is an exhaust and for it to be wired up. the bloke doing the wiring will put a base g60 map on it, so it will run 160bhp straight away, then i will look into getting it set up somewhere. looking in the region of around 260 - 270 bhp. this will make me happy

i have missed out loads of photos, purely because i would be here all day writing this up, but there is a thread on edition http://www.edition38.com/forums/index.php?showtopic=303961&st=0&gopid=2840980&#entry2840980

i will be keeping most of the updates on here from now on

oh yeah, this weekend i will be installing the false floor in the boot to tidy it up in there. battery is being moved there, along with a fire extinguisher i can imagine the turbo will be glowing white most of the time so i definately need 1! lol

Nice rocco mate

Plans sound good too

Really nice mate

Sweet rocco and project, I like your garage/workshop too!!!

cheers for the comments. should be moving onto the interior work tomorrow. installing my gauges in the dash somewhere and false floor in the back. will update with pictures at the end of the weekend.

i share that garage with my old man, we had, had enough of trying to jack cars up on a gravel drive at home lol it's normally tidyer than that aswell

This is awsome.

What manifold are you using?

it looks very different to mine, my turbo sits much higher and touches the inlet manifold.

Also what turbo? and what ecu? i spy a trigger wheel ;-)

and how comes the g60s dont clear the brakes? mine do...

it's just a standard turbo technics manifold. think my turbo converted engine is alot older. i know the early conversions used to have the turbo right at the bottom of the engine. i know mine nearly rubs on the drive shafts

it's running a t3 turbo from an rs turbo/cosworth

and also running on megasquirt/microsquirt management which is a brain fry lol

think the wheels don't fit because they are S2 calipers. was just an excuse to get some porsche wheels lol never really liked the way the g60's sat anyway, and didn't have the money to get them banded.

would be interesting to see yours if i get along to a meet sometime soon

jaques_g60 wrote:

it's just a standard turbo technics manifold. think my turbo converted engine is alot older. i know the early conversions used to have the turbo right at the bottom of the engine.

oh right. so did you buy it all as a kit? i just used an 8v turbo manifold which i got off ebay for £30 ;-)

jaques_g60 wrote:

the wheels don't fit because they are S2 calipers.

Ive got g60 steels over s2 calipers;

doh. i never really checked, i got told by so many people that they wouldn't fit. never mind, got the d90's now which sit better in the arches. are those brakes any good for the mk1? heard some people say that they would lock the car up all the time. (could just be the usual people talking about stuff they have no experience of)

i brought the whole engine with the turbo and manifold already on there. the bloke who sold it to me had already run the engine on a smaller t25 turbo and decided to rebuild the engine. then left it to sit for 3 or 4 years.

hope it runs after all this time and money i have spent

i think the S2s are abit overkill really, plus they are massivaly heavy! standard g60s will be fine for most mk1s really with decent disc and pad combo. and yeah they will just lock up if the balance isnt set up correctly.

where did you get thoe porsche adaptors from?

jaques_g60 wrote:

(could just be the usual people talking about stuff they have no experience of)

matty_mk1 wrote:

i think the S2s are abit overkill really, plus they are massivaly heavy! standard g60s will be fine for most mk1s really with decent disc and pad combo. and yeah they will just lock up if the balance isnt set up correctly.

talk of the devil.

but yea the s2s are a bit heavier than g60s which means more unsprung weight. Alcons or Wilwoods would be better realy but lots of £££

any brakes without abs will lock up when stamped on (obviously )

is it a watercooled t25?

have you experienced them tom? i know what mk1 golfs drive like, i know what g60 brakes feel like, add the 2 together makes experience id have thought

Nice rocco dude i like these when done right thres a nice on in the new pvw shame bout the mk1 though

lol the porsche adapters were an ebay purchase. however, i wish i had paid a little bit more for some decent H&R's or something similar as these one's or poo.

as for the brakes, i will just see how they go. i may end up getting a pedal box with adjustable bias if they lock up too often. the car will be used on track days evetually so i will just have to suck it and see.

im not sure if the t25 was water cooled or not. but the t3 on it now used to be water cooled, but i have been told by a cosworth "expert" that alot of cosworth owners removed the water pipes as they used to cause overheating, which seems possible. if the water is going into the turbo and getting heated up to silly temperatures, then going back into the water system, i would imagine it causes some sort of heating problems? what turbo are you running?

just got the pvw, that rocco in there is amazing ! if i could get mine to look along those lines, all sad memories of not doing the mk1 will vanish...... i hope

jaques_g60 wrote:

the t3 on it now used to be water cooled, but i have been told by a cosworth "expert" that alot of cosworth owners removed the water pipes as they used to cause overheating, which seems possible. if the water is going into the turbo and getting heated up to silly temperatures, then going back into the water system, i would imagine it causes some sort of heating problems? what turbo are you running?

thats exactly what i was about to say too, not that i'm a cosworth expert

Im running a t2 which came off my old rs turbo. Ive de-water cooled mine too. it should be spun up by like 2500 rpm ;-)

ah cool. i say he's an expert as he's a bit of a know-it-all sometimes. saying that he does own a 3 door sierra cosworth puting out over 700bhp lol it does make sense when you think about it, and is a bit of a stupid idea in the 1st place. what sort of power are you running on the t2 turbo?

also, what injectors are you running on yours? i've seen a set of saab injectors for sale that are 330cc, not sure my green injectors will be man enough to handle anything over 200bhp

jaques_g60 wrote:

what sort of power are you running on the t2 turbo?

I would be happy with 160bhp and 200 lb/ft

jaques_g60 wrote:

also, what injectors are you running on yours? i've seen a set of saab injectors for sale that are 330cc, not sure my green injectors will be man enough to handle anything over 200bhp

im running stock ones for the time being, but from what ive heard the ones you want are Bosch red 340cc ones

ive also heard of people using 16 ohm agu ones which are 315cc or something.

and you will need a 3 bar fpr too

Red top 315cc are the ones Around £50 each new i think.

ah o.k cool. i will have to investigate a bit further and see what i can find. i know g-werks sell the red injectors which run at 315cc which im sure would be more than enough. cheers for your help

160bhp should be nice in a mk1. you will put all of that power down aswell, whereas i will probably be fighting wheelspin all the time. will be fun at 1st im sure, but annoying after time will have to see how well the quaife diff works

just a little update. whilst waiting for parts to come, i got on with tidying it up behind the seats. unfortunately the carpet i ordered didn't arrive in time for the weekend. so that will keep me busy next week in the evening finishing it off got 90%of the woodwork done though. should look o.k once it's all carpeted

boot is 90% finished now. just need my mate to finish making my battery tray and it can go in. pretty pleased with how it has come out













would like the next update to be me saying the car has started up and runs like a dream. lets hope so

that looks wicked m8.

matty_mk1 wrote:

that looks wicked m8.

cheers mate. took up so much time and patience but was worth it in the end

As matty said that looks really good

Looks smart m8 but also looks heavy.