View Full Version : 1976 M1 1.8KR 16V Digi Conversion

08-04-2010, 10:52 PM
Not to leave Liam out on his own... Here is my MK1 labour of love money pit!

Before I bought it;






And some more recent ones;






I am waiting for someone to take some decent pics of it!

08-04-2010, 10:56 PM
Sure you will get plenty of offers from the talent on here Mik ;)

You didn't get to keep the 16V plates?

08-04-2010, 10:56 PM
Mick, that looks real good, mate!

My photo skill not good, but I will give it a shot.

08-04-2010, 11:10 PM
Funny you mention that about the plates, I have had some issues with them, but again today attempted to re-order them and hoping that I have been successful this time!!

I spose we need to get this car along to an event to get some happy snaps then. It is not concourse, but is great fun.

09-04-2010, 10:15 AM
another minter!!! >< Love those wheels!!


09-04-2010, 10:24 AM
I love the mk1, I would like to build one some day!!

09-04-2010, 05:07 PM
Such an awesome car Mick - happy to take some amateur shots as well.

Justin Fox
09-04-2010, 05:14 PM
Ah that is sooo mint. It's almost surreal to see old cars in such fantastic condition.

Best get some pro shots of it ASAP!!!

09-04-2010, 07:15 PM
Awesome car Mik!, not great fan of green cars but I love it!

18-04-2010, 10:07 PM
Went out to grab some Chinese, could not resist to take a shot from this angle.


18-04-2010, 10:14 PM
Yummy gear Mik!

Edit: Is it actually Oak Green?

18-04-2010, 10:24 PM
Looks great Mick. Need to get those no. plates sorted! :cool:

18-04-2010, 10:31 PM
Reminded me of this :D (admittedly it's a 2)


18-04-2010, 10:38 PM
Thats a great looking car, I love that colour.

18-04-2010, 10:48 PM
I have some complications with the plates Liam. They will either go on to the mkv or into storage until the end of the year. Until the yellows it is!

The mkii, I'd buy it in a heartbeat. Big bumper mki is no match for that car, I've got heaps of work to do to get it to that (and yes it is oak green).

Glad you like her.

03-06-2010, 05:01 PM
So a bit of an update.

There has been some spending lately - I have purchased a coolant flange adaptor that will allow me to correctly remove the sensor with out draining the coolant so it will be easier to tune. Other items coming are; a new fuel rail, new FPR (OEM), new injector seal kit and a DIN plate so I can install 3 gauges where the radio should reside.

Once I have that up and going and running as best I can I think that some dyno tuning is in order.

I'll most probably install a catch can if I can be bothered, as it is pretty tight in the engine bay and don't want to fuss with too much custom stuff.

03-06-2010, 11:46 PM
Good to see you at the point to move forward. It feels good. Be great to see it rev above 4000rpm!

Does it really need a catch can?

When are we gonna have a MK1/MK2 cruise? I've annoyed Liam about it

04-06-2010, 09:52 AM
Good stuff Mik, I miss my GTI badly :(

10-07-2010, 06:41 PM
I've been a bit quiet. But the MK1 section here is a ghost town haha.

So over the last few weeks I have ordered a new fuel rail with an adaptor for an OEM FPR which I am hoping will remedy a few things. Mainly not being able to get the thing to run lean. I also got a few other goodies coming along with it.

I went a bit mental and started to look in to some strange faults - like it having no advance over 4500 rpm - in the end I isolated it to the temperature sensor and temperature gauge both being incorrectly wired - so the obvious conculsion was that the ecu was getting the incorrect input. Today was the first time I had to take it for a spin.

Definately overfuelling, lumpy at idle - but oh how she pulls!!

*on closed private roadway*

It is not perfect but a damn sight better than any time I have owned it.

Next on the list is a new rear muffler, I am going batty with the drone - either that or an additional muffler somewhere in the system if it will fit.

Very happy to have taken her out for an hour though.

10-07-2010, 09:11 PM
Dude, that rules! It's hard to believe it's N/A the way it revs from 4000rpm.

Can't wait to see it again.

28-07-2010, 02:22 PM
Could possibly be.

I had the work done by Penrith Muffler Man, Cox St Penrith - Andrew was an awesome help and all I needed to do was explain what I wanted and he delivered! Thanks Andrew.

Here you go, this is the result - yes, we are still over-fuelling a wee bit.


So as many of you already know, this car was cast to be in Packed to the Rafters for this season - last night it made it's first, albeit brief appearance. There is sure to be more in the upcoming weeks, where you can actually see it properly!!



28-07-2010, 02:28 PM
Could possibly be.

I had the work done by Penrith Muffler Man, Cox St Penrith - Andrew was an awesome help and all I needed to do was explain what I wanted and he delivered! Thanks Andrew.

Here you go, this is the result - yes, we are still over-fuelling a wee bit.

What's with the whistle noise at the top end when you rev it?

Also did you put the metal plate with the rivets on the rear valance?

28-07-2010, 02:40 PM
Very nice MK1.

We should have a MK1 & MkII meet one night.

Go oldschool!

Drove my brothers MKII GTI on the weekend. Awesome drive.
Can't wait for the ABF conversion.

28-07-2010, 02:42 PM
Very nice MK1.

We should have a MK1 & MkII meet one night.

Go oldschool!

Drove my brothers MKII GTI on the weekend. Awesome drive.
Can't wait for the ABF conversion.

Amen to that! We tried that recently but my MK2 did a heater hose on the M4 :(

04-08-2010, 10:42 AM
A much better amount of action for the car in last nights epispde!



04-08-2010, 03:34 PM
Can I touch you! :p

04-08-2010, 03:36 PM
Indeed. Are we going to get production shots every friggin week?

04-08-2010, 03:39 PM
@Liam - you can't touch me, but I will agree to a FaceTime call
@Benough - If it airs - I'll be publishing them. :) As if you don't love it...

04-08-2010, 03:42 PM
Well I did brag a bit to my wife's aunty on FB. I want my MK2 on tellie now!

04-08-2010, 04:47 PM
i decided to watch over last nights episode online and locate those 2 images above :)

for all those interested skip to 7:00 minutes, and 19:25 to catch a glimpse of the car in action.

video here:

11-08-2010, 09:58 AM
Was round at a mates last night and half watching P2TR over dinner, instantly recognised the Mk1 from the door frame, congrats on getting such an awesomely unique vehicle cast on a TV show.

Cheers for the inspiration to get my finger out and finish mine off this weekend...

11-08-2010, 10:46 PM
Mandatory updates...








11-08-2010, 10:57 PM

11-08-2010, 11:00 PM

Just ordered your spare parts BTW.

11-08-2010, 11:08 PM

11-08-2010, 11:15 PM
Post was only $50 for your items, pretty cheap really!

14-08-2010, 12:28 AM
Do you know anyone who has ever adjusted a fuel pressure rail with a crushed can of V from the hi-beam of a MK2?

14-08-2010, 09:33 AM
No, but desperate times call for any measure!

18-08-2010, 05:07 PM
It's Wednesday - You know it!


Love the Wolfsberg sticker.





18-08-2010, 05:18 PM
Sweet. He drove it to the big house!

19-08-2010, 04:04 PM
I think they were just returning it after filming. Must have accidentally left the cameras running I guess.

19-08-2010, 05:57 PM
Love this show and have been noticing this car for a while now... I commented to my wife that's a pretty MK1. Your car is famous. You might be able to sell it later with that fame attached to the sticker price.

19-08-2010, 06:16 PM

21-09-2010, 09:56 PM
These are a bit old now - but thanks to Jon for processing them...




21-09-2010, 10:16 PM
So nice!

01-10-2010, 07:56 PM
*drool* that's one mean machine. I'm looking to buy a Mk1 with a good body but bad engine so I can do a 2.0litre transplant. Not too many Mk1s for sale here in QLD at the moment.

Btw, this is my first post on this forum. I'm crazy about Golfs and the VR6 engine and would like to build a VR6 machine one day, but for now, a 2litre Mk1 will suffice.

Great job miki.

10-10-2010, 09:09 AM
So after 4 weeks with the mechanic, the 16v is home and running better than ever. A pretty long list of fixes but all essential.

It is amazing what was causing some of the issues. The most noise from the engine bay was from a collapsed bearing in the alternator, now it's as quiet as a mk3 in there!

- fuel tank (screw holed in bottom and silastic was smeared over it. Cracked on top side, now it does not smell like a service station)
- relocated fuel pump
- new fuel rail and pressure reg, injector seals
- new accelerator cable bracket
- new AFM bracket
- replaced throttle body and flexible hosings
- new starter
- reco alternator
- new rear brake lining and wheel bearings
- CV boot
- replace ECU

Along with a few other minor bits and bobs.

It is amazingly smooth and rapid, and has a much improved exhaust note now it's properly tuned.

Could have bought Raus for the price but in my book it's still a bargain for the result. Still need to get some bodywork and trim sorted and then I can stop pouring cash into it for a few months hopefully.

Dyno next Sunday if all goes to plan (always subject to change with 4 sons) be great to get a benchmark on her.

10-10-2010, 09:10 AM
Making things understated with a chrome single grille.


13-10-2010, 10:50 AM
Will be good when the new ID tags are on! :cool:

13-10-2010, 06:02 PM
This car now puts my 8V to shame! It hauls from 2000rpm all the way to 6800rpm. The exhaust note is quite loud and has three stages. Loud, extra loud, whistle.

It's good to see it running proper after all this time.

13-10-2010, 06:16 PM
Awesome work Mik, singles always looks more finished/cleaner!


16-10-2010, 10:24 PM
Awesome work Mik, singles always looks more finished/cleaner!


Thanks heaps for the encouragement.

Added a few bits and bobs.



Replaced front bumper with a not so broken one and added the plates back that were originally on the car.. Took me an on and off a day to get it from this;


to this;



17-10-2010, 03:53 PM
First, thanks to Pierre - et. al. who were involved in organising this for the 5th year. Also a thanks to Todd for opening up on a Sunday for us all.

By the time I left I was the only NA car on the rollers and well below the other cars, being the only sub 100KW car! :banghead:

Here is the plot for those that are interested. I am keen to analyse it and work out a few things that can be improved - teach myself about AFR's and the like.


17-10-2010, 08:03 PM
From what I understand the perfect AFR is about 14.7 so what you have I think it bloody good!

I must say I'm surprised you only got the same power numbers as me. I'm certain a road race comparison would show otherwise.

17-10-2010, 08:22 PM
Nice plates!

I think the dyno was reading a little bit lower Benough, more so than to be expected (being a mainline I mean) ;)
Seemed quite a few people were down on what was expected/done previously...

17-10-2010, 08:24 PM
power looks a bit low. Shouldnt a KR be putting down around 80- 85kw?

17-10-2010, 08:31 PM
power looks a bit low. Shouldnt a KR be putting down around 80- 85kw?

I'm sure you'll see the results when they come up in hte other thread and it shuld raise a few eyebrows Tim ;)

Yeah I would have thought the KR was an easy 75+

17-10-2010, 08:35 PM
From what I understand the perfect AFR is about 14.7 so what you have I think it bloody good!

Generally most engines will make more power when there is a bit of extra fuel in there. 14.7 is chemically the correct ratio of air/fuel but only if it burns perfectly.

17-10-2010, 08:49 PM
Nice plates!

I think the dyno was reading a little bit lower Benough, more so than to be expected (being a mainline I mean) ;)
Seemed quite a few people were down on what was expected/done previously...

Well my MK2 was done on the exact same dyno at a similiar time of year/weather.

01-11-2010, 11:04 AM
So on a closed private road with my iPhone in one hand I have my review ready.

The car is now with the Techtonics Tuning 16v 7K RPM EPROM installed, timed at 10 degrees before TDC - It pulls a serious amount more than before. It still has lag down low at WOT, but once you get the revs on she is like a freight train.

As you can see it hits 7K as stated! (excuse my one handed gear changes)


The whistle is the exhaust. I had a rear muffler recently installed and that created the whistle. Needless to say, that has to change and will be coming off in the near future for something more throaty. I reckon there are some free KW's

Here is a second run - but it is near on impossible to do this sort of thing on your own.


In my opinion, it was a worthwhile upgrade.

05-11-2010, 09:37 PM
Just a nice afternoon shot.


07-11-2010, 09:26 PM
Looks tough.

26-11-2010, 05:11 PM
Weekend =


28-11-2010, 10:12 PM
header on fitted like a glove


this plus that, 8 hours later shazzam



fatty and skinny


Sound clips to come.

29-11-2010, 08:10 PM
Here is the sound from cold start, such a bad weather day I did not get it warm.


07-12-2010, 09:39 AM
Sunday drive.



07-12-2010, 06:15 PM
Sounds hot Mick :)

07-12-2010, 11:30 PM
wow that sounds pretty nice!

07-12-2010, 11:39 PM
Thanks guys - it's great fun to drive now, itching to get in it every chance I have.

Soon time to get it on the dyno and to WSID - but before I do I have an adjustable cam gear to go on! :D

08-12-2010, 12:08 AM
Sounds great! Love the MK1 golfs...

08-12-2010, 11:26 PM
Now there's a familiar set of bends Mick.

We should stick one of those little GoPro cameras just over the exhaust to see what kind of sound we get.

I am actually trying to get one from a bloke that I know in Canberra for a few days. I'll let you know if I do.

Unless you know someone close by here with one John? :D

16-12-2010, 10:04 PM
Thanks John! They are awesome!!

Dear Internet,

I have for a long time been told that the car that I bought could be a fire breathing green dragon - tonight she showed me she is.




21-12-2010, 11:18 PM
One of my favourite car films of all time is Rendevous, a clip shot in the 70's of a car racing through the streets of Paris at first light. I would like to replicate a similarly set film sometime, tonight was a bit of a test run to pull some bits together and a bit of after editing too.


21-12-2010, 11:38 PM
lets just say you went up that road a lot faster than i can in a camry :P

24-12-2010, 10:11 AM
lets just say you went up that road a lot faster than i can in a camry :P

HEH! I'd want to hope so!

For fitment on New Year.


So upon closer inspection, this is an OEM pulley that has been ground and die tapped and then connected to the aftermarket adjusting plate.


Oh and as Aust Post are doing 2 deliveries in my neighborhood today, I got some hub centric rings for the BSS too! WIN!


I also got a fused relay to boost the crappy head light situation.

Wondering if anything else turns up before Christmas?

24-12-2010, 09:21 PM
Nice MkI.

Looks really neat.

27-12-2010, 07:44 PM
Thanks for the props bro!

I did the relay mod for the headlights, just a single fused 30A between both of the low beams I considered to be adequate.

Heaps better light output, not like candles any more.

11-01-2011, 08:13 PM
So my car is featuring in July on one of the forums calendar.



You can buy one here.


Massive shout out to John for the photos, Justin and Christina for the getting behind the calendar.

26-01-2011, 09:43 AM
So a bit of an update.

I am about 70% complete on the interior conversion. It seems that it is hard to find the right staples for trimming door card these days so they are still to do.

Completed are;

Braced dashboard in place,
New anthracite carpet through rear, from boot to on top of the fuel tank under the seats, and up the guard,
Re-trimmed the rear boot panel,
Steam cleaned the new interior,
Fitted it all up.

Here are the results so far...





And did some filming on Monday for PTTR again as the car was clean I snapped a couple...


26-01-2011, 09:44 AM
Going to reinstall my fire extinguishers in the car today as well... You never know what might happen in a MK1!! :)

On the list to do before I slow down somewhat and enjoy it are;

Idler and adjustable cam pulleys/tune to match
Refurb door cards
Install gauges in DIN panel (Volt, Oil Pressure, Water Temp)
Custom intake pipe and breather diversion to catch can
Further guard flaring/rolling
New and stiffer engine/gearbox mounts
New front and rear plastic bumpers
Open single headlight grille
Paint some components under the hood to tidy it up a little
Possibly remove and replace the tints

I am sure the list will grow! :D

30-01-2011, 12:34 PM
Had a small issue while going for a drive with the little lady yesterday evening.


Lucky there was a late opening Kmart and I managed to patch it together to get home.


And some pics for clicks...



01-02-2011, 01:01 AM
Such a clean car, love the Mk 1's.

16-02-2011, 11:54 PM
So the car had a bit of airtime again this week on Packed to the Rafters. Should be at least a small amount more in the season, but you'll have to wait and see.


17-02-2011, 01:39 PM
Here is some working video...


21-02-2011, 10:20 AM
Now to put them in.


26-02-2011, 04:14 PM
So the gauges are in and working correctly! WIN!



27-02-2011, 10:19 PM
i love how simple the gauges look!

30-04-2011, 09:12 PM
Have not updated this in a while.

So after the gauges went in I took it to the track and that was quite a lot of fun. Was pretty consistent. Did over 120 laps in the day.



Have done some more Packed to the Rafters filming for the next season.


And another TVC commercial that will air not to far from now.


I have finished upgrading the interior, rebuilt the door cards etc.



A few other things cooking as well in the performance area. Just need some more time and money to get them in.

30-04-2011, 10:20 PM
Love your work. How's the RNS510 and MkV tiller retrofit progressing?

30-04-2011, 10:36 PM
Love your work. How's the RNS510 and MkV tiller retrofit progressing?

Just trying to get an uprated CANBUS gateway at the moment thanks. The challenge was always going to be to get it to talk to the steering wheel controls.

I might change direction yet and fit a car-puter. :D

03-05-2011, 09:32 PM
So over the past few months I have been fighting a bit of a battle with my car in trying to keep it running reasonably close to correct fuelling. It has been notoriously rich and really a nightmare to drive and enjoy.

I took the step that was suggested in the manual and bought a CO meter - a Gunson Gas meter, cost about $270 from the UK.

Armed with a Bentley manual my CO meter and some determination, I have struggled and wrestled with the car but today I feel that I have dialled it in to within an acceptable tolerance of where it should be.

There are a lot of measurements to Digifant 2 that feed into a final result for the ECU to deliver fuel. They are the MAF, the idle and WOT switches on the throttle body, the ISV, the Blue Temp sensor, the O2 sensor - probably other things I am not including as well.

Just so you know, this car was converted to Digi2 from K-jet before I owned it.

So to begin I tested the O2 sensor. I could not get a clean signal from the signal wire so investigated the loom. It appeared that the wiring from the connector on the ECU to the splice on the wiring where the Digi loom was connected to the original sensors. After a bit of investigation, replacing the sensor with a new one led to no change. The issue I have since discovered was the signal wire in the loom to the ECU is actually shielded (As the signal voltage is so low, .5-1 volts, this is to prevent interference) however it appears that the wire had never been correctly spliced and the signal wire and the shield had been soldered together, so the ECU was receiving a signal equivalent to the O2 sensor not being in place - which is a default enrichment mode. Subsequently I have managed to wire this up correctly and now have a correct O2 signal going to the ECU.

Last Friday, things had not really improved as much as I had hoped, and the Gunson gas tester arrived that day. I went to begin making adjustments to the idle, timing and CO to bring the idle in line and the CO down to 2% which is recommended. I went through some tests and was going through the measurement of the resistance of the Blue Temp Sensor with the engine at operational temperature. I measured the resistance and compared it to the Bentley and it was outside tolerances, so I planned to change it. I had change temp sensors on hot engines before and began to remove the clip that retains the sensor. Unfortunately I had forgotten to relieve the pressure on the coolant reservoir before removing the sensor (this is the Pro Tip) and I ended up being saturated in hot coolant. Long story short, I have received second degree burns to my arm - it will heal in time but was a stupid thing to do, I know that.


So that took me out of action until today (48 hours after).

I was stumped and thought it best to work with method so I know things were right from the start of the chain to the end. So I;

Removed the air filter, air intake tube and boots and cleaned them
Removed the CO adjustment screw and checked the o-ring
Removed the idle adjustment screw and cleaned the thread and tip
Removed and checked the operation of the WOT/idle and ISV
Replaced the Blue Temp Sensor with a known good (tested resistance) one

Then I went to the manual and used the Digi2 timing set up instructions to get that in order. No real improvement to the performance, still rich.

I sprayed carby cleaner through the MAF and this seemed to make a bit of difference to the way that the idle was sounding.

Set the Gunson up and adjusted the idle and CO screws and ever slowly I managed to get the CO down to 2%. I was pretty excited.

I took the car for a run and it is a really great feeling to have it feel like it is running 'as it should'.

After some driving I called past Illektronik's place to return some gear I borrowed and we had a yarn with the hood up. I mentioned that I had some rattles under the dash and one thing led to another and we ended up relocating the ECU from the raintray (where it has been since I owned it) to under the dash behind the glove box in the car interior. It turns out the loom was long enough apart from an extension to the wires that switch the wiper motor which was pretty straight forward to splice.

The end result of the relocation.


I am going to do some real world testing to see if small adjustments can get me a bit better low rev performance but in about a month I am going to take it on the dyno to see how things look.

The other unfortunate thing is that I have located what appears to be an exhaust leak from the raceland headers which I hope is only going to be a retighten.

Thanks for sitting through my story, I am pretty excited about todays progress. I thought I was up for a new ECU or worse to sort this out - so to celebrate I might order some new coilovers! :D

08-06-2011, 11:18 PM
The MK1 thread is pretty quiet isn't it?

All journeys have a destination, sometimes you end up somewhere unexpected.

Unfortunately, the journey of the Green 16v has been cut a little short.

A few weeks ago the car was involved in an accident and sustained some damage to the front end. At first it looked like it would be repairable, but after a closer inspection and discussion, I decided that the car was best to be assessed as a total loss.

This week has been hard but coming to the realisation that it is time to move on has been a good one. I have been pretty lucky to have this car, the support from my family who allowed me to get it to where it has been and also the chance to meet some pretty cool people and make some great friends along the way.

Over the next few weeks I will decide how to deal with where we are at where I take things to from here.

So farewell Team Green 16v!


08-06-2011, 11:30 PM
Sad to see it go, mate.

Mr Scruff
09-06-2011, 09:07 AM
Wow, sad news. Massive shame. Is there structural damage to the shell? Can you salvage much from it?

Justin Fox
09-06-2011, 10:19 AM

10-06-2011, 11:01 PM
That's a sad story :(

This is a real gem. Oh how I would buy it from you if you were in QLD!

11-06-2011, 01:48 PM
I've been reluctant to post much about the damage, but this is the end result.


14-06-2011, 04:26 PM
Nice car man !!!!!!

14-06-2011, 04:28 PM
So all of the parts apart from the drivetrain are up for sale. I am not going to make a big long post on golf.net as there are no MK1 owners here that are not on VWW but head over there for Mk2 dash, full interior and a heap of MK1 bits that are all A-class.

14-06-2011, 04:29 PM
You'll regret selling that dash...

14-06-2011, 04:30 PM
Maybe, maybe not.

I am looking forward to the things that the funds can buy for the weiß one!

14-06-2011, 04:33 PM
Group Buy?


17-06-2011, 11:05 PM
Here is a quick pic of where I am up to with the weiß one.


18-06-2011, 01:30 AM
Looks a treat mate! Keep it up.

22-06-2011, 11:19 PM
And another TVC commercial that will air not to far from now.


Here is the Campbells Real Stock ad she was most recently filmed for.


02-10-2011, 12:28 PM
Look away now, graphic MK1 content below.




End of an era.

I got $28.05 for the scrap steel however.

02-10-2011, 01:01 PM
Just read the last 2 pages mikinoz. Awful. Just awful. First things first.

How is your arm these days? fully recovered?

Secondly, your green MK1 I have seen in many debuts. Its so unfortunate. Looks like all is on the up from here on. Keep on modding.

10-10-2011, 11:23 PM
That's sad Mick.

But now I know why you have room for one more car, haha.