Zonker

Zonker's Background

The ZONKER is a 16v GTI prototype from VW Sport. The big difference is that it features All Wheel Drive and an ABS brake system. It was an evaluation vehicle for things to come from VW. It is a one-off, Ferrari yellow, concept vehicle based on a 16v GTI. This unique concept car was the forerunner to the Rallye Golfs. Nicknamed Zonker, the two door GTI was built by itself on the assembly line at Volkswagen AG's, advanced Halle 54, production facility in Wolfsburg. Unlike standard U.S. GTI’s , the Zonker is equipped with VW’s permanent four-wheel drive viscous system and VW's Teves anti-lock braking system. After assembly, the Zonker was sent to Volkswagen Motorsports’ facility in Hanover, Germany, where it was fitted a high performance, 16-valve engine, complete with U.S. emission including catalytic converter, and a close ratio, five-speed gearbox. VW didn’t stop there. Shortly after the car’s arrival to the states it was taken to Callaway Cars of Old Lyme, Connecticut. There a Garret turbo charger and custom intercooler were added. The 16-valve engine, now developing about 219hp, and Syncro 4WD combination made the Zonker the only vehicle of its kind in the world. I have obtained the documents from Callaway presented to VW Sport on the 16v Turbo DEVELOPMENT PROGRAM, 16v Turbo DESIGN PHILOSOPHY, and THE DYNO APPROACH. These documents have a great insight into the development of the Zonker. In addition to the installation of the engine and transaxle, VW Motorsports also revised the spring rate and re-valved the struts to lower the vehicle’s ride height by about 1 ½ inches. The Zonker also has and a BBS front spoiler, rocker panel extensions and a new rear apron. European bumpers and mirror housings have been painted to match the body color. The European grill with GTI & round out the list of exterior changes. Inside, the one-off GTI shows a 220-kmh and. The Recaro seats are custom leather with adjustable thigh bolsters. Leather is also found on the and headrests, door panels, and Power windows and central locking system are also standard features.

Time Line

Born ??/1987 at Volkswagen AG's, advanced Halle 54, production facility in Wolfsburg, Germany. 16v Install ??/1987 at Volkswagen Motorsports’ facility in Hanover, Germany. Arrived in US ??/1987 at ?? VW Motorsports Tour ??/1987 CART race in August of 1988 at Meadowlands, NJ USA (Submitted by Tom Doblmaier) Anyhow, I did find a few pictures which I have attached. The first 2 are of, I believe, your car Zonker1 Zonker2. I took them at the Meadowlands in NJ in August of 1988 at a CART race. I was wrong in that the hood scoop was NOT on the car yet. I included another picture taken at the same event of a VW Pace car - that does have the hood scoop (but its a US 16V car - not a syncro). I also included a shot of a GTI VW used to bring to events a couple of years earlier in 1985. Its a full-up race GTI. Roll cage, stripped interior, no dash, etc. In 1985, VW had what they called their "VW Caravan" which was a rolling display of 4 or 5 cars that they would setup at motorsports events. The racing GTI was one. They also had an SCCA Scirocco, a Neuspeed cabrio, and I believe one or 2 other cars. In 1983 and 1984 the Rabbit GTI was a big seller for VW. Then when they introduced the A2 GTI in 1985, it was also very popular, winning Motor Trend's Car of the Year award. VW was capitalizing on this, and continued to do so until around early 1993, when they fell flat on their faces (in the US at least), not making a decent car (VR6 Corrado was great but it was too expensive), until the 95 GTI VR6s came out. Submitted September 4, 2001 Carlisle Custom Compact Nationals Spring of 1989 at Carlisle, PA USA (Submitted by Chris Stewart) The Zonker was with "VW Caravan" once again showing off it's stuff at Carlisle. Chris attended the show and had taken these photos. The hood scoop is still NOT on the car yet. With this new information Callaway had not gotten the Zonker yet to add the turbo and hood scoop. Also with the Zonker is a Corrado Pace Car and the Golf Pace Car. Submitted December 30, 2001 Turbo Install ??/1989 at Callaway Cars of Old Lyme, Connecticut. Sold to Private Party ??/1992 Oshkosh, Wisconsin USA. Sold to Me August of 2001 Fairfax, Virginia USA. Rebuild Callaway Turbo Sept. of 2001 Turbo Auto, Nashville, TN USA (Zonker's Callaway Turbo Rebuild Story) Fabricate Down Pipe Oct. 2001 Turbo Power, Cameron Park, CA USA (Zonker's New Down Pipe Story) Replaced Callaway Boost Gage Dec. 2001 from 0-60 to a Callaway -30 to +30 Boost Gage. Sold to Scott August 2002. More of the story after sold VW Sport USA 'Zonker' turbo 16v Syncro

16v Callaway Turbo Motor

Intercooler

New and Old Down Pipe

Engine Bay

Rebuilt Turbo

Close Up of Turbo Location

Rebuilt Waste Gate

The Zonker's engine featured the only 16v turbo ever developed by Callaway. This system was in testing for future cars. But was never put into production. 2 kits were all that were made. This is the only working one. Callaway Turbo Rebuild Story The Zonker has always been referred to as the 16v Callaway Turbo GTI Syncro. The turbo is one of the two reasons that makes the car so unique. And let me tell you how unique. After getting the Zonker home and taking it out on its maiden drive. It was not performing, as it should have. After some testing we found that the boost from the turbo was at 2 lbs. Not what we wanted to see so off comes the turbo, down pipe (that's another story) etc. You would think a Garret turbo with the part # 107100-0 and serial YJ-L0103 would be a call to the turbo shop to get a rebuild. HA! Now I know what one of a kind means. After that failed I searched the web talking to anyone who would listen, calling every company that had turbo in their name. Finally I found Jeff at Turbo Auto in Tennessee. After receiving the turbo Jeff sreaching the Garret number. He found that it was made for Callaway. By who? Well working backwards Garret, Roto-Master, Rajay. As best as we can tell the turbo turned out as a Rajay Compact, used in formula racing. Jeff completed the rebuilt and in testing what do we find? The waste gate is setup for 25-30 lbs. of boost (this is what most of the 2 liter formula cars ran in 1988 25-35 lbs.). Now the big question is has this turbo ever worked? Callaway's 2-stage turbo system only claims 10-15 lbs. The Zonker's Garret, Roto-Master waste gate part # 300118-05 serial # VJ-L0103 is setup for 25-30 lbs.? Down Pipe Story The Zonker has always been referred to as the 16v Callaway Turbo GTI Syncro. The turbo is one of the two reasons that makes the car so unique. And let me tell you how unique. After getting the Zonker home and taking it out on its maiden drive. It was not performing, as it should have. After some testing we found that the boost from the turbo was at 2 lbs. Not what we wanted to see so off comes the turbo, down pipe (that's another story) etc. The original down pipe was a combination of VW stock pipe and modified pipes also built with no flex pipe. The new down was fabricated by Turbo Power in Cameron Park, CA. As you can see we went from a twin pipe 1.5" configuration to a signal pipe 2.5" configuration, added a flex section. Also added a rotating flange to the turbo end of the down pipe. The down pipe was made by Turbo Power, if you need turbo work or exhaust give them a call 1.800.887.2648 or visit his web site www.turbo-power.com

Body Trim Features

Zonker features a BBS Ground effects kit sold from VW Motorsports in 1987 along with the one-piece BBS wheels. This car also features european Bosch fog lights, adjustable driving lights and rear fog light! The hood scoop is functional and acts as a air intake for the intercooler.