Jetta project 200

[TurboJ]

Too bad.. But at least it will be easy to sell the SDi intake to the TDI people.

[subsonic]

Time for our weekly update

[TurboJ]

Well, I HAVE been busy with the car, so I will update this topic soon.

All the pictures are divided between two cameras, and I need to get them on my computer first.
So, an update will follow in a couple of days  

[Aki-76]

Janne´s engine look very cool,and this week it´s ready ( i hope = )..

"High end motor",ceramic coating,big flow head,modified s1bg turbo.Spring (dynoday) we see results  :twisted:

[Smokey Eddy]

           :twisted:  :twisted:  :twisted:  :twisted:  :twisted:

[subsonic]

I am very interested in this project as it is right on line with what I am building.  The intake manifold you have built based off the 1Y is very nice and will allow you to run heavy boost and high rpms while giving nice even airflow, protecting your conecting rods.  I will also be getting a 1Y intake and would very much like to do the same dual plenum modification you have performed.

On this engine, what is your opinion if a vnt turbo was to be used.  Say a gt1749vb with mechanical control.  It should be able to give 25psi very easy, all day long.  It will also produce the boost very quickly which is nice, but high boost at low rpms can be hard on the connecting rods.  I kept the stock rods but completly rebuild them, had arp connecting rod bolts installed, resized etc.  As I could not afford custom h-beam rods, I improved what I could and had the sides polished and shot peened to get the most out of them that I could.  I hope it helps.  Here is a photo:
[/quote]

I will be aiming for the 150-170hp range with the hopes of using this as a reliable daily fun driver in the summer months.  It will be connected to a
02A CTN transmission out of a diesel passat.  It has very long gears to wind out and let the turbo and rpm's work.  I have a euro spec g60 lightened flywheel and a vr6 pressure plate to transfer the power.   I have to build it piece by piece as I can afford it, but if I want it to be fast and powerful AND reliable it needs to be done correctly. Lots of research before each part selection.  Your build is just the kind of research I love to find
Jim

[TurboJ]

I'll be watching your build with interest for sure! ( Nice rods BTW)
Hopefully the beasts are all ready for summer!

My working rate with the Jetta has gone up - now I use 4 to 5 days a week building it. Wife's still around which is a surprise really  
Next week I aim to take the body to the paint shop - doors and bumpers are done already. Pictures will follow shortly...

[RabbitJockey]

lucky you, my girlfriend throws a fit when ever i take out a few hours on a saturday for normal maintenance crap like brakes and oil changes.  but i guess i'm so great that its hard for her to be with out me haha.

[subsonic]

lucky you, my girlfriend throws a fit when ever i take out a few hours on a saturday for normal maintenance crap like brakes and oil changes.  but i guess i'm so great that its hard for her to be with out me haha.

 :roll:  :lol:

[TurboJ]

OK, finally updating the topic.

I really do not like deadlines, but spring is coming and the paint shop is busy, so I have to get the body ready for painting before the end of next week. The finishing touches are always the most time-consuming as you good people no doubt very well know.

I decided to do the engine compartment myself. That'll save a couple of hours of prepping work for the paint guy.


I probably should have stripped it all to bare metal, but the factory primer is so good I didn't want to remove any when not necessery.
The whole engine bay was actually in very good shape. Only minor rust spots and the turrets were both just fine.
But since the seams were reinforced anyway, the factory seam sealer had to come off, and boy, is that messy!

Drilling holes for the strut brace proved very challenging...
Metal on the right-hand side turret top was unbelieveably hard. We spent several special-hardened drills to get the four holes done. The other side was just your typical sheet steel. Go figure...



New seam sealer and primer applied.

Yeah, I know the seams aren't shaved, but the Finnish four seasons demand some thought for rust prevention. And the bare welds wouldn't have been pretty anyway.


Switching to a 02A gearbox meant holes had to be made to the firewall for the clutch master cylinder and the Passat pedal assembly.

You can just see the extra holes in the picture. The master cylinder will go to the right from the brake servo and steering column.



Passat pedals. The clutch pedal has it's mounting point further to the left than the Golf/Jetta pedal set, so new mounting holes were needed too, even though the Passat pedal set is a 'bolt on' of sorts.
Maybe I'll need a reinforging plate between the brake and clutch pushrod holes, the firewall is very flexible as you know.



Passat pedals test fitted.


After all the modifications had been made to the firewall, more priming followed...


And finally the first coat of Tornado Rot:

sorry about the crappy picture, my camera doesn't work well with fluorescent lights  

[TurboJ]

...meanwhile at the paint shop:

Hood and trunk lid have been primed and await their turn in the 'oven'.
Doors are done, and they do look pretty good in the flesh, even though my puny photo skills hardly do them justice.



Both bumpers half-way done. Body colour sprayed on first, and matt black finish to the upper parts will follow. The rear bumper had taken a few hits in its 18-year life, so lots of elastic platic padding had to be applied. It turned OK after all, and I'm not after 100% showroom finish anyway. It's a freakin' diesel for crying out loud!


The same OEM -style matt-black finish was needed for the side trim and arches too, which meant more smoothing, etching and filling:



I think the black bits turned out OK - it's not the exact same colour as it was from the factory, but it's close enough. And at least the trim looks fresh now, and is all of the same hue.



The all-important badgeless grille also had to have its lower stripe painted...

And yes, the dust IS everywhere!

[TurboJ]

Here are some of the parts I have collected from various sources.
I'm really glad I can soon start to put it all together - absolutely everywhere is filled with VW parts! My home, the parent's house, the garage, the warehouse, you name it. It's incredible really how many parts even the most simple 80's car ( = VW ) has when you really scatter it all around.

Anyway, here's my new skid plate:

...proudly made in Russia!  :twisted:  It even has some 'cool' Russian letters on the oil plug cover, the meaning of which I haven't the slightest of clues.

'Smoke style Hella rear lights, originally out of a Jetta GTX ( 16V GTI equivalent euro-spec model ). On the left my 'a bit' faded original rear lights.



Momo Monte Carlo steering wheel. It has the same diameter as the original VW wheel, which made this particular wheel my only choice.
I HATE too small space-age wheels!!
BTW, the Momo cost me 15 € on eBay


The venerable Votex center console, complete with Votex 3-gauge holder panel. Got these by change and I'm quite glad since this is the only way to fit 6 auxiliary gauges in OEM style. (I have a 3-DIN panel for the original radio slot too). As for the gauges, well, I would 've iked VDO, but the price for all six would've been INSANE. So Autogauge it is. I hope it won't look too 'ricey'.



I got a complete '89 Golf GTI 16V interior off a German-imported parts car. It has some small imperfections, but the seats have no wear on them at all, which has to be very rare. The colour scheme isn't the best possible for a red car, but it's not like you can choose the one you like...

On the first picture you can see the horrible things I've done to my parents' attic... And if you look closely, you can see how the bumpers turned out. What say you?


The new radiator:



The Passat TD 02A gearbox:

This one was a *** to wash. It took 3 hours, many types of solvents and an industrial steam washing machine. The toughest agricultural poisons eventually bit through the grime and soon I can start the finishing touches.
I can hardly wait  :roll:


Aki made me this really nice catch tank (thanks!!):

It even has a 'tap' below the tank, to allow fitment of a drain hose.
You know, put a jar under the car and turn the tap - voilá - oil residue drained. Too cool...


Braided steel brake lines and a Wiechers K-bar brace, ARB loops, mangled fenders...

[TurboJ]

Still going to keep the original anti-roll bars.

I figure there are so many improvements on the chassis already that it may not need thicker bars. We'll see how it turns out if I get the car on to a race track come summer.


My 'new' subframe needed a new layer of paint:

Guess who'll be repainting some walls soon...


Yet another set of A-arms stripped of the original rubber bushings.
This time true German quality from Lemförder.



I got a low-miles power steering rack thrown in when I bought the subframe, so now I have two to choose from. Nice how sometimes you get the good deals too, although that hardly makes the whole project financially sane!



The rear axle requires some minor maintenance:

I just know I'm going to learn many new curse words with that one.


OK, that's it for now! I'll be working extra hard the next 6 days to get the car to the paint shop by next thursday. I'll keep you guys posted how everything goes. We might even see a complete engine somewhere in the near(ish) future. Now I just have to fing me a flywheel and a good clutch kit and I'm mostly set to begin bolting things together.

Suggestions, comments and questions are again welcome!

[Dirtrag2]

you sure are working hard at it!

You are lucky to have the time and people surrounding you to get this project going, my projekt Fox will probably take me at least a year to get this far  :oops:

BTW deadlines SUCK but they have a way of pushing you to get it done  

keep up the amazing work  :twisted:

[RabbitJockey]

nice nothing is over looked.