Jetta project 200

[TurboJ]

Then it was time to paint the G60 front anti-roll bar (23 mm stock!) and the rear strut brace:





Tornado Rot, obviously...  

...the lower front stress bar had already been painted and I even fitted it:
'

Yes, that's the subframe, streering rack, a-arms and stuff already fitted.

...and here you can see the rear strut brace in place:



While the front one doesn't even exist yet; I'll fabricate it myself when I see how much clearance there is after the engine is in.

I still did fit the mounting plates for the strut brace, custom parts made by Aki:

[TurboJ]

Goodies from good old Deutschland:


I sold some time ago the BBS -knock off wheels that I had. In the end I didn't want to do the "RS thing" like everybody does; I wanted a bit more personality. Since I also wanted some quality wheels, it took a very long time before I could settle on what wheels I wanted.

But this is what the final decision was: Open the boxes, and...



Ronal Turbo R10 15x7 ET 28.

So I also went one size smaller from my previously planned Lenso BSX 16x7.5.
Now I just have to find some sticky rubber in 195/45 R15 to cover those ronals with.

My opinion is that the 'Turbo would look better on a small bumper car, but I like them on big bumper cars too.
I'm thinking about having them painted in medium gunmetal grey in the future, I think that would work better with T-rod than the silver finish they come as stock.

[TurboJ]

Before the spring of 2011, it had been almost a full year since I had done anything to the Jetta.
That, and the fact that VW parts were almost everywhere yet at the same time always nowhere to be found, I decided to clean up the house a bit:



After which things started to look a little like this inside:

[TurboJ]

Probably the last heap of parts to be sent to sand blasting/ powder coating:



And they came back looking like this:



The front hubs dismantled so the ABS rings could be taken off and new bearings fitted:



The starter motor was so new that I didn't replace it. Of course it had to be painted then:





...and the end result can be seen here along with other parts I had done a while ago:

(the alternator was just there waiting to be taken away as an exchange core for a new one)

[TurboJ]

Labeling the last remaining bits of electrics:



More new parts:



8V GTI's CV joints since the drive shafts I aquired were that spec. For the cooling system I did a little research. I got a T3 Transporter 80-degree thermostat and a eighties Saab 900 Turbo thermoswitch for the rad fan; will blow from 82 to 68 degrees! Goodbye heat problems in city driving!

Some more freshly painted parts:

[TurboJ]

The brake booster mounting flange and the clutch master cylinder are also on:



And today I finally got to continue my work on the electrics.




The custom part of my wiring system will require many new fuses and relays to be fitted somewhere. I want them to be easily accessible yet hidden from the casual eye. So I decided to fit the fuse boxes and relay mounts in the rain tray, below the removable plastic upper part of the rain tray.

Test fitment:

...and the extra relays will go under the tray on the right - the one that would house the ECU on fuel-injected gasoline models. As for the fuse boxes that can be seen on the picture, the left one is for the 4 glow plugs, and is separate because their wires are routed differently. The one on the right will provide protection for everything else.

OK, Now I'll go and get some sleep!

More will follow, but in the meantime, have a great time with your VWs too!

[Powered by Spearco]

Its sure good to see your build updated. Glad to here all is well. Keep up the great work. Can't wait to see the finnal outcome.

[carrizog60]

still alive and kicking as i can see.

[Alleslowbuged]

Hi,

winter time is garage time, any progress?
We all are waiting for the "everthing done perfekt" result.

Best Regards
Alleslowbuged

[TurboJ]

Perfect... lol  !

But anyway, yes I have been working on the Jetta. Quite a lot actually...

I haven't wanted to post pictures yet since most of the work is of the kind you can't see.
I've been working with the electrics still, and it's really been a LOT of work.

Now the interior part and bulkhead part of the electrics are done. Routed the wires better and replaced all wires front from the firewall.
Fitted separate fuses for glow plugs, manual/automatic cooling fan control, semi-hidden engine harness, wires for extra gauges and stereo, as well
as new electric locking system with alarm and remote control. But what took most time was making it all look OEM or nicer...  

Next week I'll be doing the last bits of sound deadening for the passenger compartment, and then the dash and carpets will go on!

Then the fuel lines and tank.

Then suspension and brakes. (And cooling systems fitment and modifying the mounting points for them...)

Then... It's time for engine   -> hopefully running in... Late April...  

[Alleslowbuged]

Hi,

did you make some process, did it run allready?

Best Regards

[TurboJ]

Once again it's been a typical car building year for me --> two days at the garage at Christmas and two days in the summer. So no huge leaps of progress here.

But, I will not give up.


Sound deadening almost done. You can even spot my windscreen washer fluid line on the picture 

Yes, the reservoir and the pump will sit in the boot of the car...


Also cleaned up and treated my best dashboard:

[TurboJ]

Painted the anti-roll bar end links along with the cam pulley.


The new rear brake calipers pre-paint:


The front brake calipers and their carriers (and the rears without theirs) after the finishing layer of paint:


...and the fronts fitted with all new parts (sorry for the bad pic)


The 22 mm H&R front anti-roll bar.

[TurboJ]

I replaced all three plastic water flanges on the engine with aluminum:


Which now look suitably stealthy painted matte black:


I also visited Aki's new workshop - which really is something to be seen - but unfortunately I didn't have my camera with me. Crappy cell phone pictures don't do it justice at all.

But here are just a couple teaser pics:

If you need to build a monster injection pump, then....


...and just in case you want to put on a new cylinder head, preferably with a few tweaks, then look no further:


Tomorrow my plan is to work hard on the Jetta so hopefully there will be some progress to report later!

Good luck with your own projects!

[nathantheengineer]

Fantastic!! i have just read this from beginning to end.

I am 5 yrs into a rebuild as well (mgb) and things just take longer than you expect if its not your full time job.

Keep going and i (like many) can't wait to see the final result.

Kind regards

Nathan