Jetta project 200

[theman53]

If my wife would only read this. She thought my 3-4 year deal was too long. Keep it up Janne

[TurboJ]

Thank you kindly, fellow VW'ers!

As it happens, today wasn't such a big day after all - the VW dealership doublecrossed me in that they had given my suspension nut to someone else even though it was reserved for me 

But here are a couple more pictures that I wanted to share anyway. Tomorrow I'll drive off with my new wife to see the lovely lakes of middle Finland and the 2012 Rally Finland. Inspiration, here I come!

On to the pictures then.

This is what my new auxiliary central electric unit looks like:

...all the added new electric systems are controlled by relays mounted here and of course there is also a fuse for each circuit.
There's, for example, both automatic and manual control for the radiator fan. Should keep my cyl head OK...

And here's how I did the glow plug wiring:

Individual wires and fuses for each glow plug so I won't get stranded if one blows a fuse.

The beauty of this wiring layout is the once the rain tray plastics are on, all this is completely hidden. I like myself for that 

There is still some electric work left but I'll try to do the suspension and brakes first. Some change helps when you get frustrated by working 100+ hours on just one aspect of your car...

[TurboJ]

Speaking of the suspension, the H&R anti-roll bar is on:



...while the rear one is still waiting.



I have to sort out the fuel tank and make a new sender unit before I can fit it - the rear axle will only go on after that.

But I now have almost every part for it:



So I started to put it together.



I'll try to make it a complete rear axle and then fit it to the car once it is. Should be easier that way..

[TurboJ]

Here's how I did the sound deadening:



There is Vibroplast (foil covered butyl sheet) all over the floor, and there's foam plastic on top of that. On top of that, there's fabric rag that's glued to the foam plastic.
The front bulkhead has the original rubber mat over the foam plastic and Vibroplast. Once I put the original mat on top of the transmission tunnel too, I think the front section
is pretty much covered. The goal is that the Jetta couldn't be recognized as a mk2 by its sound levels   The trunk area will need some more work still, but it'll just be fun.

I just hope my cheapish S/S exhaust will be quiet enough. I want a civilized tourer of a car, not a farm tractor!

[TurboJ]

Oh, by the way, here's my new monster pump. Thank you Aki!



Pretty much the only things standard about this pump is what you can see from the outside. On the inside, not one component has been left standard  

-- -- -- --

-"One big turbo, please."

-"How would you like it sir?"

-"Well done, please."

-"Coming right up, sir!"

[RabbitJockey]

Oh what fun I wish I woulda took pictures when I cooked mine

[TurboJ]

OK, so there was a lot still to be done to my engine..

We had to redo the main bearing line twice because the old bearing caps were too worn.
And at the same time we put in the H-profile rods just to be on the safe side.
Aki's telling my new turbo should be able to push 240 horsepower and the new pump is good for 270 hp, so steel rods were not a bad idea

We also settled on a new finish - it's a bit bright, but I think it'll fit the dark-shaded engine bay just fine.



The turbo is looking like this when it's mounted:



Here Aki is test fitting the turbo with my new intake manifold.



The new intake manifold is here:



There's still some work to be done on it, but it's looking good.
On this long project a lot has changed during its development and one of those things has been knowledge on camshafts.
We decided to change to another type of intake manifold because a short-runner design like this works better with the aggressive camshaft
that I have. My older long-runner manifold will be good for someone's TD with a more conservative camshaft.

[RabbitJockey]

is that the stock vw exhaust manifold?  i have been curious how much hp it is really good for, i've seen gas engines use it up to 180whp

[TurboJ]

There are stock manifolds and stock manifolds...   

Some variants have been used on 1.9's developing well over 300 hp, but some are quite poor.
For example, the stock 1.6 TD exhaust manifold doesn't work well at all.

My engine will (according to today's knowledge) indeed use a modified stock exhaust manifold.
There are one or two secrets to make them work, and as you will see on the end result, some are
rather surprising.

[RabbitJockey]

I understand.  On my car I ported the runners as far in as I could but the spots between cylinder 1&2 and 3&4 is hard to reach obviously.  My manifold is originally from a 1.6td.  I did not port the turbo side much other than to clean it up since the outlet already matched the t3 turbine quite well so I did not see any reason to open it up

[TurboJ]

Took some time to organize some bolts and nuts. Now THAT was fun 




Some things are incredibly difficult to clean... I already started to clean the fuel tank years ago! I have used many kinds of chemicals
and also lots of manual work on it. Now it was time to get it finally done:






And of course once I had been cleaning it for some hours (chemicals, jet wash, rubbing with a brush and a splint... # &@§ !!  )

...it was time for paint at last.

[TurboJ]

While this bugger really got me annoyed.



Never has any part of a car been so utterly difficult to get clean. It took hours and hours and at least four types of solvents and cleaners, jet wash and blood and sweat and tears. Great! Awesome! Niiiiice!

Work in progress...



But finally:






And then of course I went on to spray it with some stainless steel coating - nice shine and top notch heat resistance.

[TurboJ]

Took a money shot of the front suspension parts. Just a shame about the rug



Then continued the assembly. Epoxy coating on those hub carriers.




aaand.. There they sit. Now just the top mounts to tighten. Someone know the tightening torque for VR6 top mount's lower nut? Oh, and the top one too come to think of it...

[TurboJ]

The front caliper carriers dismantled and the slide holes carefully cleaned.



...fitted with new slides and rubbers:



The rears needed a little more attention. They had been badly treated in their earlier life, so there was some minor rust around the slide holes.



30 minutes of cleaning resulted in a nicely oiled action on the carriers. Then I touched up some paint damage on the carriers and calipers:



Front calipers ended up like this:



That's all the brake stuff ready for assembly - finally!

[TurboJ]

02A type cable holder and related parts; they hadn't aged so well!



But some brass wire brush and minor cuts on my hands later:



Hammerite on: