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waj27

Vw Mk2 Jetta Coupe 4motion Build.

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I did start a thread ages ago but photobucket ruined it for me, any way heres another go. Always wanted a coupe ever since i laid eyes on Mike Mccoy's Mk2 OBDI Coupe

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A shell popped up on ebay and made an offer and the story of building one began, Its a 1985 Type 19 in polar silver no holes in the doors and rear quarters, small glass and the guy i bought it off had started to strip it down as he had plans of his own which fell through. How i picked it up, fortunately had all the panels doors, bonnet, boot and glass panels except the windscreen and some of the brown interior bits.

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First thing i did when i got it back was have some posts made up so i could wheel it in and out the garage and also removed all the panels just needed the naked shell, first little bits included the custom westy grill which am still working on and the duck bill splitter which i've both almost finished but will review these later. Got a decent sized garage with access right out my front entrance door can work on the shell without the need to open the main garage door and have room for a small fridge, work bench an tool box which was one thing that sold me when i bought the place.

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First thing was to get the interior cleaned up.

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Had a jig made up too so i could work on the underside which has been a great help cant count how many times it been on its side

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And started on the removal of the underseal to reveal what i actually bought 

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Boot floor cut out ready for future project.

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Getting there.

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As you can tell underside horrors as expected thought it wasn't this bad when i bought it as the top and inside looked solid but no going back now.

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Rust pretty much everywhere you can imagine.

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At this point just had to cut and cut and try to repair and salvage what i could.

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New floor pans test fit

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Both floors panels in.

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One of the challenging bits to do was the drivers rear strut.

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Then started on sealing the inner panels with Epoxy Mastic 121 

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Inner cills all expoxyed and joints seam sealed 

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More epoxy in the rear chassis legs before closing them up

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Finally starting to take shape and feel like more straight and rust free panels to actual rust panels. About 6months after buying the shell i also bought a 225 TT which i was going to use as a donor car, picked up for a steal the lady just wanted to get rid of it as a bin man drove in to the side of it damaging the wheel which was the only thing i needed to replace. total £500. Drove if for about 10months before stripping it down.

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And off it went :(

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Engine safely home.

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Engine trials, first thing i did was cut the coupe tunnel out and welded the TT tunnel which wasn't a bad fit as both floors marry up well at the front lining it up was tough to get it centre but got it done in the end. 

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TT Tunnel in.

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its was a little short at the back which I expected and meant the propshaft might be also. 

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Mocked up a plate to close the gap.

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Decided to use the TT Seat trays aswell which are slightly wider than a coupe but not an issue when you've a grinder and welder

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Bulkhead cut out to run the TT bulkhead panel, also both seat trays in

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Panel in and peddles in for test fit.

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Heater matrix in and car is now right hand drive :)

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Started on the rear subframe after.

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Box section welded into place to mount the rest of the axle holes 

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Servo fits but its close to the engine at the moment 

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Arches tacked into place.

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As the tank will be relocated i have no use for the petrol cap which only causes rust :(

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Engine in to work on the propshaft 

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Diff in 

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Prop shaft actually fits with no need to shorten it but needs lengthing slightly it’s about 20-30mm short which isn’t too major as I can use a billet to make up the difference. Need to swap the steering rack for a TT and change the front engine bracket so the engine can sit better. Deeper tunnel has saved me a lot of hustle as i might be alright with the downpipe and exhaust also the tt bulkhead panel saved me a great deal as a lot bolts onto it.

That as far as i've got so far, will update as i go.

Edited by waj27
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Hats off to you that's a lot of work. Really looking forward to watching this progress

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Made a start on the dash and steering wheel today, TT dash might not be everyones cup of tea but didn't want the dash to go to waste 

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Mounted up to the original steering column  holes.

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Not fully mounted but close enough.

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Along the course of the 2 years owning the shell i've also collected a few bits.

A Genuine brand new rear Jetta small bumper one of the last few in the Uk I’m told, was a lucky find as my original one the iron, well i think thats where tetanus comes from.

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Pair of wings, the original ones all rusted on the bottom

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Pair of doors converting to a full glass and also no holes for the door strips 

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Momo Street Racer GTs not the actual colour ones i've got as mine are red and in the attic don't have a photo , had a pair many years ago in a different car and so when these came up had to have them again, plan to get the interior recovered in black alcantara with tartan. The rear bench will be a combination of a scirocco top half and tt bottom

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Wheel choice do want a set of BBS RS but ill have to hold for now till the shell is ready, but have these in storage.

G60 Lookalikes off a corrado 5x100 which will be the stud pattern I’m going to run due to the TT rear axle being 5x100 and using a VR6 subframe for wide track, will probably get these banded at some point or do a 3 piece steel wheel split.

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Audi A8 always wanted a set but didn't have the right car to put them on.

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And these rare beauties.  Southern Ways Epsilon Mesh 15" came of a wide body 911 the rears are 10j which will need to be reduced as the TT rear subframe sits wide. I’m after Lips if anyone has some please!!! Swap willing for what I’ve currently got.

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Westy prototypes, also have one on a 7slat base but not sure if i like them might just buy a genuine one if i can find one and stop being cheap

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Edited by waj27
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Defiantly going to following this! seeing all the work underneath only brings back memories of doing mine! i feel your pain and the amount of work thats unseen! 

Welldone mate 

 

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9 hours ago, demk2 said:

Defiantly going to following this! seeing all the work underneath only brings back memories of doing mine! i feel your pain and the amount of work thats unseen! 

Welldone mate 

 

Cheers mate, starting to feel like its getting there slowly,

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Loving the work in this. keep up the updates :D Your first batch of pictures are working for me but the 2nd batch isn't

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1 hour ago, McPikie said:

This is brilliant work so far, but the second set of phtots dont show for me

That odd, you using google chrome ? 

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Little update, 

Got the engine sitting right finally, it was a little too far to the drivers side which was hitting the master cylinder had to shift it to the left by 10mm ish to clear, as i had to move the gearbox mount on the subframe due to running 02M i did the same for the rear engine mount and the results are a good clearance between master cylinder and cam cover. Running a TT servo and master as with everything so far just made it fit somehow.

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Also managed to make the TT Steering rack fit on to the subframe, meant drilling new holes as it mounts up longer than the mk2 but the benefits of this rack is that its like a quick rack i believe its  Lock-to-lock: 2:9. Rack meeting up well with the TT bulkhead panel so my setting out measurements worked out fine

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Also decieded on running a torque mount at the back of the gearbox as the engine had quite a bit of movement on the 3 mounts, its a mixture of a TT rear box mount and seat ibiza.

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Shafts should clear now that the mounts are pushed back

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My front engine mount, care of dutch build will reinforce it at the top to make sure I’ve got all 4 bolts bolted up to the gearbox currently only have 3 on the engine bracket as you can see on the photo below top one isn’t bolted up.

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Still have an issue as the brake fluid bottle is too close to the body, which I will relocate using a different one.

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Got the dash near enough where i want it to be just need to make the mounts fit

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Edited by waj27

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1 hour ago, g60pops said:

Can you use BBS Motorsport E barrels and lips for the Epsilon wheels as they are 20 bolt as well?

I have searched about that and don't think its possible, if they the holes line up then it might work but epsilon use an m10 bolts so means drilling out the motorsport holes. 

 

if anyone has a spare motorsport lip and would like to offer some measurements please help.

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Small update, 

Managed to get the dash properly mounted up and happy with how its turned out.

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Next up is to get the rear trailing arms fitted/ modified to mount up to the original axle mounting points, which will be a huge task to get right. cheers for all the comments hope some of the work will help others.

 

Edited by waj27
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Fair play mate to the amount of hours you must have put in.

Good to see a  in-depth build thread on here , keep up the good work and keep the photo's coming. 

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just to repeat what everyone else has already said, top work and I could only dream of doing this. keep it up...

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Another small update, one of the things i thought would give me a right ball ache was the downpipe and exhaust, the original TT downpipe comes off the turbo with too much of an angle which hits the rear engine mount so that was out of the question fortunately as i've used the TT tunnel means i can run the aftermarket downpipes for the TT and S3

3" from the turbo down,

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Had to nudge the engine slightly to get it in but bolted on fine as you can see everything is tight in there but nothing too major to worry about. will make a bracket for the hanger fixed onto the subframe 

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Little tight to the body but i'll just make some room when the engine is out but clears the prop and steering rack just how it should

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Other task is getting the rear arms to mount up to the body, i've seen how others tackle it with repositions the mounting points with quite a bit of cutting out of the body and the arms sit too close to the cill which is quite noticeable so going for a different approach. 

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The plan i've come up with is to marry up the TT rear arms to a standard rear beam bracket which i had spare, the arms are cast iron which means relying on the welds alone wont be a good idea but plan to use a box section sleeved over the cast arm and then bolted through and welded. Just have to make sure i get the hub dead centre with the body before,which i got a little idea how.

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The other issue is that the control arm hits the body what i've seen people do is notch the body but i've done enough cutting on this shell want to keep some things original so the plan is to use a curved plate, guys in the U.S call this Z notching or something like that.

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Will cut and re-weld the plate to the control arm, this is a control arm used on the Gen 2 Haldex system on Audi A3s / S3

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Will update soon

Edited by waj27

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Can I ask which way and how much you moved the gearbox mount to locate it to its new location? I’m just about to do mine and concerned I might not get it right. 

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4 hours ago, Big Ginger said:

Can I ask which way and how much you moved the gearbox mount to locate it to its new location? I’m just about to do mine and concerned I might not get it right. 

Best way to do it mate is bolt the gearbox cup to the 02M mount giving yourself a little room at the back of the bolt and then put the engine in bolt all the other mounts and then see how-much you need to move to clear the shaft and tack it in place, i tried doing it while the engine was out then fixed the subframe to the engine and it didn't work out too well and as the front engine bracket push the engine back which meant the shaft caught the cup.

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19 hours ago, waj27 said:

Best way to do it mate is bolt the gearbox cup to the 02M mount giving yourself a little room at the back of the bolt and then put the engine in bolt all the other mounts and then see how-much you need to move to clear the shaft and tack it in place, i tried doing it while the engine was out then fixed the subframe to the engine and it didn't work out too well and as the front engine bracket push the engine back which meant the shaft caught the cup.

Great cheers for the info. The front bracket you have for the 02m, where you have a bolt going through into the front bracket did you put that hole in yourself? Mine is blank, guess it gives you complete movement to locate the engine where ever you want it. 

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3 hours ago, Big Ginger said:

Great cheers for the info. The front bracket you have for the 02m, where you have a bolt going through into the front bracket did you put that hole in yourself? Mine is blank, guess it gives you complete movement to locate the engine where ever you want it. 

No worries yes i put that in as i didn't want to weld it on to the bracket as it would have been tricky to mount the whole bracketb

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