Jump to content
waj27

Vw Mk2 Jetta Coupe 4motion Build.

Recommended Posts

Small Update:

Started assembling the engine, painted the last few bits now waiting on dual mass clutch and cambelt to complete it.

UNADJUSTEDNONRAW-thumb-1edd.jpg

UNADJUSTEDNONRAW-thumb-1eda.jpg

UNADJUSTEDNONRAW-thumb-1edc.jpg

UNADJUSTEDNONRAW-thumb-1edb.jpg

UNADJUSTEDNONRAW-thumb-1edf.jpg

UNADJUSTEDNONRAW-thumb-1ed9.jpg

UNADJUSTEDNONRAW-thumb-1ee0.jpg

UNADJUSTEDNONRAW-thumb-1ede.jpg

UNADJUSTEDNONRAW-thumb-1f2b.jpg

VHT paint on the manifold 

UNADJUSTEDNONRAW-thumb-1f2d.jpg

UNADJUSTEDNONRAW-thumb-1f2c.jpg

UNADJUSTEDNONRAW-thumb-1f1d.jpg

UNADJUSTEDNONRAW-thumb-1f19.jpg

UNADJUSTEDNONRAW-thumb-1f1d.jpg

UNADJUSTEDNONRAW-thumb-1f34.jpg

UNADJUSTEDNONRAW-thumb-1f31.jpg

UNADJUSTEDNONRAW-thumb-1f36.jpg

UNADJUSTEDNONRAW-thumb-1f2a.jpg

UNADJUSTEDNONRAW-thumb-1f28.jpg

Picked up some Brembo 4pots fairly cheap need a refurb and will put new seals these are to be my 312 set up on the front and the rears are vented.

UNADJUSTEDNONRAW-thumb-1f30.jpg

UNADJUSTEDNONRAW-thumb-1f32.jpg

 

Edited by waj27
  • Like 2

Share this post


Link to post
Share on other sites

Small update.

Engine is now complete and back together, new clutch and belt added, happy with how its turned out.

Box on.

UNADJUSTEDNONRAW-thumb-1f6c.jpg

UNADJUSTEDNONRAW-thumb-1f6d.jpg

Mounts and Brackets on.

UNADJUSTEDNONRAW-thumb-1f7d.jpg

UNADJUSTEDNONRAW-thumb-1f7c.jpg

UNADJUSTEDNONRAW-thumb-1f7f.jpg

UNADJUSTEDNONRAW-thumb-1f74.jpg

UNADJUSTEDNONRAW-thumb-1f80.jpg

UNADJUSTEDNONRAW-thumb-1f7e.jpg

UNADJUSTEDNONRAW-thumb-1f7b.jpg

Just the suspension bits to paint then i can have the shell back.

Edited by waj27

Share this post


Link to post
Share on other sites

Small update.

Been busy getting a few bits sorted mainly suspension bits.

So the Cilo Brembos were a no go made a mistake not checking the fitment but never the less i managed to sell them and buy some Porsche 986 Brembos.

UNADJUSTEDNONRAW-thumb-1fab.jpg

UNADJUSTEDNONRAW-thumb-1fb3.jpg

Painted up.

UNADJUSTEDNONRAW-thumb-1faf.jpg

This is my set up 312 discs and how the 197 fitted. Fitted fine on the hubs and disc but wouldn't fit under the 16s

UNADJUSTEDNONRAW-thumb-1fb2.jpg

UNADJUSTEDNONRAW-thumb-1fb1.jpg

986 Brembo's are slightly smaller than the 197 calipers so get about 2- 2.5mm under the 16s just have to move the wheel weight. for those that are interested this is a straight bolt on job no need to do any modifying, you can use Mk4 golf 312mm 4pot caliper carriers which fit mk2/mk3 i don't have the spacer issue as i got to run adapters for the 2 sets of wheels i've got i'm wide track 5 stud so the disc is a mk4 golf/audi tt disc.

UNADJUSTEDNONRAW-thumb-1fd8.jpg

UNADJUSTEDNONRAW-thumb-1fdb.jpg

UNADJUSTEDNONRAW-thumb-1fdc.jpg

UNADJUSTEDNONRAW-thumb-1fd5.jpg

UNADJUSTEDNONRAW-thumb-1fd4.jpg

UNADJUSTEDNONRAW-thumb-1fd2.jpg

UNADJUSTEDNONRAW-thumb-1feb.jpg

UNADJUSTEDNONRAW-thumb-1ff7.jpg

UNADJUSTEDNONRAW-thumb-1ff8.jpg

Calipers will need painting but happy with how they fit don't get me wrong its tight but will work.

Also quickly refurbed the A8 faces to use as rolling wheels, i've also fitted some 165 40 16s 

UNADJUSTEDNONRAW-thumb-1f9c.jpg

UNADJUSTEDNONRAW-thumb-1f9b.jpg

UNADJUSTEDNONRAW-thumb-1f9e.jpg

UNADJUSTEDNONRAW-thumb-1fea.jpg

UNADJUSTEDNONRAW-thumb-1fe9.jpg

UNADJUSTEDNONRAW-thumb-1fe7.jpg

UNADJUSTEDNONRAW-thumb-1fe8.jpg

Few weeks back i dropped off my whole interior to get retrimmed by a small company in Exeter and these are the first photos i've been sent so looking forward to seeing them finished.

UNADJUSTEDNONRAW-thumb-1fce.jpg

UNADJUSTEDNONRAW-thumb-1fe3.jpg

UNADJUSTEDNONRAW-thumb-1fcc.jpg

Unfortunately the shell isn't going to be painted for a couple months but in no major rush and by then the weather should start to get better and i should have everything ready to go back in so will be more interesting updates 

 

Edited by waj27
  • Like 1

Share this post


Link to post
Share on other sites
18 hours ago, Rainbird said:

Seats look really nice - where are you having them done?

cheers mate, small company called smiffy auto upholstery in exeter

  • Like 1

Share this post


Link to post
Share on other sites

Another Small Update,

This post is me using my single garage to the absolute max over the harsh weather we just had, it wasn't going to stop me finishing off the last bits of painting.

All the bits  below i've been done with Black epoxy mastic 121, which i've used for most of my rust proofing, used with a gun and thinned properly the finish is great not quite powdercoat finish but just as thick going on and it tough once cured.

All the suspension bits are completed now just have the front calipers to paint.

Excuse my cloths line but had to make do.

UNADJUSTEDNONRAW-thumb-200d.jpg

UNADJUSTEDNONRAW-thumb-200b.jpg

UNADJUSTEDNONRAW-thumb-2008.jpg

UNADJUSTEDNONRAW-thumb-2017.jpg

UNADJUSTEDNONRAW-thumb-2019.jpg

UNADJUSTEDNONRAW-thumb-200a.jpg

UNADJUSTEDNONRAW-thumb-200c.jpg

UNADJUSTEDNONRAW-thumb-200e.jpg

UNADJUSTEDNONRAW-thumb-200f.jpg

UNADJUSTEDNONRAW-thumb-2010.jpg

UNADJUSTEDNONRAW-thumb-2011.jpg

UNADJUSTEDNONRAW-thumb-2012.jpg

UNADJUSTEDNONRAW-thumb-2016.jpg

UNADJUSTEDNONRAW-thumb-2014.jpg

 

 

Edited by waj27
  • Like 1

Share this post


Link to post
Share on other sites

Follow up from the above,

My plan this week is to build all the suspension bits up so i can have the shell on its wheels. Found some time to build the front subframe some of the items like the polly bushes i almost forgot i bought them many years ago so after a quick inventory check i had everything in stock.

Fitted the TT steering rack on to the subframe

UNADJUSTEDNONRAW-thumb-202e.jpg

UNADJUSTEDNONRAW-thumb-2022.jpg

UNADJUSTEDNONRAW-thumb-202c.jpg

All pressed in

UNADJUSTEDNONRAW-thumb-2023.jpg

UNADJUSTEDNONRAW-thumb-2024.jpg

UNADJUSTEDNONRAW-thumb-201e.jpg

UNADJUSTEDNONRAW-thumb-2021.jpg

UNADJUSTEDNONRAW-thumb-2026.jpg

UNADJUSTEDNONRAW-thumb-2030.jpg

Plan to do the rear subframe tomorrow.

  • Like 1

Share this post


Link to post
Share on other sites

Update from above.

Found some time to get the rear diff reassembled trying my best not to scratch the paint on either panels.

IMG-7235.jpg

First off was to remove the standard Haldex Insert Circlip and swap it for a Powertrack Insert which splits the power 50/50 to the back wheels.

IMG-7236.jpg

Standard one

IMG-7239.jpg

Powertrack

IMG-7237.jpg

IMG-7238.jpg

All mounted back

IMG-7240.jpg

Also upgraded the rear ARB, what i've done is use the TT front ARB and fitted it at the back which is must stiffer added new polly bushes also

IMG-7244.jpg

IMG-7243.jpg

IMG-7245.jpg

IMG-7256.jpg

Next was the rear trailing arms.

Polly bushed but also needed to use a spacer to close the gap.

IMG-7241.jpg

IMG-7242.jpg

IMG-7249.jpg

Discs and caliper carrier and strut bracket fitted, TT uses vented discs on the rear.

IMG-7257.jpg

IMG-7246.jpg

IMG-7254.jpg

IMG-7255.jpg

IMG-7253.jpg

Front subframe fully completed all mounts in bar the hubs and discs which i'll fit on the car

IMG-7252.jpg

IMG-7251.jpg

Need to fit the bulkhead panel onto the shell next, needs to be bonded on plan to do that tomorrow.

 

  • Like 1

Share this post


Link to post
Share on other sites

Impressive work as always.

Quick one, Is it obvious which way up the front arb goes when fitting? I've removed mine for paint and haven't marked which way up it went?

Share this post


Link to post
Share on other sites
4 minutes ago, Dom joy said:

Impressive work as always.

Quick one, Is it obvious which way up the front arb goes when fitting? I've removed mine for paint and haven't marked which way up it went?

Cheers mate, don't think it matters just have to have the arb links facing upwards.

Share this post


Link to post
Share on other sites

Update:

Started putting back a few things to clear some room in the garage and places i got things hidden.

First off had to bond the bulk head panel back and bolts it up.

UNADJUSTEDNONRAW-thumb-205b.jpg

Peddles in but might need to take them off to lay the sound deadening 

UNADJUSTEDNONRAW-thumb-205e.jpg

UNADJUSTEDNONRAW-thumb-205c.jpg

Front subframe in 

UNADJUSTEDNONRAW-thumb-2064.jpg

UNADJUSTEDNONRAW-thumb-2065.jpg

UNADJUSTEDNONRAW-thumb-2066.jpg

The power steering marries up to the bulkhead panel well

UNADJUSTEDNONRAW-thumb-2068.jpg

UNADJUSTEDNONRAW-thumb-2067.jpg

UNADJUSTEDNONRAW-thumb-2061.jpg

UNADJUSTEDNONRAW-thumb-2063.jpg

UNADJUSTEDNONRAW-thumb-2062.jpg

Hubs and coilovers fitted

UNADJUSTEDNONRAW-thumb-206a.jpg

UNADJUSTEDNONRAW-thumb-2069.jpg

Steering column and dash bar fitted out of all the bits i've painted literary forgot to paint this as its been out of sight but will just brush it before i fit the dash.

UNADJUSTEDNONRAW-thumb-206b.jpg

on to the rear, diff in

UNADJUSTEDNONRAW-thumb-206c.jpg

UNADJUSTEDNONRAW-thumb-206d.jpg

UNADJUSTEDNONRAW-thumb-2070.jpg

UNADJUSTEDNONRAW-thumb-2071.jpg

trailing arms.

UNADJUSTEDNONRAW-thumb-2075.jpg

UNADJUSTEDNONRAW-thumb-2073.jpg

UNADJUSTEDNONRAW-thumb-2074.jpg

UNADJUSTEDNONRAW-thumb-206f.jpg

UNADJUSTEDNONRAW-thumb-2076.jpg

UNADJUSTEDNONRAW-thumb-2077.jpg

Wheels on

UNADJUSTEDNONRAW-thumb-2079.jpg

UNADJUSTEDNONRAW-thumb-2078.jpg

The TT rear axle with 20mm adapters on the A8 7J still give some poke

UNADJUSTEDNONRAW-thumb-207a.jpg

UNADJUSTEDNONRAW-thumb-207d.jpg

UNADJUSTEDNONRAW-thumb-2087.jpg

UNADJUSTEDNONRAW-thumb-2086.jpg

UNADJUSTEDNONRAW-thumb-2084.jpg

UNADJUSTEDNONRAW-thumb-2089.jpg

UNADJUSTEDNONRAW-thumb-208a.jpg

UNADJUSTEDNONRAW-thumb-2080.jpg

UNADJUSTEDNONRAW-thumb-2082.jpg

Shell will be coming home for me to do few other bits while i wait for April, will get the brake lines sorted and sound deadening. 

Share this post


Link to post
Share on other sites
12 hours ago, demk2 said:

Love this build! what a feeling it is when it touches the ground again for the first time huh :wub:

Cheers mate, was a long day trying to make sure i didn't damage the paint while fitting all the bits and also lining holes after i've upgraded the bushes was a right job. 

As you can imagine having the shell nearly 3 years and only seeing it touch the ground once, this time it felt like am actually starting to get there.

Quick photo of the completed rear bench sent by the upholsters

UNADJUSTEDNONRAW-thumb-c81.jpg 

  • Like 3

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now

×