Rocky Mountain Club B5

Members => Member Rides => Topic started by: 34k on September 22, 2006, 12:34:53 PM

Title: Andrew(34k) 1992 VW GTI
Post by: 34k on September 22, 2006, 12:34:53 PM
(http://www.tw34k.com/images/monty/side_02.jpg)

(http://www.tw34k.com/images/monty/badgeless_01.jpg)

Mk2 Madness!

I figure it's time for an update on the Mk2 since things will be moving right along now. I've been pretty busy the last few months doing little stuff, but a couple big things are pretty due.

This Sautrday (9-23-2006) Ian and I will be pulling the 8v engine out.

Next week Apex Autobody will have the car for 3-5 weeks sorting out some various metal work including:

  -Shave Side Molding
  -Shave Side Skirts
  -Shave, Smooth and Roll/Pull Fenders
  -Shave Fender Lights
  -Shave Roof Antenna
  -Shave Driver Side Wiper Hole
  -Shave Rear Wiper Completely
  -Shave Rear VW Badge
 
Then a full window-out sand down and re-spray in its original Green Glory!
After that, she comes back and Ian and I shoehorn a spanky little VR6 under the bonet and away she goes!

I've got a fairly detailed write-up done over on my website for anyone interested:
http://www.tw34k.com/mk2gti_build.php

And a gallery of stuff here:
http://www.tw34k.com/mk2gti_gallery.php

All the parts I pulled this week:
(http://www.tw34k.com/images/monty/gutted_interior01.jpg)

My lovely assistant Wendy peeking over the seats.
(http://www.tw34k.com/images/monty/gutted_interior02.jpg)

My comfy Recaro Trophy seats
(http://www.tw34k.com/images/monty/recaros.jpg)

Euro Small Chrome Striped bumpers
(http://www.tw34k.com/images/monty/bumper_grille_lip.jpg)


Much, much more to come!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 92UrS4 on September 22, 2006, 12:38:47 PM
Awesome! Looks like it is coming along nicely! Can't wait to see the finished product.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Eric18T on September 22, 2006, 01:05:07 PM
looks great. i wish i had the space for a project like that. i can't wait to see it once it is shaved and resprayed. Are you going to cage it at that time too?
Title: Re: Andrew(34k) 1992 VW GTI
Post by: jayryan on September 22, 2006, 01:18:20 PM
Wow!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on September 22, 2006, 01:21:01 PM
I don't think I'll be putting in a cage. I'm so tall that unless i was driving with a helmet on all the time, i could seriously hurt myself.

Plus, i'm planning on re-covering the front seats and doing the rears to match as well as the headliner and door cards.

Who knows tho, the project may go more "club racer" in the future. :D

I thought about doing the door cards like the old Club Sport Porsches with just a flat panel of vinyl with a pull strap for the handle.

Maybe i'll pick up a set of door cards from the junk yard and play with some cutting and fiberglass shaping.

Mmmm, plans.  :twisted:
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Spicoli on September 22, 2006, 05:32:17 PM
Sexy!

(http://www.jewschool.com/borat.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on October 02, 2006, 02:49:52 PM
Okay, so Ian and I got the engine out last Saturday and dropped the car off at Apex for the body work which should start this week.

I thought I'd post up some pics, mostly to say THANK YOU to Ian for his garage, expertise, tools and patience with the 8v engine that I am trying very hard to get out of his garage! (3 people lined up so SOMEONE is going to take it)

(http://www.tw34k.com/images/monty/rm_engine01.jpg)

(http://www.tw34k.com/images/monty/rm_engine05.jpg)

(http://www.tw34k.com/images/monty/rm_engine10.jpg)

(http://www.tw34k.com/images/monty/rm_engine11.jpg)

(http://www.tw34k.com/images/monty/rm_engine19.jpg)

(http://www.tw34k.com/images/monty/rm_engine23.jpg)


And finally, the "One-Nerd-Power Golf", or the "Mk2 Rickshaw".

(http://www.tw34k.com/images/monty/rm_engine24.jpg)

The rest of the pics are in the usual place:
www.tw34k.com (http://www.tw34k.com/mk2gti_build.php)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on October 02, 2006, 02:59:13 PM
so cool!!!

Ian should be member of the year with all the help he provides for everyone :)

Can't wait to see updated.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ianacole on October 02, 2006, 03:10:24 PM
:oops: I just loved the opportunity to tear something apart that isn't mine  :lol:
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Eric18T on October 02, 2006, 05:44:14 PM
nice job guys..
Title: Re: Andrew(34k) 1992 VW GTI
Post by: gragravar on October 02, 2006, 07:04:22 PM
that is one awesome rickshaw.   :lol:
Title: Re: Andrew(34k) 1992 VW GTI
Post by: evil_O on October 03, 2006, 03:36:45 PM
Nice Andrew.  I am excited for you and cannot wait to see the respray... let alone ride in this bad boy.....
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on November 08, 2006, 11:21:35 AM
Okay, quick update.

I got my 1985 non-3rd brake light hatch glass (yum)

(http://www.tw34k.com/images/dz/85_hatch_glass_01.jpg)

As well as a whole slew of stuff from TMT in Germany all waiting to go on when this is finally done:

No more Rub-strips
(http://www.tw34k.com/images/monty/driver_side_progress_01.jpg)

On either side...
(http://www.tw34k.com/images/monty/pass_side_in_progress_01.jpg)

I chose to replace the passenger side fender rather than try to rebuild a G60 fender that is cut out. Here's the product.
(http://www.tw34k.com/images/monty/fender_in_progress_01.jpg)

Shaving the side marker lights on both fenders.
(http://www.tw34k.com/images/monty/fender_in_progress_02.jpg)

Rear emblem divit cut and welded.
(http://www.tw34k.com/images/monty/rear_emblem_in_progress_01.jpg)

This fender had a chunk of rust that had to be rebuilt.
(http://www.tw34k.com/images/monty/rear_fender_rust_repair_01.jpg)

Rear wiper and wiper spray nozel filled.
(http://www.tw34k.com/images/monty/rear_wiper_in_progress_01.jpg)

They've had the car six weeks now. :(  More to come when there's more to show 'n tell!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 92UrS4 on November 08, 2006, 11:25:36 AM
WOW! Looking good, I though maybe you got swallowed up by that car since we hadn't seen you 'round these parts in some time. :)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ianacole on November 08, 2006, 11:26:04 AM
At least it's starting to "move."  Lookin' good so far.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on November 08, 2006, 11:41:40 AM
lookin good.  All the subtle changes will be awesome.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on November 08, 2006, 12:21:12 PM
Thanks guys! I've been here every day reading except a week in Oct when I was in Vegas at Adobe MAX.

I just haven't had a whole lot of fun stuff to contribute lately. :D
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ianacole on November 08, 2006, 12:52:25 PM
Quote from: "34k";p="52925"
I just haven't had a whole lot of fun stuff to contribute lately. :D


That's never stopped JR ;) :P
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on November 16, 2006, 07:15:55 PM
Back at the body shop yesterday, more pics -and another "two weeks" kind of reply. I'm so glad this isn't my only means of transportation, heh.

I'm going to have them roll the fenders as well since I picked up a set of these and I'm going to need the clearance:

(http://www.tw34k.com/images/monty/pre_purchase_teledials.jpg)

(http://www.tw34k.com/images/monty/hood_filled_01.jpg)

(http://www.tw34k.com/images/monty/frontwiper_filled_01.jpg)

(http://www.tw34k.com/images/monty/passenger_fender2_01.jpg)

(http://www.tw34k.com/images/monty/drivers_rear2_02.jpg)

(http://www.tw34k.com/images/monty/boot2_02.jpg)

(http://www.tw34k.com/images/monty/roof2_01.jpg)

(http://www.tw34k.com/images/monty/drivers_rear2_04.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: jayryan on November 17, 2006, 10:49:37 AM
I'm speechless..
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 92UrS4 on November 17, 2006, 10:55:58 AM
Such a copycat, trying to make your car look like my Scout! Just kidding Andrew. It really is coming along nicely. Thanks for sharing the progress with us. I know we aren't quite ad hip as those DZ folks when it comes to MKII's but it's still awesome to see it come along,
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on November 29, 2006, 02:47:56 PM
Snowy day post...

The new rollers arrived last week and I headed over to Apex to test fit them. Nothing too exciting to report.

Two weeks til it's done...right. :yawn:  :P

Going to roll the fenders. The offset of these 928 wheels is big. Like... 65mm big. Adapters are 28mm up front and 32mm out back.

Leaves me with final offset of 37mm front / 33mm rear.

Pretty sure I measured all that correctly. It's going to be snug in those wheel wells.

I'm thinking either:
195/40s - ContiSports
205/40s - BFG gForce

Leaning towards the 195/40s.

(http://www.tw34k.com/images/monty/porsche_wheels_arrive.jpg)

(http://www.tw34k.com/images/monty/porsche_wheels_testfit.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: DenverPat on November 29, 2006, 05:03:21 PM
Oooooohhh, I love those wheels.  Veddy veddy niiiice.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on November 29, 2006, 05:11:45 PM
Quote from: "DenverPat";p="53340"
Oooooohhh, I love those wheels.  Veddy veddy niiiice.


Heh, thanks man. They're sooooo 80's-licious.  :D
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Spicoli on November 29, 2006, 07:39:23 PM
What size are your wheels?  

Personally I woudl rather go the wider, bigger footprint tire.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on November 29, 2006, 08:04:03 PM
Quote from: "Spicoli";p="53343"
What size are your wheels?  
Personally I woudl rather go the wider, bigger footprint tire.


They are 16x7.
So would I, but I may not have a choice. There's not a lot of clearance in the wheel wells especially near my coilovers and I don't want balloon-ish tires making it worse.

I think the 195 will work the treat.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Colorado_Baja on November 30, 2006, 08:40:09 AM
Coming along nicely Andy! Phone dials are my fav!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on December 07, 2006, 11:44:15 AM
I went in for my bi-weekly visit to the patient yesterday and guess what Apex told me? Yup, "couple a weeks". Nothing was accomplished since I was in there two weeks ago, but I want to stress that Dave and I have an understanding about the schedule for the car. The vast majority of the work they do and the only work they really make any money at is Insurance repairs. My car's custom work is side work and man-power wise is second priority. I knew this going in to the project and I'm not the least bit surprised about how long it's taking. I just want to make that clear that I'm not really bitching about the time this is taking. :D

Besides, this should keep me busy for a while. There certainly some clean up that's going to need to happen, but my VR has a new temporary home at Hardey's.

"Who's a dirty girl? Yeaaaaahh, you're a dirrrrrrty girl."

(http://www.tw34k.com/images/monty/vr6_01.jpg)

(http://www.tw34k.com/images/monty/vr6_02.jpg)


Along the way I found a set of these guys on the tex and a pair of new euro bulb trays from Robin. Just need to "de-yolk" them as Dan said, heh.

(http://www.tw34k.com/images/monty/tail_lights_01.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: coveredbytheblood on January 10, 2007, 01:53:15 PM
So, any updates on this yet?  I am excited to hear if there are!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on January 10, 2007, 02:12:34 PM
Funny you should ask!

The holidays and the snow storms have kept me busy and away from the body shop, but I finally have an update. She's in primer and should see paint this week!

I also have the engine eady for cleaning/paint if the weather cooperates for long enough.

(http://www.tw34k.com/images/monty/in_primer_01.jpg)

(http://www.tw34k.com/images/monty/in_primer_02.jpg)

(http://www.tw34k.com/images/monty/in_primer_03.jpg)

(http://www.tw34k.com/images/monty/in_primer_04.jpg)

(http://www.tw34k.com/images/monty/in_primer_05.jpg)

(http://www.tw34k.com/images/monty/in_primer_06.jpg)

(http://www.tw34k.com/images/monty/in_primer_07.jpg)

(http://www.tw34k.com/images/monty/in_primer_08.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ianacole on January 10, 2007, 02:59:19 PM
:woohoo:  :beer:  :greedy:  :thumbup:  :bow:
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on January 10, 2007, 03:15:58 PM
Hot Andrew.....I am so looking forward to this summer when it is either done or nearly done.  It is going to be one amazing ride!!!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on January 30, 2007, 09:33:18 AM
We have paint! They shot the car yesterday morning.

We're still a little more than a week out before I can pick her up. They still need to do buffing, sanding, undercoating and cleaning, but it's so good to see it in color again!

(http://www.tw34k.com/images/monty/paint_01.jpg)

(http://www.tw34k.com/images/monty/paint_02.jpg)

(http://www.tw34k.com/images/monty/paint_03.jpg)

(http://www.tw34k.com/images/monty/paint_04.jpg)

(http://www.tw34k.com/images/monty/paint_06.jpg)

(http://www.tw34k.com/images/monty/paint_08.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: DenverPat on January 30, 2007, 09:35:43 AM
Nice!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 92UrS4 on January 30, 2007, 09:40:10 AM
8O Looks great!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Spicoli on January 30, 2007, 10:06:35 AM
Sweet Andrew.... now only 5 more months and it will be half done.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on January 30, 2007, 11:21:08 AM
that is sooooo damn hot!!!!  I just started tearing down the MINI this morning, starting to look like your GTI :)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: gragravar on January 30, 2007, 12:23:18 PM
nice Andrew!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on February 22, 2007, 08:12:11 PM
The car is done at Apex and moved down to Hardey's Motorwerks where the engine is and where we'll be doing the install with the DZ guys! Thank you so much Ian for the help with moving and the trailer!

I want to say here another big thank you to Apex Autobody in Denver. David, the owner, is one of the most honest, customer driven business owners I have ever had the pleasure to work with. They did a tremendous job with the paint and body work and even though there was a mix up at the shop about hours spent on the car, he stuck with the original quoted price even taking a H-U-G-E loss on the deal. The pictures turned out pretty nicely, but they don't go the distance showing the quality. Hats off to all the gentlemen who worked hard on my car, and to David for everything. I know I mentioned it before, but even though it took nearly five months for the work to be done, there was never any rush on my part to have it finished since I certainly won't be driving during these Winter months. David and I had an understanding about the timing, and I have not one complaint about the job or the level of service provided.

Now the interesting part of installing the various bits and of course the engine. I've picked up a few more items I haven't mentioned yet including a set of G60 Corrado front and rear disk brakes, 15" Corrado steelies to cover the brakes in the winter, a Kamei golf ball shifter and euro/early quarter flares.

I'll probably go out this weekend and get some all-season whatever tires mounted on the steelies and see about getting the Porsche phone dials refinished. I'll also see if I can meet up with Dan to look at getting some or all of the sub frame installed and some painting on the under-carridge and engine done.

On with the pics, my fav is the fifth one down that shows how clean the paint/finish is clearly enough that you can see Wendy in it -especially the raw high rez one in the camera  :D

(http://www.tw34k.com/images/monty/paint_done_01.jpg)

(http://www.tw34k.com/images/monty/paint_done_02.jpg)

(http://www.tw34k.com/images/monty/paint_done_03.jpg)

(http://www.tw34k.com/images/monty/paint_done_04.jpg)

(http://www.tw34k.com/images/monty/paint_done_05.jpg)

(http://www.tw34k.com/images/monty/paint_done_06.jpg)

(http://www.tw34k.com/images/monty/paint_done_07.jpg)

(http://www.tw34k.com/images/monty/paint_done_08.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 92UrS4 on February 22, 2007, 08:42:57 PM
:mrgreen:  Looks great! I am really happy for you, this is turning out to be a great project.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on February 22, 2007, 09:08:19 PM
holy schnikies....that looks awesome!!!!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: SweetVW on February 23, 2007, 08:02:51 AM
She looks gorgeous!  :thumbup:   I cannot wait to see the finished work.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on March 16, 2007, 10:10:21 AM
Still plodding along here. I'm waiting on the full set of Corrado G60 brakes and spindles so progress on getting the subframe etc has been slowed. I was also off in Florida meeting my future in-laws. Yup-yup!  :D

In the mean time, I do have an update on wheels. I threw the 15" Corrado Steelies on. Camera wasn't behaving though and this is the best pic I've got.
(http://www.tw34k.com/images/monty/corrado_steelies_02.jpg)

And we also got the Porsche Phone Dials back from Woody's. It may be hard to see in the pics, but I had them polish the lips which should really stand out when I've got rubber mounted on them, and I've got a set of correct valve/stem caps with the Porsche crest raised on them.

(http://www.tw34k.com/images/monty/finished_wheels_02.jpg)

(http://www.tw34k.com/images/monty/finished_wheels_03.jpg)

(http://www.tw34k.com/images/monty/finished_wheels_04.jpg)

(http://www.tw34k.com/images/monty/finished_wheels_01.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Colorado_Baja on March 19, 2007, 09:58:17 AM
thats hot..
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ColoradoB5 on March 19, 2007, 01:27:05 PM
Andy!  I need more!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on March 19, 2007, 01:56:04 PM
Heh, thanks guys!

Winston, I've got more pics and details on my website:
http://www.tw34k.com/mk2gti_build.php

I've heard a rumor that we may be getting some of the prep work done this Saturday at Hardey's. I highly doubt we'll be actually installing the engine, but once I've confirmed, I'll give the guys who've said they can/want to be there an update about what we think can get done.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on March 19, 2007, 02:41:40 PM
IN LAWS??????  Congrats Andy!!!!! :thumbup:  :woohoo:
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ianacole on March 19, 2007, 03:11:26 PM
I completely missed that!!!  :oops: Way to go!!!!   :thumbup:  :woohoo:  :beer:
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Spicoli on March 19, 2007, 08:03:37 PM
What, Andrew is getting/already married?  When is/did this happen(ing).  oh man this is confusing...


... future tense:
What, Andrew is getting married?  When is this happening?  Congrats man.


... past tense:
What, Andrew got married?  When did this happen?  Congrats Andy.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on March 26, 2007, 11:36:58 AM
Getting married :D and THANKS ALL!

Things just took a huge leap forward! We decided to get together today and I THOUGHT we were just going to get everything layed out and organized, identify things we were still missing, that sort of thing and well... the VR went in!

There's still quite a chunk of stuff we have left to do including wiring it all up, fitting the brakes, changing out the rear tyranny mount, putting the interior back together, bolting up the exhaust et al. I'm sorry to some of the guys who had offered to help, but we have one more big day that should include firing it up and first drive and I'd still like ya'all to be there!

I've pretty much given up on the Corrado brakes at this point. They guy back East has turned into a flake and it looks like I may have to make a claim through PayPal to get my money back. *sigh* I found MSD's 11" front kit on Performance-Cafe and a 22mm Autotech front sway bar that we'll need to keep this thing planted.

There's also some parts from RS Motorsports including the correct rear tranny mount, correct fans, and a clutch slave/master and a OBD2/VAG-COM port that I still need to get from them this week.

On to the pics!

Pulling the pedal cluster and A/C stuff
(http://www.tw34k.com/images/monty/swap1/06_pedal_cluster.jpg)

Installing new 22mm master cylinder.
(http://www.tw34k.com/images/monty/swap1/10_brakebooster.jpg)

Pulling Sub-Frame
(http://www.tw34k.com/images/monty/swap1/23_subframe.jpg)

Pulling 8v Exhaust
(http://www.tw34k.com/images/monty/swap1/22_exhaust.jpg)

New Engine Mount Bushings:
(http://www.tw34k.com/images/monty/swap1/15_puckpack.jpg)

Spraying new undercoating:
(http://www.tw34k.com/images/monty/swap1/30_undercar.jpg)
(http://www.tw34k.com/images/monty/swap1/35_undercar.jpg)

Engine going in:
(http://www.tw34k.com/images/monty/swap1/39_engine.jpg)


After that, my camera battery promptly DIED.
There were a few other shots Dan and Wendy took and I'll get those together too.

If all the parts come through, we should be finishing up next Saturday. (March 31)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 92UrS4 on March 26, 2007, 11:39:39 AM
Incredible news all around Andrew! Seems like we'll be having a few more reasons to have a GTG in early April!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: DenverPat on March 26, 2007, 11:53:31 AM
Andy, think this will be ready for a nice wax job during the detail day at Detailer's Paradise?
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on March 26, 2007, 12:11:35 PM
Quote from: "DenverPat";p="56167"
Andy, think this will be ready for a nice wax job during the detail day at Detailer's Paradise?


As soon as we get the engine in and the interior back together I'll have the mk2 back to Apex to get a final buffing and wax but I plan on having it at Detailer's for the GTG. I'll have to talk Wendy into driving the Mk4 which needs the attention, heh.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on March 26, 2007, 12:13:24 PM
looking awesome Andy....can't wait to see it in person.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: gragravar on March 26, 2007, 01:11:12 PM
Andrew, Congrats!    :thumbup:
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on April 09, 2007, 11:23:26 AM
Getting close!

Installed:
Autotech 22mm Front Sway
11.1" Rotors
Girling 54 Calilpers
Pagid Pads
New Spindles
Rebuilt CVs
Power Steering
Stainless Lines Front and Rear

Now she's back on all four wheels with some interesting gap.
Even a visit from the Easter Bunny. ;)

(http://www.tw34k.com/images/monty/20070407/01swaybar.jpg)

(http://www.tw34k.com/images/monty/20070407/02cv_drivers.jpg)

(http://www.tw34k.com/images/monty/20070407/03cv_passenger.jpg)

(http://www.tw34k.com/images/monty/20070407/04spindle_passenger.jpg)

(http://www.tw34k.com/images/monty/20070407/05brakes_passenger.jpg)

(http://www.tw34k.com/images/monty/20070407/06spindle_drivers.jpg)

(http://www.tw34k.com/images/monty/20070407/07brakes_passenger.jpg)

(http://www.tw34k.com/images/monty/20070407/08brakes_drivers.jpg)

(http://www.tw34k.com/images/monty/20070407/09brakes_drivers.jpg)

(http://www.tw34k.com/images/monty/20070407/10brakes_rear.jpg)

(http://www.tw34k.com/images/monty/20070407/11brakes_clearance.jpg)

(http://www.tw34k.com/images/monty/20070407/12on4wheels.jpg)

(http://www.tw34k.com/images/monty/20070407/13on4wheels.jpg)

(http://www.tw34k.com/images/monty/20070407/easterbunny.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: jayryan on April 09, 2007, 11:51:20 AM
:beer: Yeah! :beer:
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on April 23, 2007, 12:52:08 PM
UPDATE: Wiring mostly done, custom pwr steering bracket installed, intake manifold re-painted, radiator & fans mounted, sunroof lubed up and put back in, door handles in, steering hooked back up and passenger mirror delete installed.

Braille 15lb battery on the way.
Looking for a Corrado VR Air box, if someone has one laying around.  :?

Pic Time!

(http://www.tw34k.com/images/monty/20070421/01_sunroof.jpg)

(http://www.tw34k.com/images/monty/20070421/02_sunroof.jpg)

(http://www.tw34k.com/images/monty/20070421/03_sunroof.jpg)

(http://www.tw34k.com/images/monty/20070421/04_sunroof.jpg)

(http://www.tw34k.com/images/monty/20070421/05_customfans.jpg)

(http://www.tw34k.com/images/monty/20070421/06_intake_crinkled.jpg)

(http://www.tw34k.com/images/monty/20070421/07_custom_mount.jpg)

(http://www.tw34k.com/images/monty/20070421/08_mirror_delete.jpg)

(http://www.tw34k.com/images/monty/20070421/09_chrome_handles.jpg)

(http://www.tw34k.com/images/monty/20070421/10_steering_mount.jpg)

(http://www.tw34k.com/images/monty/20070421/12_steering_mount.jpg)

(http://www.tw34k.com/images/monty/20070421/13_steering_wheel.jpg)

(http://www.tw34k.com/images/monty/20070421/14_steering_wheel.jpg)

(http://www.tw34k.com/images/monty/20070421/15_steering_wheel.jpg)

(http://www.tw34k.com/images/monty/20070421/16_engine.jpg)

(http://www.tw34k.com/images/monty/20070421/17_engine.jpg)

(http://www.tw34k.com/images/monty/20070421/18_profile.jpg)

(http://www.tw34k.com/images/monty/20070421/19_gap.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 92UrS4 on April 23, 2007, 01:18:55 PM
Yow That's Hot! Man, it is looking so good I can't wait to see it in person.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: gragravar on April 23, 2007, 01:20:23 PM
it is this part that looks scary:

(http://www.tw34k.com/images/monty/20070421/15_steering_wheel.jpg)

 :o  :o

I'd get lost too quickly.

car is really looking nice though.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on April 23, 2007, 02:09:31 PM
OMG...that is looking soooo hawt!!!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ianacole on April 23, 2007, 02:27:10 PM
Did the power steering lines get worked out?
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on April 23, 2007, 02:45:44 PM
Yeah, Hardey made a custom bracket for the reservoir out of a mk3 battery tray. That's what the bottle is mounted to in the mk3 so we ended up cutting it down to fit where we needed it. The line that runs between the reservoir and the pump is going to have to be replaced since it's about 4" too short. No biggie since it isn't a high pressure line, I'll just get it from AutoZone or whatever.

You can see the completed bottle and bracket in the 11th pic and then the top of the bottle in the two engine shots. I'm may have to paint the dip stick handle, pwr steering bottle top, and coolant tank top to match some kind of color theme.

Big Items left before it drives:
Finish up the rain tray / ECU wiring
Fix the wiring on the hatch
Install a windshield
Wire up tail lights
Add fluids, bleed and add more fluids
Wire up headlights
Put the dash back together
Alignment, big-time

Anybody know where to find the sound deadening pads that run across the underside of the dash? I'm guessing an interiors shop should be able to sort that out for me.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on April 23, 2007, 02:52:22 PM
you can actually find some sound deadening padding at a hobby lobby.  Or, if you need some dynamat stuff, I have about 50 square feet left, I can give you some of that if you want,....but need some myself for the doors of the subaru if I ever get around to putting my new speakers in it.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ianacole on April 23, 2007, 03:02:41 PM
You can come cut some of the deadening out of the remnants of my car.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on April 23, 2007, 03:09:33 PM
:lol: I'm surprised you still have any left in there, Ian.

I'm really just looking for the pads since it keeps the harness from rattling against the firewall.

Thanks for the tip on Hobby Lobby Jon!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ColoradoB5 on April 25, 2007, 10:54:09 AM
Nice Andy!  I had no idea you were getting married!  Congratulations.  Is that the girl I met with you that last time I came to town at Christmas?

The MK2 is looking great.  All of those shiny new parts really look great on that car.

I would love to take on a project like that.  Maybe when my boys are a little older, we can.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on June 01, 2007, 08:47:35 AM
Haha, thanks for the support guys. Well of all the things I've learned doing this install, probably the single most important is don't do this without a donor car sitting right there.

The deal is, without a donor car, I've found myself missing key parts that basically bring progress to a halt. Granted, it's given me time to dink around with other little projects on it, but it has slowed the over-all progress way down. I've had to go back to the shop to get parts like, the dip stick assbly, clutch slave and master, power steering reservior, battery cables, etc, etc, etc... some of which I've had to pay for and some of which I've had to find on my own, which is a little bunk since I paid for a "swap" and clearly didn't get everything. Anyway, that's not really the main issue, the main issue is that it's taking a while to get stuff done.

There has been progress almost every Saturday, just not really photo/update worthy type things.

Last weekend we got fluid in the brakes and bled, fluid in the pwr steering, clutch bled, front bumper on -or at least I got the rebar cut to fit and the front tow hook off. Weekend before I finished wiring the hatch, got the roof rails on, started trimming the dash for the mk3 cluster and some other little things.

It's getting close though. The last big thing is getting the wiring behind the dash done so I'm hoping we'll be burning some gas tomorrow. I'll be sure to post on how that goes!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 92UrS4 on June 01, 2007, 08:55:40 AM
Thanks for the update! I understand that nothing ever goes as planned. ;) Glad it's coming along though and definitely keep us updated. I really can't wait to see the car in person and go for a ride.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: SweetVW on June 01, 2007, 11:46:33 AM
Ditto.  Thank you.  I can't wait to see the finished product. 
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Spicoli on June 01, 2007, 01:32:26 PM
Andrew... think you'll have it done for DATR?

The work and quality you have done it would probably do very well.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on June 01, 2007, 02:00:13 PM
Andrew... think you'll have it done for DATR?

The work and quality you have done it would probably do very well.

It should be, but who knows, lol. As soon as we're done with the motor install, etc, i'm going to find someone who can re-cover the front and rear seats as well as the door cards to match.

I've been working on polishing a bunch of stuff including an extra intake manifold, the sun roof air deflector, hood and door latches etc.

I'm still not building it as a "show car" but it's definitely going to be my tinker toy for a good long while. If people like it, that's awesome -but I'm truly building it for fun and the love of the build process.

All in all, it's reminding me of the Porsche. Just working on it is a real pleasure.

I guess there are a few things I forgot to mention:
Braille 15lb battery is installed
New windshield is installed
Happich Pop-Out windows arrived
MFA Wiper Stalks arrived
Eibach Strut Brace arrived

These are the sex:

(http://www.tw34k.com/images/monty/20070430/happich_arrive_01.jpg)

(http://www.tw34k.com/images/monty/20070430/happich_arrive_02.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on June 01, 2007, 05:46:19 PM
are you going to be able to pop those out while sitting in the front, or are you going to have to reach in the back to open them?  I think you should automate them with some high tech thing and have a remote button on the dash :)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Spicoli on June 01, 2007, 06:05:47 PM
are you going to be able to pop those out while sitting in the front, or are you going to have to reach in the back to open them?  I think you should automate them with some high tech thing and have a remote button on the dash :)

You've seen Andrew right?  He sits pretty far back and he has long enough arms I could see it just reaching back and opening them without much trouble.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on June 01, 2007, 07:09:57 PM
ROFLMAO....I forgot, he has arms like a giraffe has a neck :)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on June 08, 2007, 12:54:25 PM
Oh come on they aren't THAT long. I can however reach the ground sitting in the drivers seat out the window ;)

Here's the official latest update:

Last weekend Hardey and I pulled the brakes to get the rotors on the correct sides. I noticed the venting was pointed in the wrong direction, which was a product of too many people around when we put them on. We also lubbed everything up and gobbed on some anti-squeal.

Next, I started tackling the dash and working on how to get the mk3 cluster in there but looking good. I ended up doing a lot of cutting and cleverly miss-cut the mk3 bezel I had so I had to find a new one at the junk yard. Luckily an easy part to find. I also found an extra sun roof metal wind deflector which I started sanding down to polish at home, an extra set of rear hatch plinths to work on smoothing later, the rear defrost connectors which were lost at the body shop which Hardey and I wired in, and we finally got the rain gutters pushed in correctly. I still need to put a bead of silicon in there to seal a couple spots where it has separated, but that's easy enough.

After that, we blead the brakes and clutch and put her back on the ground for the first time in a long time.

Last week at the yard Wendy and I found a '90 G60 Corrado which I promptly snatched the power steering reservoir out of. I know we did a lot of work getting the mk3 one fit, but this one looks much more factory which I like a LOT. When I pulled the old bottle out, we found that we had a leak on the line running from the bottle at the pump. The metal hose connector on the pump has a sealing ring that doesn't run the complete circumference of the connector and Hardey thought the hose clamp may have been on top of that creating an imperfect seal. When we reconnected the line I made sure to not put the hose over it and make sure the clamp wasn't on top this time and I hope we keep that seal this time. We also ran the vac lines and replaced one of the brittle plastic fittings.

Dan, Mark and Hardey worked on the dash/fuse block wiring which should be pretty much complete now. We plugged in the battery and started testing everything but ran into a snag where the starter motor started kicking even without the ignition on. The guys think they know why and we'll be tackling that next weekend and hopefully firing it up.

After finishing up the power steering, I pulled the struts off the hatch to see if the extra set of polished hood struts would fit back there and they do! They are a bit shorter than the stockers, but they look so nice, I don't mind.

Next we looked at the intake a bit and while I'm STILL looking for a Corrado VR Air Box(?! ANYBODY !?) we'll need something on there for now so I grabbed my extra cone filter for my mk4 and stuck it on there. We also deleted some of the case venting so I slipped an extra small filter on that for now.

The new windshield is in too. I got a great deal on some really nice glass, and it looks superb, except that they didn't ask me if I wanted the eyebrow tint on the glass, which I didn't, but I got it anyways... I'm not really happy with it since it really doesn't work with the rest of the car, but I can live with it I suppose.

This week I also found a euro Golf CL console on the Vortex which matches my minimalist interior to a T! Mmmm, rare parts ;)

(http://www.tw34k.com/images/monty/20070608/cl_console_01.jpg)

(http://www.tw34k.com/images/monty/20070608/wiring_01.jpg)

(http://www.tw34k.com/images/monty/20070608/engine_01.jpg)

(http://www.tw34k.com/images/monty/20070608/engine_02.jpg)

(http://www.tw34k.com/images/monty/20070608/windshield_01.jpg)

(http://www.tw34k.com/images/monty/20070608/pwrsteering_01.jpg)

(http://www.tw34k.com/images/monty/20070608/pwrsteering_02.jpg)

(http://www.tw34k.com/images/monty/20070608/pwrsteering_03.jpg)

(http://www.tw34k.com/images/monty/20070608/pwrsteering_04.jpg)

(http://www.tw34k.com/images/monty/20070608/vaclines_01.jpg)

(http://www.tw34k.com/images/monty/20070608/breather_01.jpg)

(http://www.tw34k.com/images/monty/20070608/dashcut_01.jpg)

(http://www.tw34k.com/images/monty/20070608/dashcut_02.jpg)

(http://www.tw34k.com/images/monty/20070608/dashcut_03.jpg)

(http://www.tw34k.com/images/monty/20070608/dashcut_04.jpg)

(http://www.tw34k.com/images/monty/20070608/hatch_01.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 92UrS4 on June 08, 2007, 01:05:41 PM
Lookin good, that hatch strut looks great!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: gragravar on June 08, 2007, 01:32:48 PM
that is looking awesome.

you can really touch the ground?  damn. :o
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on June 11, 2007, 11:16:56 AM
The swap meet at RS Motorsports was yesterday. They did a great job making the space and providing food via the grill and beverages. I sold my GTI red stripe seats for $50, a pair of speaker grills for $10, my red stripe grille and a pair of headlights for $50 and a set of rear door cards for $20. I made an easy $130. The fellow next to me with his kickin little brown Dasher that arrived packed to the roof with parts for sale also hooked me up with a set of four chrome Audi door handles for $50, so I still managed to walk away with $80 dollars net.

I already have a set of chrome door handles, but three of these came with the chrome latch triggers mine don't have and since it looks like I'm going to have to modify the handles just a little bit to get them to sit flush with the door, I'll have an extra set to play with if need be and I can always sell the extra two sets and at least get back the money I just spent. Plus, since these handles came off of a four door, two of them have no locks and I'm thinking I will use one of those for the passenger side.

MORE CRAP TO POLISH! :eek:
No work directly on the car on Saturday since Hardey was busy with his dad and Dan must have been too but Wendy suggested we go to the junk yard. (Can you believe this girl?!). We pulled a set of good looking door latches that I'm going to started polishing. We couldn't find a golf hatch latch, but we will. I also grabbed a set of the early style oh sh!t handles, the clips I need to hold the hood release cable and vac lines, a new plastic under hood grill piece to replace my sagging one, a set of four Fox door handle centers I need to play with putting chrome strips in my chrome handles (which are normally black plastic) and a few other odds and ends.

I also found some metal polish I actually like so far: Mothers Incredible Billet Metal Polish. It puts the Eagle One Nano-Nonsense stuff I was using to shame. Here's pics of my Eibach strut bar, folding sunroof wind deflector and intake manifold.

Pics of polished parts is tricky. I'll see if I can find a way to get some even diffused light and try again. I'd still like to get more of an even finish on the pieces, and I'm looking into buffing wheels to see if a machine and wheel can do it a bit better and I'll be trying the Dremel on the latches when I get to those.

As always, more fun to come!

(http://www.tw34k.com/images/monty/20070610/polish_01.jpg)

(http://www.tw34k.com/images/monty/20070610/polish_02.jpg)

Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on July 09, 2007, 11:33:15 AM
Update time? Youbetcha!

Fuel has been burnt! Of course, it was really old, crapy fuel, but we fixed that. First time we fired it up the heater core sprung a leak. No surprise really, but that had to be addressed as we couldn't get it up to operation temp leaking coolant.

Got a new heater core put in last Saturday and fired it up with the nasty fuel and here's the first tid-bit video.

http://video.google.com/videoplay?docid=-3784171163244917446&hl=en

Needless to say, it was running very poorly. We found an intake leak and removed all the old gas and filled her up with some fresh stuff and she ran b-e-a-u-t-i-f-u-l-y!

Off to get the alignment done this week and she's coming home with me to take care of putting the rest back together!

Next step, seats and door cards go off to interiors shop to get refinished. Yum!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ianacole on July 09, 2007, 11:37:02 AM
Hooray for a running car!!!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: jayryan on July 09, 2007, 11:39:33 AM
Awesome Andrew, just AWESOME!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on July 09, 2007, 11:41:40 AM
Hooray for a running car!!!

I really wish I'd gotten a video of it after we fixed the fuel and air problem. Engine sounds mean and the TT/Borla exhaust sounds just tits!

I'll post up another one soon running right!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on July 09, 2007, 02:44:50 PM
so cool.  Let me know how the interior's shop does, I think I want to get my seats re-done in the MINI :)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: SweetVW on July 09, 2007, 08:29:01 PM
Wahoo!  Great news.  The car is really looking good.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ColoradoB5 on July 10, 2007, 10:10:03 PM
That thing looks great!  I can't wait to hear how it sounds now.  Nice work!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on August 20, 2007, 01:53:25 PM
Wow, okay time for a pre-DATR update.

(http://www.tw34k.com/images/monty/20070721/01_frontend.jpg)

(http://www.tw34k.com/images/monty/20070721/04_frontend.jpg)

Here we are, just getting the front end back together at Hardey's to take my first drive and bring her home. We aren't in the new house just yet, so the mk4 is going to have to sit on the street for a week or so until we get keys.

She ran just beautifully, and sounded great!

(http://www.tw34k.com/images/monty/20070721/asf.jpg)

(http://www.tw34k.com/images/monty/20070721/asg.jpg)

(http://www.tw34k.com/images/monty/20070721/ash.jpg)

(http://www.tw34k.com/images/monty/20070721/asi.jpg)

(http://www.tw34k.com/images/monty/20070721/asj.jpg)

(http://www.tw34k.com/images/monty/20070721/ask.jpg)

It's been a rough month getting the car ready and moving Wendy and I into the new house and the rest of the family into the new garage and prep for Dubs Along the Rockies which has become our first, i dunno "unveiling" i guess. :) The list of to-dos is not short, but nothing to do but get on with it.

My buddy David helped me get the euro tails wired up as well as figuring out the "fast blinker" issue. Turns out the bulbs that ship with the euro small bumpers don't have enough pull to let the circuit think there's a bulb in it. Since I'm using single filament bulbs and foregoing the running lights for the time being I ended up using the bulbs out of my old big bumpers which worked the treat.

On to tackling the list of things to get ready for DATR next Sunday, i pulled the rear wheels to test fit the Porsche wheels with their new Yokohama S.Drive tires all mounted up and finish spraying the undercoating in the rear wheel wells. Spraying went simply as seen in the pics. I just did a lot of masking to be sure and went to town. The wheels turned out to be a different story. The lug bolts that secure the spacer/adapters to the hubs use conical 6mm alan bolts, some of which are slightly stripped. If I'd known these things wouldn't take the torque i wanted to apply to them I would have ditched these, sold them and bought a set of the H&R adapters. I'm waiting to see if someone can get ahold of a set of them for me before Friday... I'm going to check the local hardware stores for new bolts but I may need to get these things torqued as best I can with some releasable Loctite for this weekend. I'm not happy about that, but i'll just be taking it real easy on the way down and back.

I also got the dash back in and a few bits of the trim repainted. I'm not going to have time to modify the bezel to work with the cluster this go-around at DATR, but that's okay -this is meant to be a work in progress. Hell, i may not even have the headliner in.

Last few things on my list of wrap up include getting the Happich windows put in, installing the Eibach strut bar, fitting the wheels, finishing the dash and tons and TONS of cleaning/detailing.

In the final pic, finally enough room for both cars in the garage.  :D :D :D

(http://www.tw34k.com/images/monty/20070818/02_wheelwells.jpg)

(http://www.tw34k.com/images/monty/20070818/04_wheelwells.jpg)

(http://www.tw34k.com/images/monty/20070818/06_dash.jpg)

(http://www.tw34k.com/images/monty/20070818/08_trim.jpg)

(http://www.tw34k.com/images/monty/20070818/11_wheels.jpg)

(http://www.tw34k.com/images/monty/20070818/13_happich.jpg)

(http://www.tw34k.com/images/monty/20070818/15_eurotails.jpg)

(http://www.tw34k.com/images/monty/20070818/18_garage.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ianacole on August 20, 2007, 02:25:16 PM
Very nice Andrew!!  So where's the new house?
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on August 20, 2007, 02:53:40 PM
It's in Slones Lake. Just West of downtown. It's a cute little Victorian that's been updated a bit and imho features that two-car garage. ;D It took us something like six months to find something we both liked.

We'll be having a small House Warming GTG sometime mid Sept or whenever we get most of the last crap out of boxes. I'll be lettin' ya'all know!

Quick OT ian: I have your dollys still that I need to return and Wendy wants you to let Megan know she wants to get together to work on the book she gave her sometime soon.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 92UrS4 on August 20, 2007, 02:59:39 PM
Holy cow the car is looking just awesome! I can't wait to see it this weekend.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ianacole on August 20, 2007, 03:03:42 PM
Quick OT ian: I have your dollys still that I need to return and Wendy wants you to let Megan know she wants to get together to work on the book she gave her sometime soon.

No worries - whenever's convenient for you two.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on August 20, 2007, 04:33:37 PM
Andrew, that is the hotness.  You have to bring that to Burger Beer night on the 6th, I HAVE to see it in person!!!

Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on August 21, 2007, 08:47:53 AM
You got it Jon :)

Here's another little teaser, i got the wheels on. I might need to go a little lower  :D

(http://www.tw34k.com/images/monty/20070820/01_teaser.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ColoradoB5 on August 21, 2007, 09:35:06 AM
Andy, the ride is looking nice!  Congrats on the new place!  Good luck with getting everything finished for DATR.  I wish I could come, but I have family plans and my B5 needs too much love to even show up there this year.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: bog4rt on August 31, 2007, 09:18:24 PM
updates. dont be shy its been a while now
Title: Re: Andrew(34k) 1992 VW GTI
Post by: gragravar on August 31, 2007, 10:27:47 PM
updates. dont be shy its been a while now

look at the pics in the DATR thread.  he has lots in there.  the GTI is looking awesome.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on February 08, 2008, 10:50:32 AM
Been a little while since an update over here and with these little teases of warm weather I'm itching to get some more work done on the car.

First, I've got some new stuff going on. I found a company in the UK that is going to chrome some stuff for me. The pics below are not the actual items I have, but some previews of some of the stuff I'm getting back from them.

I got a set of Polished Porsche 944 door handles with new VW gaskets on.

And I just got a very 80's 944 steering wheel with new leather on it.

Of course I also picked up that set of Phonedials from Rick. I couldn't pass up that price for staggered low offset wheels. I'll be getting those refinished at some point soon here too.

I'm off to Australia and Tasmania in a couple weeks so I'm putting off getting the seats and door cards recovered until I find out how badly I damaged my savings on the trip. I don't anticipate it being to over budget so we should be good to go on that in March.

On top of that... I've been having naughty thoughts about the suspension and where to take that, but I'll leave that until I have made a decision.

(http://www.tw34k.com/images/monty/20080203/01_garage.jpg)

(http://www.tw34k.com/images/monty/20080203/02_garage.jpg)

(http://www.tw34k.com/images/monty/944steeringwheel/944wheel_12.JPG)

(http://www.tw34k.com/images/monty/porsche_handles.jpg)

(http://www.tw34k.com/images/monty/20080203/05_handles.jpg)

(http://www.tw34k.com/images/monty/20080203/06_radiator.jpg)

(http://www.tw34k.com/images/monty/20080203/07_struts.jpg)

(http://www.tw34k.com/images/monty/20080203/08_bolts.jpg)

(http://www.tw34k.com/images/monty/20080203/09_striker.jpg)


For archival purposes here's the pics from DATR 2007 with thanks to the photographers:

(http://www.tw34k.com/images/monty/datr2007/bbs027.jpg)

(http://www.tw34k.com/images/monty/datr2007/bbs028.jpg)

(http://www.tw34k.com/images/monty/datr2007/bbs029.jpg)

(http://www.tw34k.com/images/monty/datr2007/bbs030.jpg)

(http://www.tw34k.com/images/monty/datr2007/DSC003390827.jpg)

(http://www.tw34k.com/images/monty/datr2007/DSC003420827.jpg)

(http://www.tw34k.com/images/monty/datr2007/DSC02522.jpg)

(http://www.tw34k.com/images/monty/datr2007/DSC02523.jpg)

(http://www.tw34k.com/images/monty/datr2007/P8260008.JPG)

(http://www.tw34k.com/images/monty/datr2007/P8260009.JPG)

(http://www.tw34k.com/images/monty/datr2007/Picture066.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ColoradoB5 on February 09, 2008, 11:24:02 AM
Andy I think I love the garage as much as the GTI!  Looking great!  When did you start turning into a wheel whore?  LOL
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on February 09, 2008, 05:35:27 PM
Andy I think I love the garage as much as the GTI!  Looking great!

If only the garage were insulated, I'd be able to work all Winter. It's great to finally have the space to work though. Thanks!

When did you start turning into a wheel whore?  LOL

Haha! And you can't see the two more stacks behind those with my Longbeach's, Teardrop's and the set of BBS RC's. Seven sets of wheels for two cars... two of which I can't use because the Longbeach's are to small for the mk4's front brakes and the Teardrops are to small for the mk2's front brakes.

I dunno, it just sorta "happened" :D

Title: Re: Andrew(34k) 1992 VW GTI
Post by: ColoradoB5 on February 14, 2008, 08:41:38 AM
It looks like it would be pretty easy to insulate based on the pictures I see.  I am going to do mine this spring and also sheetrock it.  I have to wire a few more electrical outlets, so that tying those into my fusebox is the only thing I hesitate to do myself.  I know how to do it, just not if I would be doing it to code.

Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on February 14, 2008, 09:25:29 AM
I'm still a renter so I'd have to convince my landlord to pay for it. :D

I've got garage envy for Jon, Andrew and Cole.  :-*
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on February 14, 2008, 09:27:14 AM
awesome updates...still can't wait to see it in person and go for a ride!!!  Well done Andy, well done!!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on March 22, 2008, 06:03:45 PM
I put in the TT pedals, shows the removed large spline adapter for the Porsche wheel which fits like it was made for it, and... the beginning of something else that's missing from the interior. Stay tuned ;)

(http://www.tw34k.com/images/monty/20080322/02_no_interior.jpg)

(http://www.tw34k.com/images/monty/20080322/01_no_interior.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: kraut-sled on March 22, 2008, 08:48:26 PM
I know what is missing and were "it/they" are too!

Car looks great!!!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on March 24, 2008, 07:40:51 AM
my guess is new door cards and seats, and they are at the fabric shop next to autobahn :)....just a guess though.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on March 25, 2008, 10:43:31 AM
Hmmmmm, MAYBE!


I just got off the phone with
http://www.motorsport-tech.com/services

They are going to make me custom sized adapters for the Phonedials.
$300 for all four.

Not bad at all since the ones I have are total rubbish and H&R only makes one size (25mm) for 4x100.

I'm getting 28mm for the fronts which is the same as my crap ones and wider 35mm rears to fill out those arches a little better.

Other new stuff going on soon include a new grille, new front badge, new BMW seals for the pop-outs and more...


Jon, if you're still interested in the Phonedials Rick sold me, let me know. Now that I have these custom adapters coming in, I'm going to stick with the ones I've already got. I'll just be looking for the same price he sold them to me for. ($200)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Spicoli on March 25, 2008, 11:33:55 AM
Well it is a nice start...   ;D  Just kidding... looks awesome man. 
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on March 25, 2008, 11:36:22 AM
I think I am gonna pass on the phone dials, as much as I want them, I am pretty much as the end of the road on the MINI modifications...I have a new project in mind, and the phone dials won't fit into that at all.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: gragravar on March 25, 2008, 08:48:26 PM
I have a new project in mind, and the phone dials won't fit into that at all.

Wanna buy an old rover?   :D :D :D
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on March 25, 2008, 09:00:38 PM
haha, NOPE....Looking at Fall of 2009... a new "car" project, savings have begun. ;)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on March 25, 2008, 09:01:27 PM
Wanna buy an old rover?   :D :D :D
With Porsche Wheels :D :D :D
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on March 25, 2008, 09:02:50 PM
LOL...you guys are funny.

If I had the money, I would buy the phone dials to hang on my wall in the garage...a piece of classic automotive art..but alas, my new project needs every penny I can get.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: gragravar on March 25, 2008, 09:04:39 PM
With Porsche Wheels :D :D :D

hmmm, the rover needs a 5 x 6.5" bolt pattern.   ???  some drilling might be required.  otherwise they might just fit.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on April 03, 2008, 10:30:10 AM
Picked up a new axle from Todd and Randy yesterday. New one this time so hopefully even with the car lowered like it is, it will last more than 100 miles...

While I was there I figured i'd slip next door and pick up some other stuff that I installed yesterday. Still have some work to do on another dash I got for her. I've got the same chrome-ish stripe that will fit into the slot for the red stripe on the dash to make that match to help complete the look.

(http://www.tw34k.com/images/monty/20080402/02_interior.jpg)

(http://www.tw34k.com/images/monty/20080402/03_interior.jpg)

(http://www.tw34k.com/images/monty/20080402/04_interior.jpg)

And got a new grille in the works. Still needs some adjustments here and there, maybe some more sanding and painting... it was a serious POS when i got it. I think it helps liven up the front of the car which looked too plain to me with the 4 bar badgeless I had on their before.

(http://www.tw34k.com/images/monty/20080402/01_grille.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 92UrS4 on April 03, 2008, 11:17:20 AM
OMG! That interior is freaking incredible!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ianacole on April 03, 2008, 11:24:22 AM
That interior is drop-dead sexy!!! :-*
Title: Re: Andrew(34k) 1992 VW GTI
Post by: KWilson on April 03, 2008, 12:40:09 PM
Wow.  That looks amazing.

I was going to suggest that you switch to a chrome stripe dash, but it sounds like you already have it covered.

So, do you just replace the red stripe with the chrome stripe?  If so, I might have to look into replacing my chrome dash stripe with a red one.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on April 03, 2008, 12:45:06 PM
Well, I wasn't able to find a chrome stripe dash with the chrome in good shape AND enough extra to go on the door cards.

The upholstry shop found some stuff that works pretty well and fits perfectly into the dash.

I have one, maybe two red stripe dash trims that you are welcome to that should clip right in.

Let me know man.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on April 03, 2008, 12:47:12 PM
beautiful, just beautiful!!!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: KWilson on April 03, 2008, 02:11:58 PM
Well, I wasn't able to find a chrome stripe dash with the chrome in good shape AND enough extra to go on the door cards.

The upholstry shop found some stuff that works pretty well and fits perfectly into the dash.

I have one, maybe two red stripe dash trims that you are welcome to that should clip right in.

Let me know man.

Hmm. 

You wouldn't happen to still have the red door trim, would you?
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on April 03, 2008, 04:04:21 PM
Hmm. 

You wouldn't happen to still have the red door trim, would you?

Naw, it was pretty tatty when I pulled it. I'm sure the junk yard would have all you need and more. I can keep an eye out if you don't go often.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on April 07, 2008, 03:06:17 PM
*SIGH OF RELIEF*
Some of you know, and I've sort of mentioned it, but I have left a project that was hanging over my head pretty much since last fall. The wheel adapters that I used for mounting the Porsche wheels on my car were just f'ing terrible. They bound up REALLY badly especially on the fronts making the bolts very difficult to remove. This really is a design flaw since they use 6mm(?!) hex bolts to attach them to the hubs. This makes torquing them on hard and after some rotational and lateral pressure from driving, it makes removal a real nightmare.

I broke several tools trying to get these off including 6-8 hex bits, 3 hardened bolt extractors and my Dremel gave up the ghost.

The solution that finally presented itself was to take a bi-metal hole saw and drill out the heads. I couldn't drill out the heads normally because there were broken bolt extractors in them.

The whole thing probably could have been made easier if I had pulled the knuckles off, but for a few reasons I decided against this. Surely if it had gone on any further, that's exactly what I would have done.

Perhaps it's not the most elegant solution, but when I reached it, it seemed a good way to get out some aggression on the crappy bits without the risk of damaging the good stuff.

(http://www.tw34k.com/images/monty/20080405/01_coming_off.jpg)

(http://www.tw34k.com/images/monty/20080405/02_coming_off.jpg)

(http://www.tw34k.com/images/monty/20080405/03_coming_off.jpg)

(http://www.tw34k.com/images/monty/20080405/04_coming_off.jpg)

Needless to say, she's back on the ground and one hose away from some spring driving.
;D ;D ;D
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Spicoli on April 07, 2008, 07:30:03 PM
 :o  at least you got them off. 
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on April 07, 2008, 07:56:09 PM
nice, glad it worked out.  Can't wait to see it rolling!!!!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on April 07, 2008, 08:06:08 PM
Yeah... Thanks guys. Those things friggin sucked. I have new adapters coming in that use 12mm hex bolts, so I should be able to actually safely torque them down so the shearing force shouldn't be a problem.

I'm thinking I may come down to the detail day, though I won't be doing much cleaning on the green car, it'd be great to see everybody.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ColoradoB5 on April 08, 2008, 07:02:11 PM
Wow Andy, with as nice as that thing looks, I'll say it now: It's going to be magazine-worthy once your done.

How do the seats feel?

Dub
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on April 10, 2008, 09:06:13 AM
The seats are awesome. Some of the best early OEM seats I've ever felt for certain. I find getting into them is more like slipping them on, than slipping into them. ;) I've just got to learn to be super careful sitting down so I don't bash that driver side lower bolster down like always seems to happen.

I also better not gain any weight. They are very snug against the waist line, heh.

Quick Update: I got a length of proper hydraulic hose for the power steering return line installed yesterday. Based on a recommendation from Todd at APS I went to:

Parker Store
7030 E 46th Avenue Dr
Denver, CO 80216
(303) 289-2722

They had some very sweet black cloth braided hoses that even have some green braid to it that matches the car remarkably well. Picked up five feet of that and some T-Bolt hose clamps to hold it on with and re-did the whole return line from the reservoir to the t-fitting and back to the pump. It's all back together now and with a little charge on the battery, should be back on the road ready for Summer once I get the new axle installed.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on April 14, 2008, 02:23:35 PM
I took the car out for a spin last night after getting the new 944 steering wheel hooked up. I had to do some fabrication on it to get the horn and turn signal release tab thing working and now they both work great. I sacrificed the steering wheel that came with the car that someone in their infinite wisdom decided would look extra cool spray painted red...

First time I've had it out since last Fall. Felt great except the battery needs to be hooked up to my trickle charger. It died a couple times, and I had to jump it.

On the plus side, for the first start it cranked RIGHT over after the Winter.
Very nice!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 92UrS4 on April 14, 2008, 02:45:01 PM
Awesome! Can't wait to see it in person.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on April 14, 2008, 04:02:12 PM
I wish I could make it :(
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on April 28, 2008, 03:57:31 PM
I decided to tackle a few things this week/weekend and I thought I'd update.

First thing, I've always hated the way that the Mk3 cluster fits into the Mk2 dash. I recently picked up an early dash that uses plastic brackets to hold the cluster in place so I started experimenting. After a copious amount of measuring I found that I could two step the final product. Step one would be to leave the face of the Mk2 bezel untouched, but trim the rear and fill the gap with part of the Mk3 bezel and vinyl. This allows with less plastic fabrication/modification for the cluster to be fully visible with a clean finish. The second step which I will attempt eventually when I get enough bezels to destroy and time would be to expand the width of the Mk2 bezel to cover up the first two dummy switches in the center which should match up to the width of the Mk3 cluster nearly perfectly.

So the basic steps are:

Cut and move the existing plastic bracket to accomodate the wider cluster.

(http://www.tw34k.com/images/monty/20080425/01_custom_bracket.jpg)

(http://www.tw34k.com/images/monty/20080425/02_custom_bracket.jpg)

(http://www.tw34k.com/images/monty/20080425/04_custom_bracket.jpg)

Trim back the Mk2 bezel on the inside. The first one shows an uncut bezel. Then cut down a Mk3 bezel. I cut the back off with a lot of room to spare and then made a more fine cut of the piece on the right which is close to my final piece.

(http://www.tw34k.com/images/monty/20080425/05_new_bezel.jpg)

(http://www.tw34k.com/images/monty/20080425/06_new_bezel.jpg)

The criss-cross plastic on the Mk3 bezel needs to be smoothed to allow the vinyl to attach to it. The Dremel I used for cutting with a sanding head on it made short work of those bits as seen here. Then attaching the vinyl to the underside of the piece, you then fold it around the inside of the U to get your final piece.

(http://www.tw34k.com/images/monty/20080425/07_new_bezel.jpg)

(http://www.tw34k.com/images/monty/20080425/08_new_bezel.jpg)

After that, some trimming of the plastic on the U was needed to make it fit just right and of course some trimming of the vinyl and this is what you end up with in the dash. Slide the trimmed Mk2 bezel in over the top and make sure it all fits.

(http://www.tw34k.com/images/monty/20080425/09_new_bezel.jpg)

(http://www.tw34k.com/images/monty/20080425/10_new_bezel.jpg)

The nice thing about the early dash is that it uses plastic instead of metal brackets to hold the cluster which is very easy to work with. The bad part is, later cars have tilt steering wheels which won't fit in the dash. Well, at least not without some "minor" trimming. I took the plastic trim from my late dash and convinced it to fit.

(http://www.tw34k.com/images/monty/20080425/12_converttilt.jpg)

(http://www.tw34k.com/images/monty/20080425/14_converttilt.jpg)

(http://www.tw34k.com/images/monty/20080425/15_converttilt.jpg)

Next up is the dash stripe. Jason at Blazing Auto Trim gave me some extra chrome stripe that he used for the door cards to run through the dash. I cut these pieces and glued it into the gap. Then put it all into the car.

(http://www.tw34k.com/images/monty/20080425/16_dashstripe.jpg)

(http://www.tw34k.com/images/monty/20080425/17_dashstripe.jpg)

The final product is pretty darn smooth. I'm well pleased with finally being able to see the majority of the cluster now. It's not perfect, but it's a world of difference with how it used to sit in there with foam and with the Mk2 bezel sitting up against the buttons pressing the trip counter all the time.

(http://www.tw34k.com/images/monty/20080425/18_finished.jpg)

Next, new Happich seals, hopefully my chrome stuff from the UK will arrive this week, and SOMEONE PLEASE FIND ME A HEADLINER!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on April 28, 2008, 04:38:40 PM
I can help you re-do an old headliner

car is looking fantastic Andrew!!!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: dubaudi on May 03, 2008, 06:24:33 PM
He has a headliner!!!!!!! Thanks Andrew for the wheels. I hope the cracks dont cause to much headache.

Jeremy
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on May 03, 2008, 09:25:56 PM
Thanks again Jeremy. I'm thinking it will work out.

I really need to find something that will reinforce the material without making it too thick. I'm pretty sure fiberglass will work to repair the cracks, and maybe the resin can be brushed on the rest of it to add some rigidity. I've got my old broken one to test with so we'll see what I can come up with in the next few weeks leading up to VWOTG.

Cheers!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on May 05, 2008, 01:14:37 PM
I picked up a "new" headliner Saturday in trade for my old set of teardrops (thanks again Jeremy!). I drove up to his place and we pulled it and got it into my car. The fabric is sagging pretty bad and there is one crack behind the B-pillar and one break on the passenger side of the sunroof. However, the important bit in front of the sunroof is intact. I decided to do some experimentation with fiberglass on a piece of my old headliner since I've never worked with fiberglass before. I took a piece and broke it by hand. I then followed the instructions on laying the fiberglass on the broken parts and it was much cleaner and easier than I had anticipated. I'll be pulling the headliner out in the next couple days, cleaning it and doing the repairs in preparation of fitting the new fabric on it. Judging from how easy it went, I'll also be adding the fiberglass to the most fragile parts of the board to reinforce it and HOPEFULLY it will end up being much more robust and I won't have to deal with cracking ever again. It's VERY exciting, since it's one of the last big pieces I needed to get sorted for the summer. Of course, I'll be posting pics of the fiberglass repairs go, as well as the recovering very soon.

In the mean time, I decided to tackle the sunroof cover. I got some of the same vinyl from getting the seats recovered last month to cover it. First, I removed the fabric from the metal skeleton for the panel and laid it out on the vinyl piece I was using. Then I traced the outline of the fabric with a ball point pen giving myself a few mm extra clearance all the way around so I could trim it back to fit.

(http://www.tw34k.com/images/monty/20080504/02_sunroofpanel.jpg)

(http://www.tw34k.com/images/monty/20080504/01_sunroofpanel.jpg)

(http://www.tw34k.com/images/monty/20080504/03_sunroofpanel.jpg)

(http://www.tw34k.com/images/monty/20080504/04_sunroofpanel.jpg)

It was then a matter of cutting along the line. Once done, I made a trace of the location of the skeleton on the fabric and started trimming the round corner pieces so they would fit as neatly and flat as possible. I did end up with a few very small wrinkles on the edges which I then removed with a pair of sharp side cutters. Next comes the 3M Super90 adhesive and some fine tuning as I went. You can see here, I also cleaned the heck out of the frame with Goof-Off and then soap and water.

(http://www.tw34k.com/images/monty/20080504/05_sunroofpanel.jpg)

(http://www.tw34k.com/images/monty/20080504/06_sunroofpanel.jpg)

(http://www.tw34k.com/images/monty/20080504/07_sunroofpanel.jpg)

(http://www.tw34k.com/images/monty/20080504/08_sunroofpanel.jpg)

The center section on the original fabric is stitched to a piece of vinyl that is adheased to the center rib. You can see this on the first couple pics, it's the piece in red. Since nothing on the side facing the interior of the car has any sort of support from the factory, this is needed to keep the panel from bubbling down in the center. I didn't want to add any spray mount to the underside either since working with vinyl is fairly tricky in that if there is anything under it, you will notice the imperfection. How I solved the problem was to use the spray mount and an extra strip of vinyl to attach this center section to the underside of the vinyl. I then discovered a new use for my Bently. Since the edge of the part that's attached to the underside will be visible since it will have the spray mount on it, I took a thin straight piece of cardboard and firmly rested it on the edge. Then I stacked the Bentlys and some magazines on top overnight to ensure a clean line. This worked great and the final product pre-installation is shown here. Next, the headliner!

(http://www.tw34k.com/images/monty/20080504/09_sunroofpanel.jpg)

(http://www.tw34k.com/images/monty/20080504/10_sunroofpanel.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on May 07, 2008, 10:13:01 AM
(http://www.tw34k.com/images/monty/20080506/01_headliner.jpg)

Headliner Time!
Wendy, bless her heart, was sick yesterday and today and still came out to the garage to give me a hand removing the headliner. It's not really a one-man job, and is absolutely not a one-man job if there's any damage to it.

Once we had the board out I sent Wendy back inside to relax while I got to work.

The last headliner board took a little while to get cleaned up, but it was nothing compared to this one. I had hoped to get it sanded down and the fiberglass laid, but it wasn't to happen. All hail(fail?) the previous owners of cars and their questionable "fixes". Not only had the person who owned Jeremey's car before him decided to try to fix the sagging headliner with some ineffective blue glue, but they had decided to use staples along the rear edge. Of course, the headliner was still sagging all over the place so it was all for naught, but it left me with some serious fun to contend with.

(http://www.tw34k.com/images/monty/20080506/02_headliner.jpg)

(http://www.tw34k.com/images/monty/20080506/03_headliner.jpg)

I cut the staples out carefully, and started in on the sanding off the blue glue crap. Normally, all you need is a plain scotch pad to remove the old adhesive from the board and maybe some fine sandpaper to take care of any rough bits. This took a little longer to get less distance. Three and a half hours later, this is what I ended up with before going in for the night.

(http://www.tw34k.com/images/monty/20080506/04_headliner.jpg)

(http://www.tw34k.com/images/monty/20080506/05_headliner.jpg)

I'll be back at it tonight if it isn't too cold and wet in the garage.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on May 07, 2008, 10:45:41 AM
wow, fun project, I feel your pain, believe me, I do.

DO NOT use 3M 77 spray adhesive, it won't hold up the headliner material.  You need something much stronger and temp resistant in case the car is out in the sun and heats up inside.  It would suck to do that project twice


Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on May 07, 2008, 11:29:14 AM
wow, fun project, I feel your pain, believe me, I do.

DO NOT use 3M 77 spray adhesive, it won't hold up the headliner material.  You need something much stronger and temp resistant in case the car is out in the sun and heats up inside.  It would suck to do that project twice

I was planning on using the 3M Super90 stuff. It's supposed to hold up to the heat etc. Did you have something else to recommend?
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on May 07, 2008, 03:09:01 PM
I used Dap Contact Cement gel formula.  Not a spray, so it is a pain to apply, I used foam brushes and it worked great.  That stuff will hold forever. I got it at Lowes.  How heavy is the material you are using?  That is the factor, if it is more a few ounces per square foot, you really want an aggressive adhesive.


Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on May 08, 2008, 11:20:46 AM
Thanks Jon, I'll take a look at that stuff. My concern with the spray is that it won't be as evenly applied as I'd like and I really don't want any "wet spots" in the fabric.

Last night was actually a very nice night, so back to work!

(http://www.tw34k.com/images/monty/20080507/02_headliner.jpg)

(http://www.tw34k.com/images/monty/20080507/03_headliner.jpg)

I started the night finishing up some sanding, but I decided that I should go ahead and do the reinforcement of the fiberglass before I finished. I started by taking the sheet of fiberglass and cutting out the sections I wanted to either repair or reinforce:

* The sides where it gets thin for the sunroof are a major cracking spot, especially on the passenger side near the grab handle
* The front where it gets thin again around the sunroof crank handle and the holes for the sun visors
* Directly behind the B-pillar seems to be a common cracking point
* The four holes where the plastic plugs go through the roof in the center weren't a problem with either of the boards I've seen, but to remove and install these do see some significant pressure pushing and pulling so I wanted to do those
* The rear lip that was stapled needed reinforcement

After trimming them to approximate sizes, I went back through and trimmed them down for the corners and curves they would need to follow. After that, I started on some of the easy areas to get a feel again for the process. It really is quite easy. Aside from having to change gloves several times since they would get sticky and cling to the pieces I was trying to lay. I also learned :DUH: that I needed to work with fairly small batches of the resin. I tried the first batch with 10 tablespoons of the resin and hardener which hardened by the time I finished the four tiny squares in the center for the push plugs... In retrospect, I find it funny I made that mistake BEFORE inhaling the resin fumes.

Once I started, I couldn't stop for pictures. I had bought two brushes (get the cheeeeeeep ones!). The first was never the same after the first night I tested the stuff, even after a cleaning. The second one started firming up after about the fourth piece and I wasn't sure I had another to sacrifice. Needless to say, stopping for pics wasn't a priority. Luckily, however, Wendy came out to see how it was going and got a couple pics. She also probably saved me from a massive headache by convincing my "resin-stoned" butt to open all the garage doors. I did have the back door and window open, but once I started, I didn't realize how strong it was in there. *whew* Oh well, I figure the more mistakes like that I make, the dumber I get and the less it will bother me.

(http://www.tw34k.com/images/monty/20080507/04_headliner.jpg)

(http://www.tw34k.com/images/monty/20080507/05_headliner.jpg)

(http://www.tw34k.com/images/monty/20080507/06_headliner.jpg)

(http://www.tw34k.com/images/monty/20080507/07_headliner.jpg)

Everything turned out great and after letting it set up over-night, the board is quite sturdy. I suppose I could have done the whole thing to be sure, but I don't anticipate any problems with it. It's not like it's a high use item.

A little something else showed up too. These should ease up a bit on the ride and allow me to hit the height I'm looking for. It needs an alignment after we did the new axle, though after marking the control arm it's very close. I also will need to lift it back up close to factory ride height for them to test me so I figure I'll leave the Bilsteins on til after it's smogged, then install the Koni's and get it finally aligned.

(http://www.tw34k.com/images/monty/20080507/01_koni.jpg)



For Sale: Bilstein PSS coilovers - all hardware and spanners included. Seriously less than 2,500 miles. $800.00 Contact Me (http://www.tw34k.com/contact.php)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on May 19, 2008, 11:55:23 AM
I wrapped up a few things in anticipation of Volkswagens on the Green this weekend. I haven't updated since I've been busy with all the detailing, but I had the camera ready.

First up, I got the headliner recovered. This is the same material as the seats. As you can see from the progress pics, I used a LOT of the adhesive. They say one can is supposed to be good for 100 sq. feet and I used almost three cans to cover the headliner. It didn't soak through, but I gave it between three and five minutes to set before putting the pieces together. There were some complications on the cutting stage which unfortunately means I will probably need to source another headliner at some point... BUT the final product turned out pretty well and the issues I have is more with it being "not perfect" than with it being actually screwed up.

(http://www.tw34k.com/images/monty/20080518/01_headliner.jpg)

(http://www.tw34k.com/images/monty/20080518/02_headliner.jpg)

(http://www.tw34k.com/images/monty/20080518/03_headliner.jpg)

(http://www.tw34k.com/images/monty/20080518/04_headliner.jpg)

(http://www.tw34k.com/images/monty/20080518/05_headliner.jpg)

(http://www.tw34k.com/images/monty/20080518/06_headliner.jpg)

(http://www.tw34k.com/images/monty/20080518/07_headliner.jpg)

(http://www.tw34k.com/images/monty/20080518/08_headliner.jpg)


I spoke with Jason at Blazing Auto Trim about doing the sunroof crank surround piece as well as the sun visors. He said he didn't think the sun visors would turn out the quality he knew I wanted and suggested I use vinyl dye on them instead which is shown drying below along with the early grab handles I cleaned up.

I also put in the BMW 528 door seals on for the Happich pop out windows which turned out looking very nice indeed.

Then I took care of some errant wiring in the front end, re-wrapped and did some neater heat shrinking on some wires and relocated the horn in anticipation of getting the Corrado air box in at some point soon.

(http://www.tw34k.com/images/monty/20080518/09_parts_painting.jpg)

(http://www.tw34k.com/images/monty/20080518/10_happich_seals.jpg)

(http://www.tw34k.com/images/monty/20080518/11_happich_seals.jpg)

(http://www.tw34k.com/images/monty/20080518/12_front_end.jpg)

Lastly I picked up a spare wheel from a local Porsche wrecker so if I should ever get a flat, I'll have a spare that can be attached to the adapters instead of having to pull the wheel and adapter to mount it to the hub. This is a late style aluminum wheel. I also got the small "euro" flares for the rear on which was an interesting bit of work since I had the holes filled when I did the body work. I got them on by using rare-earth neodymium magnets attached to the back of the flares that I first plasti-dipped to keep from damaging the paint underneath. This also gives me the advantage of being able to clean underneath the flares or remove them altogether in the future if so desired. The hole underneath was still there, so I was able to rivet the flare in place and then gently place the magnets against the body.

(http://www.tw34k.com/images/monty/20080518/13_spare_wheel.jpg)

(http://www.tw34k.com/images/monty/20080518/14_fender_flares.jpg)

Up next is off to the emissions test facility with the car raised up on the coils. Then the Bilsteins come off and Konis go on. Maybe eventually my chrome parts will show from the UK... and we'll see what the rest of the summer brings before getting ready for DATR.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on May 19, 2008, 04:14:33 PM
OMG, that is so hot.  Amazing work as usual Andrew.  Truly Amazing!!!!!

I wanna come over one day during the week and want a private tour of  your car.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on May 19, 2008, 04:20:53 PM
Anytime Jon.  ;D

Oh I forgot about the pics I took on the way home from the show.

(http://www.tw34k.com/images/monty/20080518/15_photo.jpg)

(http://www.tw34k.com/images/monty/20080518/16_photo.jpg)

(http://www.tw34k.com/images/monty/20080518/17_photo.jpg)

(http://www.tw34k.com/images/monty/20080518/18_photo.jpg)

(http://www.tw34k.com/images/monty/20080518/19_photo.jpg)

(http://www.tw34k.com/images/monty/20080518/20_photo.jpg)

(http://www.tw34k.com/images/monty/20080518/21_photo.jpg)
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Spicoli on May 19, 2008, 04:33:36 PM
Wooooow!   looking good. 
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ColoradoB5 on May 22, 2008, 04:37:47 PM
Dang Andy, that's just awesome.  That's something to be proud of!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on May 22, 2008, 04:45:01 PM
Thanks guys, got a bite from a magazine, actually. But i don't think it's really ready for that. We'll see though.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on June 02, 2008, 01:51:57 PM
To begin with, I received the parts from the UK (liquidmetalrefinement.co.uk) and I'm really not happy with the results on some of them. Maybe I'm being to critical, or maybe this is just the kind of stuff that the euro cars just deal with and doesn't show up in photos online or in magazines. Who knows. I don't really care, but I'm not keeping these things like this. The owner, or at least the only fellow I spoke with there, is Matt Johnson. He's not easy to reach via email which is the only contact I've had with him. I've had to send emails to him multiple times to get him to respond. On top of that, I ordered and paid the parts February 2nd 2008 and even though I was told they would be sent out in four weeks time, they didn't arrive until May 19th. At first I was told the strut tops didn't meet his standards and needed to be redone. I told him I appreciated his attention to detail, that the quality was very important to me and that I would be patient. This sort of delaying happened pretty much up until I got the parts. Now I've sent him another email over a week ago expressing my less-than-thrilled response to the quality and... nothing.

ANYWAY, since I'm not sending these back and throw more good money after bad, and not all the 40 some odd bits I had him do are bad, I'm going to install what I've got and make a trip to the junk yard and pull other parts to have someone else redo them. I haven't decided the extent to which I will be chroming pieces, but I'm working on a list now.

(http://www.tw34k.com/images/monty/20080526/05_bootlatch.jpg)

(http://www.tw34k.com/images/monty/20080526/06_bootlatch.jpg)

(http://www.tw34k.com/images/monty/20080526/07_doorlatch.jpg)

(http://www.tw34k.com/images/monty/20080526/08_doorlatch.jpg)

On to more happy stuff, as I've mentioned, I needed to get the car smogged. To do this in Colorado, they run the car on a little dyno and measure the emissions at the pipe. Before they will let you run the car on the dyno, you have to be at or close to stock ride height. They also use this sort of fork thing that goes on both sides of the tire and I wasn't about to let them dyno it with my Porker wheels on so I needed to lift it up and get the Corrado steelies back on. Piece of cake.

(http://www.tw34k.com/images/monty/20080526/01_coildown.jpg)

(http://www.tw34k.com/images/monty/20080526/02_coilup.jpg)

I also took a shot of the engine which I haven't done in a while and test fit the Porsche spare wheel while it was in the air.

(http://www.tw34k.com/images/monty/20080526/03_engine.jpg)

(http://www.tw34k.com/images/monty/20080526/04_spare.jpg)

Emissions testing went okay -THE SECOND TIME... It failed the first time with high Nx. I had told Jason at Blazing Auto Trim I would swing the car by for him to take some photos of the interior installed and I poked my head into the shop next door, Autobahn Premier Service. Todd glanced at the results and said I was running lean. One new 3.5 BAR fuel pressure regulator later and we pass with quick-pass. Thanks Todd/Randy!

Up next, I started installing the new Koni coilovers. I had some time on Saturday to get some work done and I should have the rest of that put together as soon as I can find an hour or two in the next couple days. It's so nice to be able to walk away from a project like that and know that I don't HAVE to drive it the next day.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on June 02, 2008, 04:42:40 PM
OMG, looking so amazing, I bet you are dying to get the Konis in.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: jayryan on June 03, 2008, 06:42:05 AM
Andrew this is oner of the coolest builds I think I've seen in a while. I miss my Fox after looking at the finsihed car. It was such a fun car to drive.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: 34k on August 26, 2008, 09:28:05 AM
So it's been a little quiet on the little car front for a while. It's not that I haven't been busy with car related things, because I have. It's just a slightly different focus the last two months.

Namely, I bought a NEW GARAGE!

(http://www.tw34k.com/images/monty/20080807/01_newgarage.jpg)

You can't tell by the pic because we still have a LOT of stuff in boxes in front of the cars, but I could easily park another car side-ways in front of the two and have plenty of room left over for work benches, cabinets and tools. It's really the biggest two-car I've seen in this area which is the Potter Highland neighborhood on the hill just West of downtown. It's got very tall ceilings, two 24" vent fans in the rafters, it's wired for 220 and I can't wait to get started hanging some insulation and panels on the walls and finishing the floor to make it more comfortable.

We just closed yesterday but we had to be out of our rental on July 31 so we've been staying in the place since August 1st, but we didn't want to really unpack until after closing -Murphy being the bastard he is.







Oh and there's a 3 bedroom house behind the garage too.


(http://www.tw34k.com/images/house/frontviewhouse2_500.jpg)

(http://www.tw34k.com/images/house/frontviewhouse1_500.jpg)

(http://www.tw34k.com/images/house/livingroom1_500.jpg)

(http://www.tw34k.com/images/house/diningroom1_500.jpg)

(http://www.tw34k.com/images/house/bathroom_500.jpg)

(http://www.tw34k.com/images/house/kitchen3_500.jpg)

Title: Re: Andrew(34k) 1992 VW GTI
Post by: 03Indigo on August 26, 2008, 10:27:20 AM
wow, what a great house Andrew, congrats on the new pad!!!!!

Title: Re: Andrew(34k) 1992 VW GTI
Post by: Spicoli on August 26, 2008, 10:55:30 AM
Envy is painful..... nice house andy.
Title: Re: Andrew(34k) 1992 VW GTI
Post by: gragravar on August 26, 2008, 02:05:53 PM
house (and garage) looks great!  nice choice!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: ColoradoB5 on August 26, 2008, 08:20:27 PM
Nice garage man!  The house ain't too bad either!
Title: Re: Andrew(34k) 1992 VW GTI
Post by: Noob_Shum on August 27, 2008, 03:58:01 PM
 :o 8) Wow, the car(s) and the place look great! CONGRATS!! :)

Jonathan
Title: Re: Andrew(34k) 1992 VW GTI
Post by: redline on August 27, 2008, 10:49:43 PM
congrats Andrew! The house looks great!