Author Topic: PROJECT CAR: Mk2 Jetta ABF Conversion  (Read 75922 times)

0 Members and 1 Guest are viewing this topic.

Offline Filx

  • ##
  • **
  • Posts: 4802
Re: Mk2 Jetta Upgrade
« Reply #30 on: May 09, 2008, 09:55:59 pm »
Sweet. Is that a Mk4 shift knob I see?
FAIL - First Attempt In Learning

Offline AngleBox

  • ##
  • **
  • Posts: 3739
Re: Mk2 Jetta Upgrade
« Reply #31 on: May 09, 2008, 10:19:58 pm »
It is. Not certain I'll be as fortunate. Will need to see how the budget works out. So far, all projections are I have exactly $.43 left to spend.

Offline gti vr6

  • ##
  • **
  • Posts: 2857
Re: Mk2 Jetta Upgrade
« Reply #32 on: May 10, 2008, 06:53:00 am »
Looking good guys!!

Will you run the air bags like in the car pictured?
1979 Mk 1 GTi
2014 Amarok 4m HL

Offline AngleBox

  • ##
  • **
  • Posts: 3739
Re: Mk2 Jetta Upgrade
« Reply #33 on: May 10, 2008, 08:14:50 am »
Vert1 talked me into a full conversion. Airbags, ABS, full suspension, wiring loom, etc. Should be pretty nifty!

Offline NasTnaS

  • ##
  • **
  • Posts: 4831
  • Live and Learn.....
Re: Mk2 Jetta Upgrade
« Reply #34 on: May 10, 2008, 09:23:38 am »
Vert1 talked me into a full conversion. Airbags, ABS, full suspension, wiring loom, etc. Should be pretty nifty!

good stufff, that'll be the way to do it!
...Nigel Aston

1967 Alfa Romeo GT Junior
1971 Porsche 911T
2006 Audi RS4 Avant

Offline gti vr6

  • ##
  • **
  • Posts: 2857
Re: Mk2 Jetta Upgrade
« Reply #35 on: May 10, 2008, 11:38:56 am »
Vert1 talked me into a full conversion. Airbags, ABS, full suspension, wiring loom, etc. Should be pretty nifty!

If you have it you might as well use it... Good one.
Like flix says its another awesome project. Look forward to seeing the car re-assembled and rejuvinated  8)
1979 Mk 1 GTi
2014 Amarok 4m HL

Offline 80 Vert

  • only milk and juice comes in 2 litres
  • ####
  • ****
  • Posts: 8338
  • All thats left to do is everything!
Re: Mk2 Jetta Upgrade
« Reply #36 on: May 10, 2008, 06:27:21 pm »
Haha you're a funny guy! Talked me into it, didn't take much then did it?  ;D
2013 Chevrolet Camaro ZL1
2010 T5 Transporter TDI
2003 Jetta Coupe soon to be R36TT
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 Carrera 4
1980 1303 Beetle vert, in pieces

https://www.facebook.com/pages/West-Worx/460154187360186

Offline AngleBox

  • ##
  • **
  • Posts: 3739
Re: Mk2 Jetta Upgrade
« Reply #37 on: May 10, 2008, 06:38:38 pm »
Haha you're a funny guy! Talked me into it, didn't take much then did it?  ;D

The official press documents state the following: "It's all Vert's fault"

Audi Life

  • Guest
Re: Mk2 Jetta Upgrade
« Reply #38 on: May 10, 2008, 06:48:45 pm »
It's true, I read them :police:

Offline 80 Vert

  • only milk and juice comes in 2 litres
  • ####
  • ****
  • Posts: 8338
  • All thats left to do is everything!
Re: Mk2 Jetta Upgrade
« Reply #39 on: May 10, 2008, 06:49:32 pm »
Ohh well thats ok then, I'm used to getting the blame.
2013 Chevrolet Camaro ZL1
2010 T5 Transporter TDI
2003 Jetta Coupe soon to be R36TT
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 Carrera 4
1980 1303 Beetle vert, in pieces

https://www.facebook.com/pages/West-Worx/460154187360186

Offline 80 Vert

  • only milk and juice comes in 2 litres
  • ####
  • ****
  • Posts: 8338
  • All thats left to do is everything!
Re: Mk2 Jetta Upgrade
« Reply #40 on: May 12, 2008, 05:30:36 pm »
Lots of progress today with 2 of us working on the Jetta.
Started off this morning by cutting away the extra firewall bulkhead that MK2's have so that we can fit the MK3 heater/AC box.
None of the holes realy line up exept the large oval one where the heater core pipes come out through, we just made a cardboard template and transfered all the dimentions to the MK2 firewall and started cutting.

Also had to cut a hole for the AC drain since this car will now have AC too. Trial fitted the box a couple of times to get it sitting right and then realised that the air intake for the fan is in the wrong place on the MK2 body so another plate was fabbed up for that to correct the problem.
2013 Chevrolet Camaro ZL1
2010 T5 Transporter TDI
2003 Jetta Coupe soon to be R36TT
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 Carrera 4
1980 1303 Beetle vert, in pieces

https://www.facebook.com/pages/West-Worx/460154187360186

Offline 80 Vert

  • only milk and juice comes in 2 litres
  • ####
  • ****
  • Posts: 8338
  • All thats left to do is everything!
Re: Mk2 Jetta Upgrade
« Reply #41 on: May 12, 2008, 05:57:09 pm »

This shows the bulkhead cut away and primed with black zinc
« Last Edit: July 03, 2008, 04:57:42 pm by vert1 »
2013 Chevrolet Camaro ZL1
2010 T5 Transporter TDI
2003 Jetta Coupe soon to be R36TT
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 Carrera 4
1980 1303 Beetle vert, in pieces

https://www.facebook.com/pages/West-Worx/460154187360186

Offline 80 Vert

  • only milk and juice comes in 2 litres
  • ####
  • ****
  • Posts: 8338
  • All thats left to do is everything!
Re: Mk2 Jetta Upgrade
« Reply #42 on: May 12, 2008, 06:08:54 pm »

We ended up usin a MK3 throttle pedal as I didn't like the way the MK2 one runs up through the rain tray and then its quite a sharp bend for it to connect onto the ABF engine. Solution was to make a couple of brackets to position the MK3 pedal where I wanted it and weld in place.
It now uses a MK3 ABF throttle cable and exits through the firewall where a MK3 one would.


The heaterbox has a new core in it as I don't want to be pulling it all apart again when the old one starts leaking. So after fitting the throttle pedal and engine bay wiring the heaterbox was fitted again and is there to stay now.
While the heaterbox was out I also made a plate for the airbag module to sit on which was welded to the tunnel in the same place where it would sit in a MK3.

With the heaterbox in place the AC lines were run and re bent a little to suit the MK2 body. You'll also see the ABS unit in place along with the shifter cables etc.
« Last Edit: July 03, 2008, 04:58:56 pm by vert1 »
2013 Chevrolet Camaro ZL1
2010 T5 Transporter TDI
2003 Jetta Coupe soon to be R36TT
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 Carrera 4
1980 1303 Beetle vert, in pieces

https://www.facebook.com/pages/West-Worx/460154187360186

Offline 80 Vert

  • only milk and juice comes in 2 litres
  • ####
  • ****
  • Posts: 8338
  • All thats left to do is everything!
Re: Mk2 Jetta Upgrade
« Reply #43 on: May 12, 2008, 06:25:53 pm »

All the wiring looks kinda messy now and doesn't realy come out in a picture but where everything is placed looks really factory.
The brake booster is ready to go back in as all the wiring is now in place and runs through the firewall behind the booster so it was a lot easier to take it out for this job.
Will have to lengthen the pedals as they are way too high off the floor, It seems that MK3 pedal boxes are mounted lower in the car and therefore have shorter pedal arms but again some mods will fix that.

All the brake lines were re-bent where possible for a factory look and clipped to the firewall to keep them straight and out of the way.
The rear lines were too short to plug into the ABS pump so I had to machine some double ended fittings to be able to lengthen them so they could reach the pump.
2013 Chevrolet Camaro ZL1
2010 T5 Transporter TDI
2003 Jetta Coupe soon to be R36TT
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 Carrera 4
1980 1303 Beetle vert, in pieces

https://www.facebook.com/pages/West-Worx/460154187360186

Offline AngleBox

  • ##
  • **
  • Posts: 3739
Re: Mk2 Jetta Upgrade
« Reply #44 on: May 12, 2008, 07:45:22 pm »
WOW  :o Talk about a productive day! Looks like it will be wrapped up by Friday! Unfortunately some key parts from the States haven't arrived yet. I really wish sites would be more accurate when things are a) on backorder or b) need to be sourced from another warehouse  >:(