VASK Forum (VW Audi SportKlub of NZ)

VOLKSWAGEN => Mk4 Golf - Bora - New Beetle => Topic started by: 80 Vert on March 10, 2010, 06:30:38 PM

Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: 80 Vert on March 10, 2010, 06:30:38 PM
Once the last bits on the Vento are done I will be away on this one, I had intended on buying a peasant spec Bora to convert but a 4 Motion Highline just happened to land in my lap and was way to cheap to pass up.
Just made sense to use that car as a project as its already got the heated lecky seats, sunroof, climate air AWD etc.
It will be done as a full on road car, not fussed about weight as the big engine will take care of that.

As some of you know I did start on a MK2 R32 but in the end I just found it was too old to drive every day especially since being used to my current MK4 Jetta, had I gone through with it then it would have been a huge step backwards.

Finaly I'll get to use the R32 donor Golf that has been sitting around for the best part of a year, the idea is to go forged internals (rods/pistons) to lower the compression ratio to 8.5:1 so that we can turbo it!  ;D
Garret GT3582R was a consideration but after doing a bit of reading I now think this will be too small for my goal  :o.
I will post some pics of the car in the weekend, in the meantime I'll be looking at selling the current Jetta  :'(




Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on March 10, 2010, 06:45:33 PM
Good luck with this John, its going to be awesome when its done :)
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on March 10, 2010, 06:51:46 PM
wow!
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: Aidan on March 10, 2010, 06:52:38 PM
How many other MK4 Bora/Jetta coupes would be out there?

Going to be so cool to see being built and finished!
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on March 10, 2010, 06:59:11 PM
Nice John.
Is the project car the sliver Bora that had the Golf front on it that was at Turners last month?
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 10, 2010, 07:18:06 PM
Yes it is Nik, the Golf front has been sold and is coming off next week, new genuine Bora guards have been ordered along with brand new rear 1/4 panels.
There are a few Coupes out there but only a hand full, 1552 designs in the States did one but I don't like the rear side window in theirs, VW also did a concept coupe (CJ concept) and thats what I'm basing mine on.
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: Hoff on March 10, 2010, 07:43:52 PM
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fwww.niot.net%2Fniot_570%2Fvw%2520jetta%2520cj%2520niot.net%25201%2520%25281%2529.jpg&hash=3e1613defc3dd9e5443d959298c5cfaa1836d17a)

something like this then john?
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 10, 2010, 07:45:03 PM
Yes thats the CJ concept coupe, clay model only.
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: Omes on March 10, 2010, 07:51:27 PM
R32 big turbo 4motion - You will be the first in NZ to be doing this John - effin awesome. First to be doing this in Australasia I wonder!?  ;)
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on March 10, 2010, 08:11:16 PM
If this was my car, i would have just done the R32 conversion with big Turbo, but as usual John wants to do other stuff.

All cool, and good luck.
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: phil on March 10, 2010, 09:25:36 PM
Sounds cool. So will I be seeing my pics I took of the Jetta popping up on TradeMe soon  ;)
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 10, 2010, 09:27:45 PM
I'd say so Phil seeing as they are by far the best ones I have  :laugh:
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on March 10, 2010, 10:56:03 PM
Quote from: qta4 on March 10, 2010, 08:11:16 PM
If this was my car, i would have just done the R32 conversion with big Turbo, but as usual John wants to do other stuff.

All cool, and good luck.

Twin turbo is the way to go Noel. Single turbo's are so 2008  ;D
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on March 11, 2010, 07:13:40 AM
Looking forward to this one!
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: slowmo on March 11, 2010, 09:44:00 AM
can you hold on to the Mk4 jetta supercharged for a few more months.. i'd love to own that! but i'm guessing it will be big $$$  :(

another cool project on the way!
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on March 11, 2010, 09:58:21 AM
So is the new highline a 4 door that you will make two door or is it 2 door already?
Is the highline a V6?
So you will use the current highline running gear but just put the R32 donk in with a turbo on it?

Can you sell the mk2 body to Hans cheap he needs one.
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on March 11, 2010, 10:13:11 AM
Yes Jem the Highline is a 4 door V6 just like mine. :)
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on March 11, 2010, 11:24:09 AM
awesome!
Title: Re: Project car: MK4 Jetta Coupe 4 Motion R32 Turbo
Post by: omad on March 11, 2010, 06:23:46 PM
Damn, just bought another car... Couldn't put the dog in the Bora though...
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on March 11, 2010, 06:29:12 PM
So you are going with Jetta over Bora with this one John? :police:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 11, 2010, 07:03:57 PM
Jetta R it will be  :P
just been looking at turbo manifolds and I think I'll be going with this ATP mamma jamma, nice low mount unit with plenty of RHD clearance and it has a 44mm wastegate V band attachment  :o
Supports up to a GT4094 turbo  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 13, 2010, 10:28:01 AM
This is the car to be cut up, bit of a shame really but it has to be done  :laugh:
So far the new Bora guards arrived yesterday and the new 1/4 panels are about 7 weeks away ex Germany.
Just this morning I bought some GTI doors in the States, they will be some time off arriving as I'm going to try and consolidate some other stuff like engine parts with them to make shipping more worth while.

Located some HID Bora lights in Germany so thats another tick in one of the many boxes, somebody had removed the rear leather seats and replaced them with cloth GTI ones  ::) before the car was repo'd making it another thing to get but I managed to source some during the week which gets the interior back to how it was supposed to be.
Just little bits happening so far but progress none the less, will be stripping the R32 in the coming weeks when the bulk of the work begins  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0049.jpg&hash=57ce4b8dbb8232a47a5fd65a6275dc10588bfa2d)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0048.jpg&hash=d0d9164695966e56e86cc2b774d1a9e5eeca98b2)

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on March 13, 2010, 10:43:26 AM
So whats the plan with the body John?
Remove front doors, remove the "B" pillar, put larger 3 door Golf doors on? How are you going to make the rear 3/4 panels?
Is the angle on the back window going to change?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on March 13, 2010, 10:51:53 AM
cut cut cut >:D :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 13, 2010, 10:53:13 AM
Nik, the rear side window is going to be a major on this one as there is not much similarity between the Golf and Bora sides unlike the Vento we did.
The 4 doors will come off, drill the spotwelds out and remove the B pillar all together, I ordered brand new Golf rear 1/4's and the rest of the internal structure that can be salvaged will come from the bent R32.
Most of the B pillar and internal structure on that car is ok so there won't be a lot of additional panels I'll need to buy, the doors I bought are the larger 2 door Golf ones.
If you imagine the rear door window and 1/4 glass as one then the new window will be a little longer than that, going glass on this one also for a more factory appearance.
I have a side on shot of the concept CJ coupe thats being scaled up into a line drawing to get a better understanding of proportions, need to get that window spot on.

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on March 13, 2010, 11:00:04 AM
Sounds like a way bigger challenge than the Mk3 Vento Coupe.
Do you have a time fram you are working to or a date when you would like it finished?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 13, 2010, 11:18:29 AM
Yeah it sure will be way more work/challenge but thats exactly what i'm looking for, just doing the engine swap is too easy and would all be done too quickly.
I think the bulk of the bodywork will get done over winter, the most limiting factor will be $$$ but hopefully the Jetta will sell reasonably quickly which will help things move along.
I'm hopefull on a competion in a year, I think thats achievable if things work out to plan.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: steve03 on March 13, 2010, 09:25:09 PM
Cheers for the parts John and Ty, Look forward to seeing this take shape.. the vento is an awesome piece of engineering, so I'm sure this will be the business!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 16, 2010, 08:33:23 PM
Bought some GTI doors, glass last week and had them delivered to the shipper today, will try and combine some engine parts with them so hopefully they can leave the States in the next 3 or so weeks.
Slowly but surely things are beginning to happen.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on March 16, 2010, 08:43:05 PM
Quote from: Vert1 on March 13, 2010, 11:18:29 AM
"the most limiting factor will be $$$"
I recon :P By the time I have fixed enuf cars to make a living I am almost over my projects.
But then you fix water blasters so cars would be fun to you ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 18, 2010, 04:46:40 PM
I had a very nice chat with the previous owner of the R32 this afternoon, she gave me a bit of an insight as to what happened.
Her brother in law borrowed the car, him and his mates had been "hooning" in the car and they were reportedly doing 180km/h as they approached a 35km/h corner which of course they never made.
Pretty much went straight on and off the road only to be slowed somewhat by a row of trees, car rolled and the rest is history.

4 people in the car and all of them more or less walked away, they all had injuries of course but none life threatening.
She was so impressed how the car stood up that they purchased another MK4 R32, I always figured it was a high speed crash but wouldn't have guessed 180km/h  :o
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 18, 2010, 04:59:11 PM
And the result of that crash is this: Just a little bent, some bog and she'll be right!  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0050.jpg&hash=4cf068f64c1c91ad0ae9c7bb767107f257e63ba6)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0051.jpg&hash=dc87fc9fe34f45de7628d2143c384b9526229492)

There's not a straight panel anywhere, even the petrol flap is broken  :laugh:
The business end is fine though, hmmm R32 turbo- bring it on!  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0052.jpg&hash=0023fd42f1665d7d9152b389bbb1e15cebb04ddf)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on March 18, 2010, 05:22:02 PM
John that looks like it will buff out! haha, did it come on those superleggera's?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: shearer on March 18, 2010, 05:23:44 PM
 :o
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Aidan on March 18, 2010, 05:49:57 PM
Quote from: tyz-fly on March 18, 2010, 05:22:02 PM
John that looks like it will buff out! haha, did it come on those superleggera's?

The wheels were sold to Subverse.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on March 18, 2010, 06:27:38 PM
She doesn't want the CDs she left in her old/my stacker back does she John? ;) ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 18, 2010, 06:50:56 PM
Haha didn't think of that.
She's going to look for the key and she also still has the owners handbook for it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 21, 2010, 05:55:48 PM
Sorted some new rims for the project today, 18x8 for the front and 18x9 on the rear. Oohlala  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: The Truth on March 21, 2010, 06:25:07 PM
Wow, those are high on my want list, also high on the can't afford list! Genuine not replicas?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 21, 2010, 06:34:14 PM
Do you know what genuine ones are worth?  :'(
Been looking for some in Japan and untill I find some for the right money these will have to suffice.
Can get you a set too if you want?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Aidan on March 21, 2010, 08:13:32 PM
What's a replica set of those babies worth?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: The Truth on March 21, 2010, 09:22:13 PM
Quote from: Vert1 on March 21, 2010, 06:34:14 PM
Do you know what genuine ones are worth?  :'(
Been looking for some in Japan and untill I find some for the right money these will have to suffice.
Can get you a set too if you want?

Oh yea, I know exactly how much genuine ones are, thats why I asked! Hmm, I'm tempted, but right now I have more pressing car issues than wheels, might have to wait a while on that. Cheers for the offer though.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Aidan on March 21, 2010, 09:53:53 PM
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fimg.photobucket.com%2Falbums%2Fv686%2FNateVr6%2FMotorstadt4_Show_0189.jpg&hash=4bbf8362ae0c251e9dd0b834352823cf6c0f5f7f)

LM's too. Yum!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on March 21, 2010, 09:56:09 PM
arent those superleggera III's?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 21, 2010, 09:56:33 PM
Yep looked at a set of those too, mucho dollero's, most in japan are 5x114.3
Ultimate goal is for some proper BBS's but I'm very happy with these wheels atm, will probably re paint centres a darker silver.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on March 21, 2010, 09:58:28 PM
Quote from: Vert1 on March 21, 2010, 09:56:33 PM
Yep looked at a set of those too, mucho dollero's, most in japan are 5x114.3
Ultimate goal is for some proper BBS's but I'm very happy with these wheels atm, will probably re paint centres a darker silver.

DO IT!!!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Aidan on March 21, 2010, 10:00:05 PM
Quote from: tyz-fly on March 21, 2010, 09:56:09 PM
arent those superleggera III's?

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fimg.photobucket.com%2Falbums%2Fv686%2FNateVr6%2FH2Oi07037.jpg&hash=aeffaa082195a3727e9f78ce581550cde725683e)

Nope.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on March 21, 2010, 10:08:58 PM
ahhh i thought it was this one

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi728.photobucket.com%2Falbums%2Fww287%2Ftyzfly%2Fboracoupe1.jpg&hash=9b1c79fc4647830e392cc9e10f44e43c2732bcdd)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Aidan on March 21, 2010, 10:11:35 PM
Quote from: tyz-fly on March 21, 2010, 10:08:58 PM
ahhh i thought it was this one

It is I think. A few changes though.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on March 21, 2010, 10:13:23 PM
must be Johns car in the future! Looks good John
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 21, 2010, 10:21:46 PM
Same car, different wheels. Wrong side window shape.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on March 21, 2010, 10:24:10 PM
Quote from: Vert1 on March 21, 2010, 10:21:46 PM
Wrong side window shape.

Yes, does look a bit wrong doesn't it. It curves down too soon.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 21, 2010, 10:25:37 PM
Yep, doesn't suit the lines of the body at all. My one will be vastly different.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on March 22, 2010, 09:28:00 AM
Still looks hot I think ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on March 22, 2010, 11:28:37 AM
I thnk it look ok to. Really shows the potential of the Mk4 as a coupe though.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on March 22, 2010, 09:09:02 PM
This is the twin turbo kit you're looking at ...... right  >:D

http://www.youtube.com/watch?v=4mmyC1H6Ldo&feature=related (http://www.youtube.com/watch?v=4mmyC1H6Ldo&feature=related)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 22, 2010, 09:43:05 PM
I really like this car, sounds especially sweet.  HPA twin turbo. Kit is 40K odd  :o
http://www.youtube.com/watch?v=vd7vqb5-58g&feature=PlayList&p=0E5B5C8FFDA51390&playnext=1&playnext_from=PL&index=20
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on March 22, 2010, 09:47:24 PM
Quote from: Vert1 on March 22, 2010, 09:43:05 PM
I really like this car, sounds especially sweet.  HPA twin turbo. Kit is 40K odd  :o
http://www.youtube.com/watch?v=vd7vqb5-58g&feature=PlayList&p=0E5B5C8FFDA51390&playnext=1&playnext_from=PL&index=20

I know  :'( :'(
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 24, 2010, 11:44:39 AM
GUTTED  ;D
Check out the angles of the A & B pillars kids, show just how poked it really is  :laugh:
Will cut up the body next week and then there will be only 31.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0053.jpg&hash=c1c573ae224ab0da02c9f96baf110b60d7e1f26e)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on March 24, 2010, 11:51:03 AM
damn, its awesome that they survived!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 30, 2010, 04:23:31 PM
Got a nice surprise in the mail this week, the previous owner sent me the spare key for the car (key was missing from Turners) saves a bunch of hassle getting another key etc etc.
The new 1/4r's also arrived, at least 4 weeks earlier than first advised but thats cool  ;D
Will be nice to work with brand spanking new panels, just have to wait on the doors now.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0041.jpg&hash=a1f0be22cc8bd38cd97bffc53cfaf25554dc2fd8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Aidan on March 30, 2010, 04:39:54 PM
Quote from: Vert1 on March 24, 2010, 11:44:39 AM
GUTTED  ;D
Check out the angles of the A & B pillars kids, show just how poked it really is  :laugh:
Will cut up the body next week and then there will be only 31.

Controversial, but it's almost a shame they survived. The driver at least?

Is it really the first one written off?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 31, 2010, 04:46:31 PM
There's no turning back now!  :laugh:
Confirmed / ordered engine parts so let the fun begin, will look at shipping the doors in the coming weeks so it won't be all that long before its Christmas again.

Decided on doing the engine properly with lowered compression pistons instead of a head spacer, not only for the correct squish but the pistons are also forged so they'll take plenty of punishment.
Couldn't quite stretch to getting the turbo just yet but i'm still undecided on that one anyway, one of the suppliers suggested that the GT3582 will be too small and felt that a GT4088 would be "nice" for the R32 engine :o
So just a waiting game again for bloke jewelery to turn up, oh goody can't wait  >:D
Integrated Engineering rod set
JE forged pistons
ARP headstud kit
ATP turbo manifold
630cc injectors
Stage 4 Southbend clutch
Billet steel flywheel.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: chis on March 31, 2010, 05:12:07 PM
yikes another classy monster by the vert1

are we ever going to see a vert1 hatch emerge?  I can't see it now!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on March 31, 2010, 06:04:10 PM
Precision 6765SP billet turbo or Garrett GT4088R .85AR - any smaller is a waste of time.  :P
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 07, 2010, 03:57:49 PM
I'm trying to do a little on the car most days, doesn't always work out but at least its moving forward slowly.
Mainly concentrating on gutting the inside so that some cutting can commence, I'm going to leave the car as a runner for now simply making it easier to move it around.
This car is going to be way more complicated bodywork wise than the Vento, the MK4's triple and quadruple skins in places make it quite awkward to drill/cut apart nicely.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0053-1.jpg&hash=8026f988e91963aea231f51720492d52fdbeff44)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: veedubman on April 07, 2010, 04:34:07 PM
I know John interms of a Vert1 Hatch :P

howsabout a Limosine MKIII Hatchback..

with like 3 or four doors or somthing!

now that would be cool..

your main clients in a limo service would probably be young south africans from browns bay going to school balls.. and wanna be rappers lol!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on April 07, 2010, 05:49:59 PM
Quote from: Vert1 on April 07, 2010, 03:57:49 PM
I'm trying to do a little on the car most days, doesn't always work out but at least its moving forward slowly.
Mainly concentrating on gutting the inside so that some cutting can commence, I'm going to leave the car as a runner for now simply making it easier to move it around.
This car is going to be way more complicated bodywork wise than the Vento, the MK4's triple and quadruple skins in places make it quite awkward to drill/cut apart nicely.


Did you put the coilovers in the car or were they already in it?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 07, 2010, 06:53:30 PM
Nah they came with the car. They are weitec ones and they seem to ride quite well.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on April 07, 2010, 07:00:19 PM
Quote from: Vert1 on April 07, 2010, 06:53:30 PM
Nah they came with the car. They are weitec ones and they seem to ride quite well.

Throught they were, the green springs are a give away for Weitec suspension.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 07, 2010, 07:17:47 PM
They have a very coarse thread on them Nik, makes for very easy adjustment up/down IMO.
With the coarse thread the double nuts don't seem to seize up like with other coilovers sets that I have had the misfortune of adjusting.
Of course they were wound all the way down by the previous owner so it must have been an utter pig to drive with it that low.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 07, 2010, 09:49:23 PM
This is more the look I'm going with window wise, the glass will extend all the way up to the B pillar and the section of door frame between the two bits of glass will be painted black to make it appear as one.
Doing the car in the same R32 blue also.
Friend of mine is going to scale up a drawing so that we can fine tune exactly what I want, then print out a 1:1 line drawing of the window. Yeap sounds easy  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on April 07, 2010, 11:23:49 PM
that pic is really nice John
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: gti vr6 on April 09, 2010, 05:16:08 PM
mint...
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 09, 2010, 05:17:55 PM
Not so mint  :laugh: ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0060.jpg&hash=0dd7e3a257077235912f6346359872d9438fe34f)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GLIDN on April 09, 2010, 05:40:34 PM
anyone need a 4 motion rear for there GTI?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 09, 2010, 05:54:33 PM
Propshaft, haldex, gearbox is also available along with the boot floor.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on April 12, 2010, 01:14:16 AM
Front engine, rear drive conversion anyone?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 12, 2010, 05:24:10 PM
Bit of action from the weekend, reinforced the roof structure by welding some pipe in to support things while the B pillar is removed.
Cut the B pillar out with the ole sawzall like a knife through butter it just makes short work of it.
Then its on with the tedious job of grinding through each spot weld to be able to peel the exess metal away so that I'm left with a perfect factory edge to weld the new panel/pillar to.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0060-1.jpg&hash=95ebe84b03fd72a9ecc69eac10ffc1c25c2895a9)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on April 13, 2010, 01:13:38 PM
are you going to cage it John?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 13, 2010, 04:34:06 PM
Not this one, full road car with a proper interior and glass side windows.
Been looking at/agonising over drilling the roof off and decided today that in order to do a proper job of the side structure the roof skin has to come off so the glass guy is coming tomorow to cut the screens out (have to come out anyway for paint) so then its just a matter of a bunch of spotwelds and the skin is off.

With the roof skin off it means that it makes welding the pillar and acess to the side structure much easier and its how the factory would have done it had they made a coupe.
I still need to find someone with an R32 I can take some measurements from, anyone on here have one?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: AndyGti on April 13, 2010, 04:51:49 PM
howd you go about getting it certd for the alterations?? or is it easy and a case of droping it off and getting that stupid $500 piece of tin?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 13, 2010, 05:11:57 PM
Cert is no problem, engineer will look at it while its in progress.
I'll get him in once I have the pillar in place and the outer skin is ready to go on.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 14, 2010, 12:54:11 PM
A mate of mine had a play with some window shapes and did an overlay on a 4 door Jetta to see what would be possible, thinking about doing a cutback on the rear side glass like the BMW coupe and also the Monaro.
Still playing with shapes right now but the goal is to scale the final design up 1:1 and make a cardboard template of the desired window in order to make the window frame.  :P
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 14, 2010, 01:29:35 PM
Another variation on the same, a little more detail on this one and it shows the shape a lot better.

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on April 14, 2010, 01:31:42 PM
Quote from: Vert1 on April 14, 2010, 01:29:35 PM
Another variation on the same, a little more detail on this one and it shows the shape a lot better.



like DAYUM!!! thats hot! >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on April 14, 2010, 02:21:52 PM
I like the little flick angle on the back of the window, bit of a cue from a Mk1 3 door.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GLIDN on April 14, 2010, 02:59:39 PM
that looks good john.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on April 14, 2010, 03:12:57 PM
Lower it!


:P
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: badhabit on April 14, 2010, 03:27:03 PM
had another play with the new window shape onto the 1552 car.
You can see just how different the shapes are.
They've tried to put to much of a curve the back window for my liking which means the C pillar has gotten a little weird.
Still abit more fine tuning to be done but we're getting there
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: badhabit on April 14, 2010, 03:30:11 PM
we took the angle that appears at the guard / rear bumper and reflected that in the cutback on the window.
The curvature on the new rear window is probably closer to that seen the front window / A pillar. No point in adding curves into a design that aren't there already - less in more and all that! ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: badhabit on April 14, 2010, 04:21:57 PM
and now for a little colour! really need to do some work today sometime - nahhh
Think the colour is roughly right.
low enough for you Phil?
Added the chrome to the rub strips too, breaks up the side panels nicely.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: HaNs on April 14, 2010, 04:41:35 PM
I think curve in the back corner looks better.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: gti vr6 on April 14, 2010, 04:46:01 PM
Nice, the straight line looks hot. Better than the curve IMO  :police:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on April 14, 2010, 04:58:39 PM
Quote from: gti vr6 on April 14, 2010, 04:46:01 PM
Nice, the straight line looks hot. Better than the curve IMO  :police:

+1, it looks factory
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 14, 2010, 05:02:47 PM
Quote from: badhabit on April 14, 2010, 04:21:57 PM
and now for a little colour! really need to do some work today sometime - nahhh
Think the colour is roughly right.
low enough for you Phil?
Added the chrome to the rub strips too, breaks up the side panels nicely.

Holy crap man, were you bored today or something?  ;D
Starting to look more like what it should be, probably make the cutback a little smaller and have a "thicker" C pillar other than that it looks pretty good.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Turbo on April 14, 2010, 05:15:18 PM
Quote from: Vert1 on April 14, 2010, 05:02:47 PM
Holy crap man, were you bored today or something?  ;D
Starting to look more like what it should be, probably make the cutback a little smaller and have a "thicker" C pillar other than that it looks pretty good.

was going to suggest that.

smaller window/thicker c pillar looks better.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on April 14, 2010, 06:24:46 PM
Hot
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 14, 2010, 08:33:15 PM
Started thinking about pop out windows  :D (don't ask  :laugh:) on the way home tonight and wondered how difficult they would be to make happen.
Seems pretty feasable to have electric opening pop outs, I know the Sharan (bad example I know) has them on the rear most windows so mechanisms won't be a problem and if I look at non VAG the BMW stuff would work.
Very usefull and would be uber cool, hmmm more to think about.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on April 14, 2010, 08:48:08 PM
Do it. There is a kit for mk1s that does this. 130tcs have it from standard but motorized sounds great.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 14, 2010, 08:54:00 PM
Yeah Beetles also got them as an option, probably the same sort of components too.
Sounds like something you should get for Maddie, defo will be doing some homework on this- quite like the idea really.
Ideal thing would be to operate them from the drivers door using the rear door window switches.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on April 14, 2010, 10:35:08 PM
Really expensive if you find Mk1 rear opening windows. Must be mechanized John.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 17, 2010, 06:36:12 PM
A bit of an update from the past week and today, Started by drilling apart the R32's LH side panel even though it was damaged all I needed from it was the B pillar and some associated sheetmetal.

Drilling out 100's of spotwelds is not that much fun :'( but over the years I've kinda perfected it down to a fine art, I find that a 7-7.5mm drill bit works really well and once you sharpen the bit you also grind it so that the point is really shallow thus meaning you can drill through the 1st skin and not the 2nd one.
there are spotweld drill bits that have a cutter that cuts around the spotweld but these are too big and just leave you with a great big gaping hole to weld up later  >:(
Mainly used the air saw to cut the bulk of the sheetmetal away to the point that I could see what I'm dealing with.
All thats left after a days work in the second picture, rest is in the scrap bin ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0064.jpg&hash=00de20e99ab57d00f2f22a646ed533e50e19dcf9)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0065.jpg&hash=74297698fc1a8a8f317784b46b796dd7a700c1af)
I contemplated doing this conversion without taking the roof skin off but after much looking and agonising there really wasn't much of an option left so during the week I called my glass guy in to cut the windows out and the roof got picked off, to my surprise there wasn't many welds holding it on.  Look Ma no roof! :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0061-1.jpg&hash=c31d12607b8df4529bec43e18618ed27685ddb04)
These MK4's are a complex piece of work, triple and quadruple skins in places, way more work to drill/cut apart nicely than the Vento we did.
Got stuck in cleaning up where the 4 door pillar got cut away getting things ready for the 2 door one to go in.
MK4R32 was nice enough to call by during the week to let me measure the door opening on his R32, since our car was a bent mangled wreck there really wasn't any way of knowing if the door opening was close or miles away.
Armed with the right information I pressed on only to find that the what I thought one useable pillar from the R32 is also mangled beyond use, I have a RH one coming from the States with the new doors but unfortunately I've now come to a grinding halt on the LH one also and probably will need to find a replacement one to be able to carry on  :-[
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0062-1.jpg&hash=17de10d5dc2011ca01b13b9c6db69d87a403cfa1)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0063.jpg&hash=f31b8fca22f4be171ec90981dae011245937e89f)
Really pissed me off to find that out the hard way but in the end its probably a bit of good luck as I should really be waiting until the doors get here before I weld the pillar in, still who wants to wait?  ;D
On the plus side the engine bits will be here in the same shipment  :o ;D :o












Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on April 17, 2010, 07:46:30 PM
haha i love how you make my problems seem so small. you're a sick f#@ker!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 17, 2010, 10:38:53 PM
Just gettin started Choppy, just gettin started  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 18, 2010, 02:57:09 PM
Cool, great work.
Can I ask you to do another of version 2 but this time extend the window right upto the door edge (ie have no body coloured B pillar) and also black out the painted door panel between the door glass and side glass.
LOL does that make sense?  :laugh:
The more input the better really, the rear window will make or break the look of this in many ways.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 18, 2010, 03:16:31 PM
Oops sorry, second image.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 18, 2010, 03:37:23 PM
Tend to agree now seeing the other bits done, one thing is for sure the black on the door works and also the window extended right up to the door.
Ok thats cool, just have to work on the kink now, its amazing how just a couple of minor adjustments changes everything.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 18, 2010, 03:44:41 PM
Thats pretty much nailed it I think, now only to go and make it  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on April 18, 2010, 04:21:14 PM
hey John have you thought about doing a glass roof?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 18, 2010, 04:34:30 PM
Nah a sunroof is enough for me.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: JDVW on April 18, 2010, 05:27:59 PM
That last one is by far the best. Looks awsome!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Turbo on April 18, 2010, 06:28:18 PM
what about raising the sill line a bit?
not even sure if that's possible with the stock doors, but sort of follow the bonnet line? would look pretty smooth i reckon.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 19, 2010, 10:49:16 AM
Bit the bullet this morning and ordered a genuine new B pillar ex Germany, there's no other way to do this right.
Unfortunately it means coming to a halt with it for now but I'll just wait till the doors are here before I carry on with it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 19, 2010, 05:04:35 PM
There's one problem with not having the needed parts to carry on with the job at hand, the mind wanders and starts thinking about what other changes I can make  :laugh:
Sooooo, yesterday I thought about enlarging the plate recess to the size of a euro plate which I had intended to do anyway but while I'm at it I thought why not install a MK5 tailgate opener handle/badge thingy?

The area where the stock badge is now isn't really large enough so the idea is to enlarge the plate recess to the size of the black lines and also angle them the same as the edges of the tailights.
The swage line would end up with a kink in it so that the area where the badge is drops down to the plate recess in effect giving me a lot more flat area to mount the handle, the size of it is the black circle I drew on the lid, don't know if any of that makes any sense but anyway  :-\ Yay? Nay?
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0067.jpg&hash=a25548dd738549ecbc19cdbcbd26044cf34ba04c)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: JDVW on April 19, 2010, 05:32:18 PM
can you not buy a bootlid with the euro size recess? get trash or someone to photoshop
the boot lid with a mk5 gizmo could be cool
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 19, 2010, 05:36:18 PM
Yeah if someone can do it that would be cool, I'm useless with computers and photoshop  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on April 19, 2010, 06:46:37 PM
I wouldn't ever do something like that vert.
But you would and will. :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on April 19, 2010, 11:36:38 PM
That looks cool, all of it.. This is going to be one mint ride!
You have some serious skill (and balls!) John
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 20, 2010, 07:48:39 AM
Pretty much but with squared corners.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: omad on April 21, 2010, 03:59:32 PM
I like the cleaner look myself...

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi295.photobucket.com%2Falbums%2Fmm143%2Fomadthedirtyclimber%2FUntitled-1.png&hash=fce6ffb5f245b6832a05752257e3466277b90f6d)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: omad on April 21, 2010, 04:09:07 PM
Or even this is better... my photoshop skills aren't that good though...

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi295.photobucket.com%2Falbums%2Fmm143%2Fomadthedirtyclimber%2FUntitled1.png&hash=e6627f5ae7b29adf2b1bdfc8126c0d4d52dbbbef)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 21, 2010, 07:38:20 PM
Yep thats was the other option I looked at BUT...............complete change of plans  >:D
Weekend will reveal if my crazy idea works out or not.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on April 21, 2010, 07:44:21 PM
Quote from: 80 Vert on April 21, 2010, 07:38:20 PM
Yep thats was the other option I looked at BUT...............complete change of plans  >:D
Weekend will reveal if my crazy idea works out or not.

Smoothed boot and number plate in the bumper?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 21, 2010, 07:47:10 PM
Thought of that but........no!  :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SteveC on April 21, 2010, 07:48:18 PM
Quote from: Golfboy666GTI on April 21, 2010, 07:44:21 PM
Smoothed boot and number plate in the bumper?


I think that the number plate recess breaks up what could be a large flat expanse of metal, in other words, "yes dear your bum does look big in that"

what about keeping the existing boot line, widening (and maybe lifting) the number plate recess, then use a smaller VW emblem with the whole emblem acting as a push button release rather than the Mk5 pivot?  the Mk5 badge is big because the Mk5 rump is big
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 21, 2010, 10:41:17 PM
Geez Steve, did ya have to let the cat out of the bag!  :laugh:
I'm going to trim the MK5 handle down in size on the lathe and still use the opener thing but with smaller emblem, will then flush fit this where the stock badge was.
Will also widen and lift plate recess- will be an interesting little project, good thing to try some fancy panel bond stuff Wurth make as welding it will warp the crap out of it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SteveC on April 22, 2010, 08:13:48 AM
wow, spooky,

you may want to think about where the pivot would sit with a smaller badge, John, the Mk5 rear badge is 110mm dia with the pivot on the horizontal centre and while the action is fairly light, pivoting a smaller badge might get a bit tricky to operate unless the pivot is lowish on the badge

using the badge as a press button may be easier in day to day use
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 24, 2010, 04:20:45 PM
Something about making the panel bigger where the badge sits just didn't seem right so I've ended up going off on another tangent  :P
Started looking at the MK5 handle and thought why can't I just make that smaller and fit a smaller emblem  ??? Can only try and see what happens.

Pulled the MK5 handle apart and took the badge off the outside, was a real challenge to figure out how to reduce the diameter in the lathe but I ended up boring a hole right through the centre and mounting it on a spindle so that the dia could be machined down leaving the hinge on the inside all intact.
Turned out pretty well, assembled again it looks something like this
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0068.jpg&hash=e1e39b26192a96198737c482dc21f54c3dd76ef5)

Then marked out the hole to be cut in the lid and used the trusty air saw to cut it out, trying to keep something round is exceptionally difficult as the eye picks everything up.
With the hole the right size I needed to have an edge to give the hole some strength and also some depth so I rolled a ring from some flat bar and welded that to the edge of the hole and ground it up.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0069.jpg&hash=08afca1720b56a611663db9c554e82dcfbe031d0)

The MK5 handle has an outer ring that is urethaned to the hatch which the lock/handle then attaches to, with mine I had to cut a flat on the bottom of it so that it would fit in the Bora's lid.
Getting the badge smack bang in the middle was interesting but once I had set it in place with urethane I just let it dry.
With the urethane dry I went and made steel braces to keep the handle firmly in place, just had to fit the Bora's factory badge to the handle and presto almost finished  ;D
Also got on with cutting the licence plate opening to be able to widen and raise this, really loving the metal work- doubt anyone will notice but thats just the point  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0071.jpg&hash=e7f2ba80669779726df82460e068f8c5601dc20e)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0072.jpg&hash=742df7395f65319a1a502d367620e543d7bf76ed)









Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: badhabit on April 24, 2010, 09:05:43 PM
you fullas pretty clever! crap just imagine what you could do if you really tried! ;) bit of time and a welder.....
Looks pretty stealthy i must say.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 24, 2010, 09:29:58 PM
LOL, time and a welder  ;D Hahaha now where have I heard that before?
Oh thats right, when we turned your squareback guards into notchback guards  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on April 24, 2010, 09:57:01 PM
thats trick as!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 25, 2010, 10:45:02 AM
All this bodywork may not be all that interesting reading but I'm certainly enjoying doing it and learning new stuff in the process, sometimes you just gotta give it a go............
Next item on the list is to widen the licence plate recess, doing that without warping the crap out of the sheetmetal would be a challenge so I'm going to have a go with panel bonding adhesive and see how that works out.

Some of it will be welded where there are double edges etc but for the most part glue will hold it together  :laugh:
Had marked it all out a while ago so it was just a matter of coming up with a plan where to cut and get going on it, cut the end sections out first so they can be raised and pushed out.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC04757.jpg&hash=f0a44ca1383144e7a6d551b224f241453c0222d5)
I raised the end pieces 30mm and reshaped the tops of them for a nice fit against the upper part of the lid, still have to flange the end where it meets the outer skin and that will allow for a nice flush fit.
Once the outer panels are in place then I'll cut the entire center section out and make a one piece new one to fill the hole thats left, better way to go then adding filler pieces everywhere.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC04761.jpg&hash=0104871cc6a9bd4b54bfd90d8972c851e93480a7)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC04758.jpg&hash=45635f1d5c7fcbda3a220556d4c6e08fac1d6662)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GTI's on April 25, 2010, 11:03:03 AM
 Your ripping into this one Verty, So fast!
Should be a weapon!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 25, 2010, 11:05:49 AM
Wish I had more time to work on it, would get a lot more done but work keeps getting in the way.
Engine parts / doors arrive in 3 weeks, will hit it full force then  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Omes on April 27, 2010, 10:54:03 AM
Nice nice nice! Ive always been a fan of that MK5 boot opening badge mod onto the mk4's. Clean and OEM.
Verty makes it look so easy!  :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: slowmo on April 27, 2010, 11:41:44 AM
looks good. how do you make it waterproof?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 28, 2010, 04:55:44 PM
The MK5 badge/handle is a 2 piece design with a seal in between to waterproof it.

Something else I've wanted to make for years is an english wheel, been making components here and there for the past couple of months.
I bought the rollers over 5 years ago but like all good things it takes time to get around to it, with most of the parts made I welded it all together today but the proof will be to see if it actually works.
Couple more things to finish, a coat of paint and its done.  Never used one before so no doubt the learning curve will be steep  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0073.jpg&hash=dc820739801357979edd945b2f19a925ca0bd2ad)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SteveC on April 28, 2010, 05:07:14 PM
a recent Shed magazine had an article on making an english wheel, it may have some tips on using one
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 28, 2010, 05:09:03 PM
Cool, thanks.
Also found videos on youtube, search Lazze Jansson- amazing stuff.
Going to buy a shrinker/strecher in the coming weeks, will need it to make the rear window frames.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SteveC on April 28, 2010, 05:14:46 PM
http://www.theshedmag.co.nz/cms/index.php?option=com_content&view=article&id=150:make-a-handy-english-wheel&catid=74:aprilmay-09&Itemid=100004 (http://www.theshedmag.co.nz/cms/index.php?option=com_content&view=article&id=150:make-a-handy-english-wheel&catid=74:aprilmay-09&Itemid=100004)

not the whole article, but that issues is still available http://www.theshedmag.co.nz/cms/index.php?page=shop.browse&category_id=1&option=com_virtuemart&Itemid=100004 (http://www.theshedmag.co.nz/cms/index.php?page=shop.browse&category_id=1&option=com_virtuemart&Itemid=100004)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: JDVW on April 28, 2010, 07:26:03 PM
Thats solid, you looking to make tank armour vert?!  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 28, 2010, 08:03:42 PM
Haha tank armour, good one  :laugh:
Nah just made it from scrap lying around the shop, I like to make things solid  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: gti vr6 on April 29, 2010, 09:29:21 AM
Cool, there was an article in the Shed magazine with a how-to on making an English Wheel.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 01, 2010, 04:17:44 PM
On Monday I bonded in the side pieces so that they could set over the week, they also got welded in a couple of places so I don't think they'll be going anywhere soon.
Once cured I cut the middle section out completely and had to then make a panel to fill the hole left behind, looking at it I thought yeah that shouldn't be a problem- how hard could it be?  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0075.jpg&hash=bb558d16f950e83c163d13abbf1c64d6b1fc0aab)
Well..............It was difficult to make, very difficult in fact. Started with a cardboard template of the hole to give me an idea of the size the panel needed to be and cut it out of .75mm sheet metal.
I then put the double swage line in it at the bottom of the plate recess, once this swage was done the panel became much stronger and more difficult to work.
Into the english wheel, and having no clue what I was doing -started wheeling a roll into the panel to match the shape of the outer boot skin.
Surprisingly it didn't take much effort in the english wheel to start a curve forming and once you get your head around what does what as far as stretching the metal goes you begin to understand how it all works.

Repeated test fits revealed that there is quite a lot of shape in that lower panel where it meets the bumper, with the swage line nearing the right shape that I wanted it now meant that the very bottom of the panel had big lumps/ highs /lows in it due to the excess metal from the curve that the english wheel put in it.

There is a process called tuck shrinking that you can use but its much easier to go and buy a stretcher/shrinker, what this machine does is to pull the metal back together where you have too much and pull it apart where you have too little.
Again figuring out how much to shrink the panel is the hard bit but it soon started to look a whole lot better and not much effort was required with the shrinker to bring the panel back straight again.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0080.jpg&hash=6996659d6bbe03b7cff67f2bb1f4de566bbedb9d)
The key for me was to keep test fitting the piece in the lid and little by little it started to take shape.
I flanged it all the way around and once I was happy with how it fitted I bonded it in, a little filler and primer should see the job done.
Its not often I stand back and look at something and think holy s**t I just made that!  ;D
just this one piece has taught me quite a bit about sheet metal fabrication and I'm pretty keen to try some more stuff now, I have a lot of respect for guys who are good at this stuff and I think doing is the only way to learn.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0076.jpg&hash=1359ebfefa4bf96ce2fa7ec385a0bc86caccc38a)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0079.jpg&hash=3f82418debcc123c7829162434c5d5fdc5e5a3d6)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0078.jpg&hash=931c14a0e8cdf03747888599380ef0e3f174ec39)






Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 01, 2010, 06:17:50 PM
Before and after, all that for a euro plate  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0067.jpg&hash=a25548dd738549ecbc19cdbcbd26044cf34ba04c)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0074.jpg&hash=be1408a35a8ee2bd5ba421fc69dacb197428ae4f)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on May 01, 2010, 09:03:15 PM
Your the NZ version of Chip Foose, AWESOME John
The subtle upgrades are always the best, they complete the overall project, however, unless pointed out as custom are not initially recognized as different 8) 8) 8) 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on May 01, 2010, 09:52:17 PM
Quote from: SOFTLAD on May 01, 2010, 09:03:15 PM
Your the NZ version of Chip Foose, AWESOME John
The subtle upgrades are always the best, they complete the overall project, however, unless pointed out as custom are not initially recognized as different 8) 8) 8) 8)
here here i second that,-all of it!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on May 02, 2010, 08:33:35 PM
Nice work :)
I used to do a lot of rust work back in the rusty days.
I used to bend up and hammer a few patch panels and I seemed to have a real knack for it that many others doing the work at that time didn't. Tho of course the pros were always there ;) Like you vert.
I used to stand back tho after a few jobs and think wow I did that well, making up little box bits to remake bolt mounting points etc.
But I would like to do what your doing there, that's real time and patients.
You have an excellent work shop.
Lastly :D What is that red handled tool in the boot there? Another clamp or a special cutter?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on May 03, 2010, 05:12:28 PM
I'm pretty sure all the nascar panels are hand-rolled.  Madness I tell you.  Awesome work John. I always enjoy watching your work take shape (pun intended).
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 03, 2010, 05:13:41 PM
Doors and go fast parts arrive 10-5, good times coming.  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on May 03, 2010, 05:23:25 PM
Hurry up and get this thing going already!  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 03, 2010, 09:55:35 PM
Gimme the parts and I will.  :-*
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ritmo on May 03, 2010, 10:10:35 PM
Did you buy a shrinker/stretcher Vert? Come up on trademe often, cheap chinese though.

Ok looked on trademe, good selection: This is handy. Frees up both hands
http://www.trademe.co.nz/Business-farming-industry/Industrial/Manufacturing-metalwork/Other/auction-287136325.htm

Would need to build stand tho.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 03, 2010, 10:12:56 PM
Yep, was halfway through making the boot panel and realised I needed one so that was my excuse  :laugh:
Bought one from Mac Donald machinery, cheap chinese but works awesome- don't know how I would have managed without it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on May 03, 2010, 10:16:25 PM
The red handled tool? is it a special cutter?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 03, 2010, 10:19:50 PM
What red handled tool? The one holding one of the side pieces in the boot skin?
Thats just a fancy vise grip  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on May 03, 2010, 10:40:57 PM
oh. i thort it was a niffty hand nibbler or something :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on May 05, 2010, 06:45:50 PM
When do the bits arrive John? Any updates?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 05, 2010, 06:53:39 PM
Nope, still waiting- driving me crazy!  :-\
Parts arrive 10-5 so should have them by weekend after next, will crack on with the bodywork and tear the engine apart.  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 12, 2010, 05:18:29 PM
Righto, not much been happening with this lately other than waiting for bits to turn up so here's a bit of an update from this last week. Parts are in the country and being unloaded so hopefully they will be delivered before the weekend.  :P

The new LH pillar did arrive from Germany on monday so I thought I?d see how its going to work, fitted like a glove first time round! Put it side by side with the R32 one you soon realise how rooted the old one was.
Had to cut some more of the sill away to get it spot on but that?s about it, naturally I wanted to carry on with it but having no door yet means that I couldn?t double check the gaps to the rear ?.

Somehow it feels wrong to start cutting into brand new factory panels  ;D but oh well it has to be done, I left plenty of excess at the wheel arch end to be trimmed back later.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0086.jpg&hash=c3cf7e87d2d7c1b25ee7b6fc06c0a7122c75cad3)
With the pillar and rear ? held on the car with vise grips it looks like everything will work just fine, the measurements I took from the bent R32 were dead on accurate on this car also as was the door opening I measured on MK4R32?s car so in all reality the pillar can?t be in the wrong place.  :laugh: (he says full of confidence  ;))
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0087.jpg&hash=7ece37d03ffc98a6592bb16f5461c958924762df)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0088-1.jpg&hash=862b7bf0f4852b3d3d8cc70bea1c3dd0624f288c)
Should I weld it in without having the door was the question? What could possibly go wrong?  ;D

In the end I thought screw it, I'm welding it in. (can you tell I?m inpatient?)  Took all the precautions I could have and measured everything 5-6 times so here?s hoping the door fits the hole  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on May 12, 2010, 05:56:53 PM
You might have made a mistake, because i usually measure 8 times, and have made bad mistakes.

I now measure 10 times ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 12, 2010, 06:09:32 PM
Nah, its sweet  :laugh:
Proof will be Saturday when I hang the door,  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 13, 2010, 02:16:40 PM
Just bought some OEM R32 side skirts, funny thing is that the wreck I had did have some on it but I thought I'll never use those and sold them doh!  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: AROUSN on May 13, 2010, 04:24:01 PM
Quote from: 80 Vert on May 13, 2010, 02:16:40 PM
Just bought some OEM R32 side skirts, funny thing is that the wreck I had did have some on it but I thought I'll never use those and sold them doh!  :laugh:

And i still havnt fitted them yet lol, the time will come tho, eventually.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 13, 2010, 09:52:44 PM
Might have a bit of a get together at the workshop in a 2-3 weeks if anyone is keen to have a gander.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on May 13, 2010, 09:55:22 PM
Keen John  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on May 14, 2010, 11:25:17 AM
John, you're crazy. ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 1.8t on May 14, 2010, 11:37:04 AM
Great idea
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 14, 2010, 09:22:58 PM
Santa came by today  >:D :laugh: >:D
Lots of goodies to fit.  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Period_Correct_ on May 15, 2010, 09:43:18 AM
man this thread is just ooooozing awesomeness..... makes it so hard to reply....
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RevHappy on May 15, 2010, 11:31:42 AM
omg cool
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 15, 2010, 04:37:12 PM
Pretty good amount of progress made today, spent a while drooling over the new parts this morning and then got to work.
Fitting the door was a bit of a moment of panic  :laugh: Fitted in the hole just fine but when I put the rear 1/4 skin on the door gap was all over the place! Got that warm fuzzy feeling of oh s**t the pillar is in the wrong place :(
Still its all welded in so it aint goin anywhere now, minor adjustments to the door hinges and rear skin saw the gap getting better and better and after more than an hour of fiddling with different things its pretty much perfect now.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0091.jpg&hash=56e5a909bfab808b41671dcb2468afcc4f009233)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0093.jpg&hash=aa649a509d99d585247756c15bc160dc5627b9bd)
At the end of it all the pillar was always in the right place but with so much adjustment everywhere it just takes time to get it right and also these doors were never off this car anyway.

Once I was happy with the door gap I put the door lock and striker plate on to make sure that everything opens and closes as it should.
Fitted the guard also to check fit and gaps, found I had to shift the door back a couple of mm to be able to line that up and make the gap even between the two.
Pretty stoked with progress so far so this arvo I started cutting the other side apart fror more of the same  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0099.jpg&hash=c9ea3bf3a40f0c3c1a5c27019ffef4edefe6286b)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on May 15, 2010, 05:18:33 PM
Sounds like progress. Looks like the C pillar is going to be a bit of mission along with the horiztontal transom between the B & C pillars. You're certainly going to get better at welding and fabrication  :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 15, 2010, 06:07:56 PM
Yup the C pillar will be fun, good way to learn though.
Oh these came in too  ;D 18x8's in front and 18x9's out back
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0094.jpg&hash=382fb0f6ce72217e1f0f56dffb970679237bd14e)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on May 15, 2010, 06:18:49 PM
WHEEL PORN
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: divey_ on May 15, 2010, 06:33:57 PM
^^ those are nice.. should of done a group buy!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on May 15, 2010, 07:49:04 PM
as one would say ......i just jizzed when i saw that wheel
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on May 16, 2010, 10:15:00 AM
Nice work, I really wish I had patience like you seem to have. I can do mechanical work all day long but bodywork I just do not have the time or inclination for. Going to be a brilliant finished result!!  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: robh on May 16, 2010, 11:16:43 AM
Are they real BBS or copy?  They look stunning.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 16, 2010, 11:28:25 AM
Quote from: M on May 16, 2010, 10:15:00 AM
Nice work, I really wish I had patience like you seem to have. I can do mechanical work all day long but bodywork I just do not have the time or inclination for. Going to be a brilliant finished result!!  ;D

Cheers guys, the car seems to be progressing well and I'm really enjoying working on it doing the body work.
Much more involved than the Vento and learning new stuff about metal fab so its pretty cool really.
Its just a shame we (NZ) are so far away from the rest of the world as getting parts to make something like this happen is a real mission and takes months of planning to get some parts here.

Hopefully I'll be able to fit the RH pillar in the next couple of weeks and then push on with the window frames which will be the hard part to get right.
By then the new bonnet should be here to be able to test fit and set all gaps.

Yeah the wheels are copies Rob, originals are made from unobtanium. There are sets in Japan but super expensive, I was surprised at how light these wheels are.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on May 16, 2010, 11:30:11 AM
Looking good John 8)

What sort of bonnet are you planning to use?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 16, 2010, 11:37:34 AM
Stock Bora one has been ordered.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 16, 2010, 02:01:12 PM
Some snaps of the other bling I took yesterday, will get on with engine stuff once the body goes to the painter for some primer work.
JE forged 8.5:1 pistons and Integrated Engineering I beam rods
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0095.jpg&hash=31901c492e5fa575f5652d071018997ea9ee598e)
Southbend stage 4 clutch and billet steel SMF, its packed so well in expandable foam I haven't even bothered to rip into the packaging  :-\
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0097.jpg&hash=0c94cbdca3ff2ead0fb8d4e2c4dd0022724d3276)
ATP turbo manifold with a v banded wastegate fitting.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0098.jpg&hash=1de6db71d6f88ba716c62433fc7a366e4082f589)
Raceware headstud kit, OBX LSD
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0096.jpg&hash=33d4b6f910898573d1a02fa1c63064790403cdb6)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on May 16, 2010, 05:38:03 PM
Finally, NASCAR parts into a VW. Now someone will finally have a quick car.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: AndyGti on May 16, 2010, 06:18:33 PM
what were your reasons to choose obx over quaffe for your diff??
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 16, 2010, 06:27:25 PM
The OBX in the Vento is performing great and is less than half the price of a quaife.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on May 16, 2010, 06:34:08 PM
Remember where John was born. ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: gti vr6 on May 17, 2010, 06:48:01 AM
Why spend mega bucks when you don't have to.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: AndyGti on May 17, 2010, 07:28:49 AM
ive heard you gotta rebuild obx diffs tho??
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 17, 2010, 07:48:42 AM
Change the bolts and washers, all of 40 bucks worth.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: AndyGti on May 17, 2010, 10:03:38 AM
how often??
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 17, 2010, 11:01:42 AM
How often what?
Bolts/washers are a one time thing only.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: AndyGti on May 17, 2010, 03:48:04 PM
sorry how often do you have to rebuild the units? im asking cos im gonna be looking into diff's soon.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 17, 2010, 05:22:29 PM
You don't ever have to rebuild them, there's nothing to rebuild.
Replace the washers and bolts and thats it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: AndyGti on May 17, 2010, 06:45:04 PM
oh  :D cheers john. as you were!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 20, 2010, 09:06:46 PM
Had the certifier in to cert a couple of cars today, showed him where I was heading with the new project and he seems happy enough.
Lots of questions about what i'm doing, how i'm doing it as it seems modern cars with all the saftey features and crumple zones is not something the LTNZ like you to play around with- especially cut the whole side off and change it  :laugh:
Since its really a Golf with a Bora skin he doesn't see too much of a problem with it, factory pillars and factory doors used all helps out.
He thought the turbo'd R32 was a great idea and in his words "that should go pretty well"  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 27, 2010, 04:59:14 PM
Some progress from the last couple of weeks or so I've now come to the most interesting part, shaping the rear side window frame.
Decided to use the upper part of the rear door frame as a lot of it is already the right shape for what I want,  just cut the window frame off each rear door and then removed the outer skin from the rest of the frame.
Bit of a waste of perfect rear doors ;D but it makes a lot of sense to do it this way, much nicer end product doing it like that.
Quite a lot of massaging is needed to get the edges bent where I wanted them but so far its worked out pretty good.
I used the strecher to bring the back end of the window frame around more to get the cut back in the rear window so that it more or less matched the angle of the rear lights.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0101.jpg&hash=a6238ec4a7f1de9e1b7255ad61eb30d5806b3cc9)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0102.jpg&hash=bea84073dfb254f96e67e46d9b50e623facfc111)
Most of the picture above is just bodged together with duct tape just to get an idea of final design as its quite difficult to visualize the finished window with several different colors and lines running all over the place.
Have now started to weld this in place and also started making the inner structure for it.
Once both the inner and outer parts of the upper window frame is done I'll start on fitting the rear 1/4 skin and finishing the return piece that will blend into the new skin.
Looks like the BBQ get together will happen on the 5th june for those that want to have a look at this and talk some crap about cars  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0103.jpg&hash=b1770db9c3f64959108e4c60294e30722e803a4d)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on May 27, 2010, 10:01:52 PM
Looking good John :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: robh on May 27, 2010, 10:42:50 PM
John, what are you plans on the inlet manifold?  are you going to run the stock unit?  they are plastic aren't they on the R32?

Do you think it will cope with the heat and pressure?

Would be a shame to lose it and the fancy variable inlet tract wouldn't it?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 27, 2010, 10:48:14 PM
Inlet manifold will have to go in favour of a short runner intake as the plastic unit only handles 12-15psi. Have toyed with the idea of making my own version based on the factory one but made of aluminium.
Short runner mani will give me much needed room for the turbo and piping though, HPA make a nice one but for less than half that I could make my own one.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on May 27, 2010, 11:00:11 PM
John... Type 34 pics please! 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 27, 2010, 11:08:00 PM
Oh ok only if you insist ;D, bog std so far 1963 all original (with original rust) but this is what I'm aiming for
Its still a couple of months away from arriving and then it will sit in the corner for a while to come.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2Ftwo15.jpg&hash=49df47a88165e80e92fa31e31acf657076f388b7)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on May 27, 2010, 11:10:07 PM
They are so awesome ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 27, 2010, 11:14:39 PM
Yeah, Jetsons cars  ;D
I have always loved them and looked many times at buying one so finaly I decided to go for it.
Pretty long term project as it needs a lot of work but it is an original California black plate car so thats very cool.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 28, 2010, 05:06:20 PM
Alrighty back on track with this, spent some time welding after work last night and got the outer panel welded on without too much distortion so it came together pretty well.
There's a strip of sheetmetal under the join of the two pieces and they have been plug welded onto the strip underneath making it a pretty strong join.

I made the return for the window (the bit that the glass will sit on) on the shrinker with a strip of sheetsteel 20mm wide forming it to the shape of the window panel and welding it together.
Tomorow I'll have a go at making the inner parts to hopefully complete most of the frame and can then concentrate on welding the 1/4 skin on.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0107.jpg&hash=3683ca8464c1f0ee32e5f5bbdb6ccc89fc49d8d2)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on May 29, 2010, 09:03:06 PM
A bit of a guest post from me today  :)

As I was a bit concerned at how slowly this build is progressing I headed out this morning to lend my able assistance  ;) After discussing the mornings plan of attack with John we set to work. It's quite staggering when you start getting your head around it how much difference there is between this build and the Vento - the complexity of shapes and custom work required is quadrupled at least.

I can see many, many hours disappearing into getting the small details exactly right. So while at times it appears a lot has been done there will be many times where a lot of hard work yields minimal visual progress. Dealing with that will be a test of patience and determination.

With the outer window skin now in place it is a matter of bridging the gap between the outer skin and inner structure along the top of the window area. John took some measurements and we headed off to slice up some flat panel steel into a long sliver. Then onto the make shift folder to gently hammer in a nice, crisp bend. Tap, tap, tap...
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC04976.jpg&hash=cc098a40b43a6885c536fcfe85edee3d2aeaee4d)
(Note the panel above this in the picture is the shaped up RHS outer window skin from the donor rear door)

Then starts the slow process of forming the shape to match the window. Into the shrinker, back to the car for a test fit, into the shrinker (and so on and so forth...........)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC04978.jpg&hash=f9b120be6fc07792466654882d72e7e32b7e4cc7)

Final part is shrinking the tight rear corner into the panel.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC04979.jpg&hash=a79c1651c24ba1b5bfb42f11e5ee073131987a89)

You can't really see much in this pic but here it is clamped in place for final sign off that the curves are all ok. As you can see there is still quite a lot of excess material on the body side, that will get trimmed back later.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC04980.jpg&hash=3ed32f7f70159d36a63b96ff2287829f811ea437)

From there it was off to the drill press to drill the holes for the plug welds and here it is getting welded in place. Fresh steel, ahhhh sounds so crisp when it's being welded.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC04981.jpg&hash=7df6a5318b5acfaf6fecf4236d38b7605ce73788)

The inner edge was then trimmed back to suit and welded as per below. Here it is before the final clean up
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC04983.jpg&hash=7ea06bfad875cef748b59a984e97edd41a55e20f)

Then while I cracked on to removing the under seal in the rear wheel arch (b_tch of a job) to prepare it for the body panel to be welded on John set about making the smaller, fiddly bits for the rear corner of the window as you can see completed near the bottom left here.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC04985.jpg&hash=ab3d3c0af73798807f3a11a7a22508a5e3f072cc)

Next steps are to finish off the inner panel work, weld on the outer 3/4 panel then on to the next side!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on May 29, 2010, 09:09:36 PM
Great work as always guys, with great pictures to accompany the words, most informative. ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 29, 2010, 10:33:16 PM
Geez Phil you didn't tell me that you'd taken pics of me welding, kept that one all to yourself didn't you!  :laugh:
After Phil had to go I finished off the rear corner piece I made earlier and ground it up pretty much completing the upper part of the frame and started on cutting the outer 1/4 skin to size.
Once I figured out where I wanted to join the skins the cut was made and outer panel taken off the car to prepare the area for welding, have made join strip and plug welded that to the body.
Hopefully I'll get some time during the week to weld the outer panel on so that by our BBQ next Sat one side will be completed.
By the way if anyone who wants to come along doesn't know my adress then just PM me.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0060-2.jpg&hash=632e3d3fd1be1c7ada8ec70558eedf98c3e6e5f0)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on May 30, 2010, 08:52:26 AM
Will you use glass or not for the rear window vert, clearly all custom?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 30, 2010, 10:46:50 AM
Yup, will be having glass windows made. Had a look at a E46 BMW last week and it looks like I'll be able to use the actuators out of one of those to get my electric pop out idea to work.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on May 30, 2010, 12:06:08 PM
Quote from: 80 Vert on May 30, 2010, 10:46:50 AM
Yup, will be having glass windows made. Had a look at a E46 BMW last week and it looks like I'll be able to use the actuators out of one of those to get my electric pop out idea to work.

Very, very cool John.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Alfashark on May 31, 2010, 12:28:49 PM
So far, so awesome :)

Keen to head up and check it out this weekend... Where do we find you?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 31, 2010, 06:35:04 PM
Have pm'd you my adress so see you Saturday  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 02, 2010, 09:26:42 PM
Been doing a bit on this after work the last couple of days, with all the interuptions during the day in the shop makes it a pain in the ass to try and concentrate on the welding side of things and also by the time you get nice and comfy to weld something next thing the phone rings  :laugh:
Anyway I decided where the panel join had to be and cut the panels to suit, made a joiner plate and welded that to the car's rear 1/4 panel.

Did all the prep on the Golf rear 1/4 as far as drilling holes where needed for the plug welds and placed it back on the car, when I originaly lined everything up and set the gaps I screwed the panel on with self drilling screws to keep it in place.
I could have used cleaco's but didn't have any at the time but this makes the whole process sooooo much easier as the new panel just goes back on pretty much where it was set originaly and the gaps still line up.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0064-1.jpg&hash=a98381de9aadced626a16365d0fd0f122907947f)
Pretty much went around the whole panel and plug welded it keeping an eye on the door gap making sure things didn't move around.
Around the wheel arch area I used some panel adhesive and once dry the lip needed to be hammered over with a hammer/dolly to complete the wheel arch.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0061-2.jpg&hash=62e814df777094868f5c95b3125e1d7a54bc79e4)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0063-1.jpg&hash=2ecd9f7c31e39953c29a4f5dbcc3c4842727bdcd)
Just the gaps left to fill in the sills, had a D-OH moment there, cut a section of good sill from the donor car and started welding it in only to find that the sill panel tapers inwards a little at the rear of the door so in the end it had to be cut out again and re done! Don't ya hate that  >:(
Had to fix the mangled part of the R32 sill I was hoping to avoid using, good way to waste a couple of hours  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0065-1.jpg&hash=5dc4c27357b250a78fabfd74039fbde6de60aefb)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0067-1.jpg&hash=df0f5467a9ed69bd05a14a2202febc5bbf2a6f4a)
So, there you go half a coupe done. Ugh now to replicate it on the other side.  ;D
Cut the roof edges back and placed it on the car to make sure it still fits and everything looks good, at least it gives ya'll somethin to look at on Saturday  >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on June 02, 2010, 10:00:57 PM
Nicely done John 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Simon* on June 03, 2010, 04:29:51 PM
Quote from: 80 Vert on June 02, 2010, 09:26:42 PM
So, there you go half a coupe done. Ugh now to replicate it on the other side.  ;D

Wait, you're gonna do both sides?!!!   ::)

Why not just keep it as an unconventional 3 door?   ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: veedubman on June 03, 2010, 04:31:35 PM
Quote from: Simon* on June 03, 2010, 04:29:51 PM
Wait, you're gonna do both sides?!!!   ::)

Why not just keep it as an unconventional 3 door?   ;D

Dont laugh i always thought that would be cool!

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 03, 2010, 09:28:40 PM
Yeah it would be cool..............but on someone else's car, not mine  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GTI's on June 03, 2010, 09:31:14 PM
The mazdabator?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: dubstar on June 04, 2010, 11:23:04 AM
There was a prototype Mk1 Golf in the 70's that had the '3 door' asymmetric arrangement.  Can't find a pic at the moment, but there's one on the interweb somewhere.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on June 04, 2010, 12:09:41 PM
Modern take would be the mini clubman
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VeeDub on June 04, 2010, 04:02:15 PM
Left side is looking great! Unfortunately I won't be able to make it up to check out the progress tomorrow, have a prior engagement to see Shapeshifter play in Brisbane  :D Will see it again soon no doubt though  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 09, 2010, 09:33:37 PM
Just secured a MK5 GTI flat bottom steering wheel for a different look, I had intended on getting a Scirocco wheel/airbag and although these are a direct fit in a MK4 and the light goes out they will not deploy at all or deploy delayed at best in an accident  :o
Some Mk5 and all MK6 have a dual stage airbag unlike a single stage airbag on the MK4's, This meant that I ended up going for the MK5 GTI wheel and a MK5 airbag from the City Jetta which is pretty much a facelifted MK4 for some markets like China/Canada/Mexico etc.
Those cars all have the single stage airbags so that will all work out sweet for a new look.
Scirocco wheel, looks pretty nice in a MK4- too bad it won't work  :(
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2Fimages.jpg&hash=bd5f998ec033c6e69e8140f35bdeca1a4bca48ba)
MK5 GTI, will get rid of the button panels as nice alloy inserts are available  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FIMG_4679sm.jpg&hash=c2595d0c4acca0471a60e30c06380dee405eb9ef)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GLIDN on June 10, 2010, 12:58:39 PM
Where did you get the wheel from and how much?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 10, 2010, 01:39:23 PM
Bought it used on fleabay USD 200
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 13, 2010, 11:50:38 AM
The great thing about doing another car project is the constant flow of new goodies in boxes turning up, yesterday the new airbag arrived in the post, didn't think they would ship it that way but there ya go  :o

Replicating the window frame on the other side presented me with a new set of challenges, quite a bit more difficult than I thought.
Made a start on it last Sat after our BBQ by making a carboard template of the finished side so that I could use that to determine where the window line ought to be.
Problem was how does one hold the template, metal panel, and then stand back to look at it  ???

I ended up tacking the panel in one spot to hold it so that at least one corner could be set where it needed to be and worked from there.
Spent a big part of Monday's Holiday on doing the upper frame getting that positioned and welded in,
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0068-1.jpg&hash=af7443a82336ec205872a96fe8cfd6b27a005439)
Bits and pieces here and there during the week saw the upper inner and outer frames completed and the rear 1/4 ready to go on for good getting closer to the metalwork being done. ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0070.jpg&hash=508fc84bb410f6ef7c7bf4c8f0d6272ed4ded801)
Yesterdays mission set was to finish grinding the welds, finish the lower window corner, drip rail, sill section and get the roof on.
Quite ambitious I thought but surprisingly all got done except welding the roof back on, a little more work/priming/sealing is needed to be able to weld the roof back on for good.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0071-1.jpg&hash=30df45f5d36ed1ab9ad871fd633fd395b9f5eb8c)
I fully stitch welded the RH side after advise from the painter so that means I'll have to stitch weld the other side also before it goes off to him in the next couple of weeks.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0072-1.jpg&hash=2c784658fe4c5d5d044f70df0a0465d97ebea756)




Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on June 13, 2010, 12:55:27 PM
Moving along nicely, what was the reason behind the added welding advice from the painter?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 13, 2010, 02:06:15 PM
He was concerned that in time the line where the two panels meet will become visible in the paint, only way to overcome this is to fully seam weld them together.
Thing being it introduces more heat/warpage to the panel which was the reason I didn't do it in the first place.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 14, 2010, 06:03:28 PM
Certifier dropped by to check the metalwork, all good to go  ;D
No need to look at it again until finished and driveable.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on June 14, 2010, 06:59:44 PM
Not even for the small engine upgrade...?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on June 14, 2010, 07:37:53 PM
How are you finding the second side? Faster, easier, better quality?  :D Panel will fail if you don't fully seam it. I was under the impression brazing would work (I believe it introduces less heat) post spot welding.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 14, 2010, 09:44:14 PM
Quote from: AngleBox on June 14, 2010, 07:37:53 PM
How are you finding the second side? Faster, easier, better quality?  :D Panel will fail if you don't fully seam it. I was under the impression brazing would work (I believe it introduces less heat) post spot welding.

The second side was a right pain to get it the same as the 1st one, quite a bit quicker though as I already knew where to cut panels and what parts I had to make.
Tig may also work but I think that too will produce too much heat, will just mig it like the other side.

Neil the certifier had no concerns about the turbo  ;D, his comment "cool, that should go pretty good"
He seems more concerned that airbags, seatbelts and modern safety stuff is retained correctly.
Only down side I'm not allowed to cut anything to do with frontal impact to make the intercooler fit  >:(
Late model cars are a right pain to modify, had I chosen to do something like a MK6 most likely it will not be allowed, LTNZ does not want anyone to modify new cars structurally.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on June 14, 2010, 09:47:25 PM
Quote from: 80 Vert on June 14, 2010, 09:44:14 PM
Only down side I'm not allowed to cut anything to do with frontal impact to make the intercooler fit  >:(

I know what order the certifying will get done in  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 14, 2010, 09:48:54 PM
Not what you think  :laugh: already found an intercooler thats going to work without cutting the bumper support.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on June 14, 2010, 09:52:07 PM
Make sure you get that panel seam done right. I've just had the door on the Anglia re-sprayed. It was spot welded and cracked through the paint about 5000 km's later. Given the amount of rattle in the old girl, that's about 30,000 Jetta miles.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 14, 2010, 09:56:08 PM
Yep thats exactly what the painter said may happen if I don't seam weld it, did that on the Vento so don't really know why I was thinking differently on this one  ???
Don't need crap like that once she's painted.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on June 14, 2010, 10:05:10 PM
Quote from: 80 Vert on June 14, 2010, 09:56:08 PM
... once she's painted.

Still going with R32 blue I hope? 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 14, 2010, 10:07:57 PM
Sure am, will look noice with the chrome trim down the side.  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: badhabit on June 14, 2010, 10:18:06 PM
Quote from: 80 Vert on June 14, 2010, 09:56:08 PM
Yep thats exactly what the painter said may happen if I don't seam weld it, did that on the Vento so don't really know why I was thinking differently on this one  ???
Don't need crap like that once she's painted.

it's a 'she' because of the trouble it causes! ;D don't they all ::)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on June 14, 2010, 10:21:40 PM
Go Alaskan Green - very cool colour. Couldn't find any good pictures in the 30 seconds I dedicated to tracking one down.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 16, 2010, 08:10:44 PM
Welded the roof back on tonight, off to the painters tomorow for a jam job.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 19, 2010, 03:12:54 PM
Off it went on thursday, the guy has already made a start on it which is good to see.
One of the doors has had an el bodgo american repair on it so there's a bit more work for him to straighten that out.
I suspect he'll have it for a couple of weeks maybe and then I'll be onto the interior stuff trying to figure out how to make/change the headliner and rear interior bits come together.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0075-1.jpg&hash=5237c6e3b6effac0e74a538b72340cb11d379a3c)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on June 19, 2010, 04:04:07 PM
The metalworks done?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 19, 2010, 04:07:36 PM
Yup all done and dusted, on with interior and drive train.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on June 20, 2010, 12:08:58 AM
sheeesh no flies on you!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RevHappy on June 20, 2010, 12:14:26 PM
that things on fire, your getting though everything so fast
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 20, 2010, 02:25:25 PM
Fire? where's the fire  ;D
Didn't think I was going that quick, only having the one project on the go makes all the difference besides I loose interest if things take too long.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 24, 2010, 09:09:44 PM
Was at the painters today pulling some parts out, lots of progress been made with both rear 1/4'rs and upper roof line pretty much done waiting on primer.
Sills are next and then the boot lid, should have it back in a week or so.
Its looking so much better already, can't wait to get it back.

A friend of mine recently bought a spray booth/ bake oven so it looks like I can get back into doing some car painting again and will most likely paint this car myself  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 29, 2010, 05:19:34 PM
A month or so ago I ordered some Skoda Octavia mirrors from the UK as I'm not a great fan of the ugly big NZ spec mirrors and the small Jap ones are no better.
Unfortunately the seller was a right pain to deal with and had to actually do a paypal dispute on him in the end to get him to respond after paying him  >:(
Good news is the mirrors did turn up but as expected they don't anywhere near fit the MK4 door, easy answer is modify them  :laugh:

Cut up a set of stubby's for the base/mounting plate and plastic welded that onto the Skoda mirror for a nice fit on the MK4 door, thin coat of filler to smooth things out to be followed by some primer and texture coat for that OEM look.
Will paint the housings body colour with the rest of the car.  :)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0064-2.jpg&hash=ee4af0730bca816476369a50f5a3ae6657391297)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0065-2.jpg&hash=1a1461460b32d2e19c17fa18848a4b3847e4125a)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on June 29, 2010, 05:25:48 PM
Hmm, interesting. I was having vague thoughts about trying to get some auto folding mirrors with indicators in them for mine.
Now I know it's possible at least :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 29, 2010, 05:28:46 PM
At least on your car they would bolt straight on Rob, not so on a MK4 unfortunately.
The mirrors are the same as 9N2/3 Polo but the base plates are completely different.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on June 29, 2010, 05:40:00 PM
I'm not sure they would - they are from a Mk2 Octavia aren't they?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 29, 2010, 06:15:29 PM
Good point Rob, these are off an 08 model.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on July 04, 2010, 03:50:36 PM
With the car back from the panel man the headache of working out what to do with the interior was looming large. John and I had talked about this quite a few times as being the fiddliest part of the project and I for one was not looking forward to mucking around with plastics and trim. Fitting and refitting. Etc, etc. Thankfully John had a pretty good idea of what to do.

But there's no avoiding it and after a quick vacuum of the interior paint dust we charged into it................. by fitting the mirrors!  :D Here's a few pics of the car as it was first thing in the morning and half an hour later with the mirrors trial fitted.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05159.jpg&hash=c60a418a28409801d6b4394bde87e6723b12e58f)

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05157.jpg&hash=b58e316c2b0ee986c7571d99fbce3101c10b1fc7)

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05165.jpg&hash=f64b82b8b121e464e566a86f60f9bebec71d9a4b)

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05164.jpg&hash=f9ccbe5b130feb61cbd82c258036c162a3eabd4d)

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05163.jpg&hash=8e345e095758c82441c16328f73feec1a10c0a45)

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05166.jpg&hash=f9b1f7793707592ae790c85ef262cbf9432b6139)

After that warm up John went and collected a bunch of the interior parts and we got into the real work. First thing was the R32 rear interior quarter panel trim which was carefully trimmed at the back to fit the new rear window design. That was a bit of a mission as the leather on the panel is glued on some with some funky shiz that takes patience and a sharp blade to slowly peel back without ruining it.

We then fitted the parcel shelf (that I managed to break a clip on, grrrrr  >:( - Simon can you get the clips separately?), the C pillar trim and the rear seat to check the fit. Pretty much everything clipped into place with a bit more trimming of the quarter panel trim as you can see here.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05170.jpg&hash=094449dff48d4122ee5c7c228175db5a28bff525)

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05169.jpg&hash=076e45c2d41016afa2e15a2011c05d679aaabfcc)

That does leave a gap to the window as you can see - the plan is to plastic weld and extend the C pillar trim to meet the window glass as so you can see from my technical design drawing below  :D It will obviously be retrimmed when this has been completed. (The headlining will also get a similar treatment later)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05168-1.jpg&hash=f5965f2c33c6e3c61edf3fcf1d7f9e67b4ad10bc)

That also left a gap between the C pillar trim and the parcel shelf where the seatbelt comes through from the boot. After a bit of thought we cut down the Bora plastic trim and fitted just the top part to fill this gap. This will later be trimmed to match the parcel shelf but you get the idea here on the drivers side.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05178.jpg&hash=1b57f76c2b9d67918077bac2704c4bc60b030e81)

And a few shots of the final test fit for the day - gives a good idea of how the interior of the coupe will feel when finished.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05176.jpg&hash=f67dd4bbe370d80289c34de183554cf16c82ef84)

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05175.jpg&hash=3154b26aa03a199153049c49f47fd6cbfcb12bb4)

Oh, and a random shot of the custom "Euro" plate recess  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05179.jpg&hash=52fed790d6cad58d4c262b02076b9eb9f3fb8d1d)

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: JDVW on July 04, 2010, 04:54:19 PM
 :o Looking good! get those steelies widened though  :laugh:
On another note is that a TA22 in the background? and whos is it?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on July 04, 2010, 04:58:35 PM
Hhahaa, those steelies won't even fit soon! Yep that's a mate of mine's TA22 (with 3T-GTEU T3/T4 setup) John's doing a bit of work on it for him.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VeeDub on July 04, 2010, 05:00:39 PM
Looking bloody great boys! I really like that bootlid..
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: JDVW on July 04, 2010, 05:03:21 PM
Gotta love ta22's.

Whens the car getting painted? cant wait to see this thing going!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 04, 2010, 05:17:34 PM
Paint is some months off yet, now that the primer is on I'll wait a month or so to let it all shrink/cure and then 180 grit block it and re-prime to cure again for 3-4 weeks before I start wet sanding.
A friend down the road just bought a spray booth so hopefully he'll have that up and running by that time so that I can paint it myself this time.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on July 04, 2010, 05:36:31 PM
Quote from: 80 Vert on July 04, 2010, 05:17:34 PM
Paint is some months off yet, now that the primer is on I'll wait a month or so to let it all shrink/cure and then 180 grit block it and re-prime to cure again for 3-4 weeks before I start wet sanding.
A friend down the road just bought a spray booth so hopefully he'll have that up and running by that time so that I can paint it myself this time.

Have you painted a car before John?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 04, 2010, 05:39:18 PM
Yeah I have, quite a few of them actualy as one of Dads buildings had a paint booth/bake oven in it but that got sold and removed quite some years ago and kinda wish I'd bought it off him back then but thats too late now  :(
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 10, 2010, 03:36:13 PM
Todays task was to re-seal all the joins that were welded on, wire wheeled the bottoms of the sills/floors and inner wheel arches to get them nice and clean to be able to apply lots of new sealer to keep water out and stop it rusting my new baby
Once all that is dry I'll shoot some rust preventative in there for a helping hand.
Its a job I realy hate, getting all that sticky crap on your fingers and on anything else you happen to touch.
Finished off by stone guarding the sills and blending it into the factory finish as best I could, will have R32 side skirts going on anyway so none of it will realy be seen.

The painter was nice enough to cover my suspension and everything under the car in primer overspray  so thats another clean up job to do, just don't understand how these guys hve no pride in what they do I mean how difficult is is to wrap some paper around those things?  >:(
I did get some seals and actuators off a Sharan during the week for the pop out idea so the coming weeks will either see it working or me giving up and going with fixed windows  :D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0066-1.jpg&hash=eb7220b8cc60c61e89930161f098c661eca386f4)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on July 10, 2010, 06:28:19 PM
man this things gonna be plush!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on July 12, 2010, 07:31:12 AM
I think John that to most painters its just another car. If you want them to be really careful not to get over spray over the undersides you will have to say this is a show car and I really want you too spend the time to cover everything.
Nobody will care about your car as much as you do unless you make them.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 12, 2010, 09:26:11 AM
Yep that pretty much sums it up Jem, thats why I try and do everything myself.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 18, 2010, 11:48:37 AM
How to make the rear windows into pop outs? thats been the burning question the last couple of weeks so I thought a trip to AA wreckers to have a poke around to see what cars have opening side windows might be a good idea.

Kevin at AA is great to deal with, pretty much all they had was a Pugeot GTI and a couple of Sharans and it became apparent that the Sharan seals and acuators were the way to go and it keeps it VAG.
Funny enough talking to Kevin he said that one of those vans the guy drove it in to their yard, handed them the keys and walked away!  ;D He was fed up with the constant repairs it needed and wanted nothing more to do with it  :laugh:
Anyways I came away with 2 sets of seals, rear glass (for the hinges) and the actuators. First thing was to make the seals fit the Bora body, cut and glue sections together to make the right shape thats mainly the reason I needed 2 seals to make 1 making up what you see below
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0060-1-1.jpg&hash=2cdcdd6dc3d6091e130007d320d6ddf6f255262d)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0061-3.jpg&hash=846d656009ca9a45d3deaa6e37bba370e72aa294)
It becme obvious that the silly little factory B pillar piece needed to be cut away to provide room for the window hinge, cut cut cut away  :laugh:
With the pillar section cut out the frame needed to be modified top and bottom and a filler strip added.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0062-2.jpg&hash=ceb69383362fe74ee9043d8954e4fd99b47729ad)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0063-2.jpg&hash=73128a59d8d8a92b6f9a3688a0410a3bc162e665)
Had to smash the Sharan glass to get the guide cannel off to be able tho use that, not quite the right shape so the shrinker comes in handy again.
Cut it to length and used the door to hold it in position, looks like a factory deal now so thats what we're looking for.
Had to cut the hinge points off and new ones need to be made. They seem to be made from some sort of spring steel and I thought maybe BBQ tools may be made from a simmilar material, since we don't have any for me to cut up I'll go have a look at Mitre10 today to see what they have.  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0064-3.jpg&hash=5ab1ffd040952a152eb0fb928266321082b05b6e)





Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on July 18, 2010, 12:55:21 PM
This just keeps getting better, can't wait to see more
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: deedub on July 18, 2010, 01:05:27 PM
I love it! The one and only 4 motion R32 Turbo Jetta coupe, complete with pop out windows sprung with high quality BBQ tool hinge points  :laugh:

It's incredible the stuff that you can fabricate. And it all looks so factory !
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SteveC on July 18, 2010, 01:05:56 PM
depending on the size/thickness you need, good quality paint scrapers may be the thing
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 18, 2010, 02:52:11 PM
Thanks guys, yussss Mitre10 comes through!
BBQ tools were no good, too many holes  :laugh: so I bought a plastering trowel!  ;D
Nice flat piece of spring steel to cut my hinges out of, once those glass guides are mounted I'm going to make some mock windows out of plywood with ribs screwed on to keep the right shape in order to test the actuators and seals.
Glasshape can then use those as patterns to make the windows, getting quite exiting with the prospect of actual windows being made in the very near future  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 20, 2010, 08:26:11 PM
Well the plastering trouwel sucked, made from high carbon steel not spring steel  >:(
Just broke in half when I tried to bend it, as it turns out I have a whole roll of spring steel at work  :laugh: so I'm sorted now.
Weekend will be interesting.................
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on July 20, 2010, 10:37:14 PM
You want the same stuff that those bloody mk2 exhaust 'C' clamps are mad out of, they have some bloody spring in them >:(
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on July 20, 2010, 11:05:23 PM
Quote from: SOFTLAD on July 20, 2010, 10:37:14 PM
bloody mk2 exhaust 'C' clamps

They are not popular with me... have always been a nightmare!

Thankfully I no longer own any :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on July 24, 2010, 09:52:36 PM
I went out to give John a hand today - he'll probably have a bit to add to this but here's my take on the days activities. First thing that happened was the camera battery died so all pics are iPhone, but anyway.....

I was pretty impressed with the work done on the b pillar to integrate the Sharan pop out metal work and seals. So the mission was to make the window mould. Faaaark me if the devil isn't in the detail on things like this. Started out with a cardboard template (upside down here)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FPicture005.jpg&hash=ece802e5ae822f65b62004dcdc804a55c9a4bdf0)

Then transferred that onto 4mm plywood
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FPicture002.jpg&hash=42a1aa7b6b817527f0c206f182183a91c13223ff)

Then started cutting stringers using the door frame as a template for the curve. It actually got a lot more complex than the below but I didn't get a pic of the finished product - maybe John can grab on during the week. But here's the vertical stringers in place and some curve starting to form on the ply.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FPicture010.jpg&hash=9e426af7735f9b2a9e992ebef4ebab1521803805)

The question is how perfect this mould has to be for the glass guys? Something we agonised over - it's pretty straight forward to get the initial part of the job done but as you start tweaking the curves and making it fit perfectly the headache starts setting in. Aaaargh, Panadol please!  :D

But in the end it started coming together well and the fit and shape is pretty decent, maybe a few more tweaks but here's the current finished product. Funny to think that took all day.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FPicture003.jpg&hash=fcd3249e5f76ed1d629cbdb8bef25c181cbf39d2)

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FPicture008.jpg&hash=e99de7ad7e8f31173bd43e091556096ba02bebc6)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SteveC on July 25, 2010, 09:36:44 AM
looks like it fits really well, but have you made allowance for the fact that the glass would be laid up on the outside of this mold?  that might affect the fit inside the frame, or is it so close that it doesn't matter?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 25, 2010, 09:45:47 AM
Thanks for lending a hand Phil, its one of those jobs that requires more than one pair of hands  :laugh:
Looking back it would have been much easier to use thicker more sturdy ply but that means it wouldn't fit into the front guide which would have posed a whole new set of problems.

Making these fit the body well was much harder than I thought it would be, bit of a compound curve towards the back which the wood doesn't seem to like doing.
Funny how it took all morning and part of the afternoon to make one side and yet the other one only took a couple of hours  :)
At least it proves the idea has some merit and the hinge works so its just down to fitting the acutator.
I'll get the glass guys to come and have a look at it to make sure I'm on the right track with these templates before the glass gets made.
I did speak to them briefly about what they needed and by the sounds of it they just need my template for the shape and curvature but time will tell really.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SteveC on July 25, 2010, 02:41:48 PM
if you had problems with a compound curve with 4mm, thicker ply would have made the job harder
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 02, 2010, 05:35:44 PM
Saturday wasn't a good day on the car  :( Started on lengthening the C pillar trims and managed to completely damn one of them with the plastic welder, still don't quite know how but anyways its rubbish now.
Moved on to doing the headliner as that also needs extending to meet the side windows, that didn't go well either so pretty much a whole days work down the toilet!  >:(
Kept thinking about the headliner on Sunday and thought a hot melt glue gun might work so I went and bought one, of course once I had the glue gun I just had to go and try it  ;D more time at work  :D
Made a template, cut the pieces out of a donor headliner and glued them together which worked out great.
Filled the join with extra foam and sanded it smooth on the side that you see, for a bit of added strength I glued some cotton type material over the whole area (the black pieces) so none of the join is visible and is now ready for its top material which I still need to go and buy.
The fit is awesome, sits nicely into its guides on the pop out seals and with the B trims and rear interior trims in things are looking up.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0065-3.jpg&hash=40fd0bbb1c79ceb86046227654da4cc5153dc633)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0067-3.jpg&hash=42b43943c67dc762b191971bec557b1e96405764)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0066-2.jpg&hash=eed8236ae3050be13b406692e1ff4eae3f9d6fee)
What to do about the ruined C trim...............????
Remembered AA Wreckers had a Bora a while back so stopped in there today on my way back and that particular car was waiting to be collected for scrap!!  :o
Pulled the trims out and noticed it had electric memory seats in it!!!!! SCORE!!  ;D
Came away with the seats and trims for 50 bucks, so a HUGE thanks to AA Wreckers  ;D
Being that my factory leather seats are electric and don't have release levers to get in the back I'll use one of the memory positions to roll the seats forward meaning with the set from AA I can make my passenger seat memory operated also.
Whats the chances of finding a set of those in NZ?  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on August 02, 2010, 09:17:33 PM
Nice find!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 03, 2010, 10:08:47 PM
Need your ideas people, what should I do with the interior colors?
Keep headliner and A, B, C pillars off white/cream as per factory or go with an all black interior?
Remember my carpets and seats are black already.

Kinda partial to the contrast of the cream/black but also like the idea of an all black look.
Only thing being is that I'll need to color all the lights, mirror, sunvisors etc.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on August 03, 2010, 10:17:52 PM
You can get all the lights/handles etc OEM in dark grey/black ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 03, 2010, 10:22:47 PM
I know, seems the 05 Jetta in the US was all black, but...........which way to go..........??
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on August 03, 2010, 10:27:41 PM
Quote from: 80 Vert on August 03, 2010, 10:22:47 PM
I know, seems the 05 Jetta in the US was all black, but...........which way to go..........??

Black gets my vote... love it
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on August 03, 2010, 11:32:48 PM
i would go black aswell, after a couple months, you'll find that the taller people that sit in your car will have left their marks on the roof lining
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on August 04, 2010, 08:04:50 AM
All black John nice and clean one colour, is the dash two tone? What about the doors as this would sway my decision  :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 04, 2010, 08:10:23 AM
Just a all black dash and door cards this time Chris, I had to buy a whole other car to be able to do the 2 tone on yours  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on August 04, 2010, 10:56:25 AM
Hope your A/C works REAL good.  It'll get toasty hot in there in summer!  But it'll look great!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Omes on August 04, 2010, 01:07:21 PM
Defo all black John, it's what I got in the MK2 and wouldnt want in any other way. Feels that bit more classy.

Just sit in the new MKV GTI with the all black pillars and roof too and you will be convinced as to why  ;D

That silver Bora at AA's also had the fully 'close off' type dash vents and sport clocks! Nice as, hope they didnt get the scrap too!  ::)  You were there at the right time to get those seats for a mere $50! what a steal.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 04, 2010, 03:52:25 PM
There was a lot of good stuff left on that Bora, pitty to chuck it all away.
It was a better deal than that Omes, rear trim, seats and perfect lower lip for $50  :laugh:
Looks like black is a popular choice, will have to start looking for black grab handles and related parts I think.
Also a visit to Reid & Twiname might be a good option to see what they have in the way of headliner material / colors.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on August 04, 2010, 04:56:32 PM
Yeah I vote all black too - will be keen to check out that head liner material place as I need to redo the headliner in the wagon.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 04, 2010, 05:01:35 PM
Maybe go see them on Saturday if they are open Filx?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 07, 2010, 06:32:57 PM
Pretty epic progress has been made on the windows and I have to say that I'm pretty stoked with how its all turned out.
C pillar trims are done, extended them and covered with some cloth to strengthen them a bit more.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05298.jpg&hash=0cc2cf31ef498916764d783073711e20dfc18253)
Been thinking about how to open and close the windows for a while now and right from the beginning I realised that the actuators would have to be remote mounted instead of right near the glass as is on a Sharan but how to do that...........?

Thought a weedeater flexicable was a good idea so went and got one but because of the thickness of it you can't have too sharp of a bend in it, would have worked ok but there had to be a better solution so kept looking.
My mate Paul sugested a handbrake cable and at first I thought he meant from a pushbike but then I realised a car one might do it.....................?  Good thing there's a pile of them lying around  ;D
Yep that was the magic solution, used the cable / outer conduit and housed all of that in some stainless tube which I then bent to the right shape for the car, cable moves free az  ;D
Made several thread adaptors to be able to use as much of the Sharan hardware and ended up with what you see below.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05291.jpg&hash=f700e3d9f09a30c9e2a316eb229f323afae6800e)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05292.jpg&hash=02b5dc5a990d7537d4f8d937c69b54313d5f69c1)
Getting the S/S tube bent and sitting in the right place was quite the task but eventually a couple of brackets got welded on to hold it under the rear parcel shelf with the actuator mounted a little further back.
Still playing with ideas on how to cover the mechanism on the inside of the car but a solution will present itself sooner or later
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05296.jpg&hash=30d7688725044090cca0c28486a9fb574ecd0e7f)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05297.jpg&hash=a34e98e10a9463749862ea0746788b7e99efd231)
After about 10 times taking it out and making minor changes we ended up with this following vid Phil insisted on taking  :laugh:
http://www.youtube.com/watch?v=75yUpIZ-CcI
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on August 07, 2010, 06:41:02 PM
NIce one!!!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on August 07, 2010, 06:58:23 PM
Saw it all working today when I droped in while JT was doing his pre-match warm up.
It works really smooth and the bits Vert has done with the interior trim is very impressive
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on August 08, 2010, 11:43:08 AM
its like one of Q's gadgets.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 09, 2010, 06:56:05 AM
It sounds funny :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Period_Correct_ on August 09, 2010, 07:09:53 AM
very nicely done, does the cable buckle when it opens the window?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 09, 2010, 07:59:18 AM
nope, cable stays nice and straight  :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 09, 2010, 09:44:03 AM
Now looks like the windows may be getting made in OZ, can get them done exactly the way I want with the compound curve and all.
They can also do the black dot matrix around the edge like VW does it instead of a solid black line.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: gti vr6 on August 12, 2010, 07:39:00 AM
Looking good, but wheres the gaffa tape and cable ties to hold it all together??

:-\ ;D :-\
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on August 12, 2010, 07:45:02 AM
Quote from: 80 Vert on August 09, 2010, 09:44:03 AM
Now looks like the windows may be getting made in OZ, can get them done exactly the way I want with the compound curve and all.
They can also do the black dot matrix around the edge like VW does it instead of a solid black line.

detail!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Turbo on August 12, 2010, 10:15:36 AM
very impressive build.

i couldn't even make those wooden window molds in a month let alone a day.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Bullseye on August 12, 2010, 11:53:56 AM
Quote from: Turbo on August 12, 2010, 10:15:36 AM
very impressive build.

i couldn't even make those wooden window molds in a month let alone a day.

John did it in 2.46 seconds  ;D.

Awesome progress guys; lookin forward to the next barby to drool
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Turbo on August 12, 2010, 12:02:19 PM
2.45 actually. ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 12, 2010, 08:44:52 PM
Cheers lads, pretty happy with progress.
Will spend saturday doing panel fit and gap the doors to begin painting prep, paint is still a while off as I still have to install the intercooler and do a custom bumper  ;D
I think I'll do another BBQ once the shell is painted  :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 13, 2010, 11:06:17 PM
Who's car?
My 2nd fuse box is held up by cable ties and going strong.

But back to verts supreme build :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 15, 2010, 03:26:36 PM
With no firm plan of what I was doing yesterday not much got done, besides I helped some dude fix his gearbox after he managed to completely strip one of the gearbox mount threads  ;)

Anyways, after faffin about with that I re-set the gaps on the doors which my painter had decided to mess with when they did the priming so at least now the doors can come off and back on without upsetting the gaps again mking things a lot easier to re assemble everything once the paint is done.
Mounted the bumper to start looking at doing another custom one to fit around the intercooler which will be here in the next 2-3 weeks.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05299.jpg&hash=cff2e5ac836543c53f2300e7daae68c3b59a6ab2)
For a bit of fun and to waste some more time I put one of the wheels on to get an idea of where they sit, even with a square ish tyre they could still do with a spacer to push them out flush- not bad for a 9" rim and goes to show that MK4's can swallow some decent width tyres.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05301.jpg&hash=6be0a861cc7c4efadecfdff027485e20a0151ea3)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05300.jpg&hash=095af43e6258f0a70ccf4c38e72df3d4bc3df8ef)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on August 15, 2010, 05:53:44 PM
Quote from: 80 Vert on August 15, 2010, 03:26:36 PM
..besides I helped some dude fix his gearbox after he managed to completely strip one of the gearbox mount threads  ;)

What kinda monkey would do that...... oh wait, I think I can see his car in the background of that first pic  :laugh:

Those wheels sit so damn well - perfect width/offset for people that like quite square sidewalls on their tyres. If you don't mind a mild stretch I think a 9.5" at around ET30 would be no problem.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on August 15, 2010, 06:29:28 PM
Leave the tyres square, stretch is for girls................. ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 20, 2010, 08:56:23 PM
Short runner intake comin up, just bought most of the stuff I need to make one off Vortex.
Laser cut head plate, 6 trumpets, throttle body flange, intake runner material and extra fuel rail if I need it.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCN3402.jpg&hash=20695b32f03a2fe074ff4fb761ba30a2b4db62d4)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCN3401.jpg&hash=c834199bfd837ca66f772d6c8fa22f0cfcdb4fc3)
Just have to cut runners to length, make intake plenum and weld it all together. Whoohoooo engine build to be started very soon!!  ;D

Found someone for the software also, using our existing tuneable Maestro7 we have in the Vento I can get a 630cc map for an R32 turbo using a 4" maf with a GT35 1.06AR.
Their car made 426 whp at 1 bar boost  ;D also using lowered comp pistons like mine but they also run Schrick cams.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on August 20, 2010, 10:57:39 PM
Quote from: 80 Vert on August 20, 2010, 08:56:23 PM
Their car made 426 whp at 1 bar boost  ;D also using lowered comp pistons like mine but they also run Schrick cams.

Try achieving that with 4 little 450cc cylinders!!  ;D ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 21, 2010, 12:59:25 PM
Its just too easy M.
Spend some money, hey presto.
People act like they think they are onto something but are they ???
I'm not trying to rain on any parades but I find the fabricating work Vert does himself to be more interesting that piecing together a high HP motor.
Don't get me wrong I like a few flash motor bits too, but its the guy making 800hp out of a 1.8t that is the only one treading new ground.
426 is just bolt on.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on August 21, 2010, 01:25:40 PM
My point was that the guy treading new ground will spend mega mega bucks to get to 800bhp, there are guys with VR6 "based" engines, all be it 24v head ones that are cracking off huge numbers without the mega bucks.

I could spend around $3-4k tomorrow and I am very confident I could produce 500bhp out of my old 12v VR6, but it doesn't really suit what I want from a MK2 Golf.  ;D ;D

Either way I am just on the wind up as just about my favourite engine of all time is the Ford YB and it is a 4 pot.  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 21, 2010, 01:29:37 PM
Aha  :)
You love those VR6s don't you M ;D

You would have to boost it tho eh?
What is a vr6 max revs?

It is good that this car is a 24v V6 and not another 1.8t ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Period_Correct_ on August 21, 2010, 04:12:34 PM
oooooh shiny ali bits... better get the tig out...  :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on August 21, 2010, 04:34:59 PM
Quote from: BB on August 21, 2010, 01:29:37 PM
Aha  :)
You love those VR6s don't you M ;D

You would have to boost it tho eh?
What is a vr6 max revs?

It is good that this car is a 24v V6 and not another 1.8t ;D

I do like the VR's yes but I am not so pig headed that I think it is the best engine in the world, unlike some people on this forum who have the "Whatever I have is the best" attitude....... I think we all know the type.

To me the noise is appealing, and having 2.8l in a small hatch, but I know they are only 25bhp or so up on an ABF. I do also enjoy the 180 and above spec 1.8T engines, but in 150bhp form they are a very boring power plant, with very little character or charm.

Boosted the VR's are monsters though and with the 24v heads they are plain silly with boost, and very strong to go with it. 1.8t will bend rods at 300ish bhp(some have been lucky above this  :D), VR6 have been as far as 600bhp on standard rods and pistons. Although yes they do have 2 extra rods to distribute the torque to.  ;D

But in the same vein, the Cosworth YB can do 600+bhp on standard crank, rods and block. It needs new pistons and a fair bit of head work but from 2000cc and 4 pots that's a stomping effort.

Anyway, I will stop ruining John's thread.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 21, 2010, 09:47:38 PM
With all this talk about VR6 engines lately ;D I started thinking about ripping the lump apart, besides it will take some of my focus off the drama I'm having finding a suitable manufacturer for my windows.
Like M I also like VR6's, 3.2L ones that is  ;D No substitute for cubes, but then I like V8's even more  :laugh:

Started out bolting the whole motor to the engine stand and was somewhat concerned at the sheer weight hanging off our el cheapo engine stand which I thought might just break in half but no such problem occurred  :D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0060-1-2.jpg&hash=842488869276869bb541bcee324e5c9023330d55)
Found the power steering pump to be broken from the accident but no other damage found.
Actually took quite a few hours to break that sucker down to a short block but I just took my time with it as I don't want to wreck anything.
The plastic inlet manifold is a work of art, shame it can't be used on this motor again. The throttle body also is Huuuuggge compared to a 1.8T one, no wonder I need a 4" MAF housing on this.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0061-4.jpg&hash=b9e3a4cbd5152031a1a4598aa18ac626407e8bb4)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0062-3.jpg&hash=46c47193b234b91595049e4615230b6a5c53a50f)
Some piccys of the R32 head, wouldn't have been many in NZ stripped down this far  ;D
Motor is super clean inside, still it should be at only 42,000km.
Next week will hopefully see the shortblock being stripped and go back together with the new slugs and rods  ;D Let the good times roll.............
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0063-3.jpg&hash=7c07838f98d8ac1bfe121c4891bbb855bbffbedf)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0064-4.jpg&hash=11017281b3b232c81eb0291112468417a93a4ca1)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SteveC on August 21, 2010, 10:36:01 PM
do I spot a K-G tailight?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 21, 2010, 10:43:13 PM
Yup  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on August 22, 2010, 12:05:52 AM
Looking at them pictures confirms my thoughts John, 24v head will not fit on 12v block, different stud pattern I am sure.

As you have them apart you should try!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: b0000st on August 22, 2010, 11:05:23 AM
On a separate note if anyone ever has issues with the secondary air system with regards to flow the channels below the exhaust ports block up solid with carbon and also the channels on the face of the head that are almost a figure of 8, had this issue with a V5 and have heard of it happening elsewhere too. Sorry to hijack but the pictures show the problem areas nicely.

Matt
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 22, 2010, 04:57:12 PM
I'll be getting rid of the whole air injection system and write it out of the MAP.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on August 22, 2010, 06:26:54 PM
Check out this guy's IM!  *drool*

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fwww.motorgeek.com%2Fgallery2%2Fd%2F95121-2%2FVR6StaggeredRunnerIntake3.jpg%3Fg2_view%3Dcore.DownloadItem%26amp%3Bg2_itemId%3D95121%26amp%3Bg2_serialNumber%3D2%26amp%3Bg2_fileName%3DVR6StaggeredRunnerIntake3.jpg&hash=bb22c04bb3f7c729040959a4f9b53da5844f4820)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 23, 2010, 09:06:45 AM
Is that air system one of those daft ideas that pump air into the exhaust manifold to fool a CO meter shoved up the bum to thinking it runs cleaner?
If so great that you are deleting it.

Thats how this world is, create more pollution and effort to try and hide some pollution.
  Reversal world rears its head again.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on August 23, 2010, 09:47:07 AM
Quote from: BB on August 23, 2010, 09:06:45 AM
Is that air system one of those daft ideas that pump air into the exhaust manifold to fool a CO meter shoved up the bum to thinking it runs cleaner?
If so great that you are deleting it.

Thats how this world is, create more pollution and effort to try and hide some pollution.
  Reversal world rears its head again.

It does seem quite pointless.
Mine's on the shelf in my garage.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on August 23, 2010, 12:01:47 PM
Quote from: BB on August 23, 2010, 09:06:45 AM
Is that air system one of those daft ideas that pump air into the exhaust manifold to fool a CO meter shoved up the bum to thinking it runs cleaner?
If so great that you are deleting it.

Thats how this world is, create more pollution and effort to try and hide some pollution.
  Reversal world rears its head again.

No the extra oxygen that is pumped in from cold helps heat the CAT up faster to get it to operating temps in order to clean the exhaust gas efficiently. That is the official reason.

Or if you are a cynic then yes it means it will pass emissions tests from stone cold as there is more oxygen in the exhaust stream.  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 28, 2010, 08:19:57 PM
The engine build came to an abrupt end last week when I found out that somehow I ordered the wrong pistons for the motor  :P
Still don't really know how I managed such an epic oversight and ordered 0.5mm oversize slugs but anyhow they don't fit in the hole so luckily the guys at Integrated Engineering are going to exchange them for me so the wrong set is on their way back to the US, frustrating but there ya go............

Had to quickly come up with a plan for this weekend so since the 24V is sold I thought I'd pull the lump out and start gutting the car so that I can begin doing some painting soon.
Since the windows are also up in the air I decided to paint the car in stages meaning I'll do the engine bay, wheel wells, interior and then get the whole thing back on its wheels before I paint the exterior.
Anyways this is where it all started 9am this morning  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05361.jpg&hash=f557b67f63a89589222e0854bdb5022243349490)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05363.jpg&hash=91208e33cf2b0ab34117f1e287ff0a2c474f0ee2)
By 10.30  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05364.jpg&hash=07f2757306dc88d07b45dfac0ba8f9ac35d01cf9)
Pulled the gearbox off the engine as I'll use this over the R32 one, reportedly quite a bit stronger than the R32 box which this car is gonna need.
After a nice lunch at the Cafe with NasTnas and Filx I got on with stripping the rest of the engine bay of all its clips, wiring, susp and basically anything that could be unbolted to make painting better and easier.
Can you say GUTTED  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0060-3.jpg&hash=b9515c4667d0c6c1e25c5dc4ba95d89fa3c98f78)
Now where does all this crap go.......................?
Just have to rip out the rear subframe & gas tank and the shell will be just that.  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0061-5.jpg&hash=f253ba56e639668c71a23c0816e2c2ba083c7e27)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on August 30, 2010, 11:16:27 AM
Im enjoying watching the process John.
Where are you looking to getting the rear windows done at the moment?

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 30, 2010, 06:34:28 PM
I sent one of the patterns off overseas yesterday so we'll see what they can make of them.
Seems that I complicated things hugely by doing the pop out thing  :laugh: but this new company seems confident they can get it right.
There is actualy a bunch of places that can do it but they are only interested in container loads of windows  ::)

Thanks to Filx the new turbo has been ordered, sooner than I wanted but they are not on sale every day  :laugh: GT3582R 1.06AR with a Vbanded exhaust.
So yeah, thanks a bunch Phil the budget takes another hit  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on August 30, 2010, 06:53:42 PM
Hi John, i am also enjoying this build process, looks great.

The only thing that concerns me just a bit, is getting the heat out of the engine bay.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 30, 2010, 06:56:41 PM
Yeah I don't know what to do about that yet, have triple core ali radiator coming and also going to run an external oil cooler.
Thing is with a road car you'll only be "on" it for seconds at a time but it will still make lots of heat though.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on August 30, 2010, 08:49:21 PM
Quote from: 80 Vert on August 30, 2010, 06:34:28 PM
Thanks to Filx the new turbo has been ordered, sooner than I wanted but they are not on sale every day  :laugh: GT3582R 1.06AR with a Vbanded exhaust.
So yeah, thanks a bunch Phil the budget takes another hit  :laugh:

Hahhaa, most important part of the car! Boooooost  ;D Many thanks to Paul at NZ Performance, really good guy to deal with.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fwww.nzperformance.co.nz%2Fstore%2Fimages%2Fuploads%2FNew%2520images%2FGT714568-1%2520GT3582R.jpg&hash=213c40023f37a0c7a7df1335ce8f64bfd8bfbb40)

Actually been a bit of a tough decision - we spent a lot of time investigating and reading up on as many options as possible. However the R32 turbo market obviously isn't as big as that for the 1.8T and there seems to be many variations on the (relatively) small amount of conversions so there's few really consistent themes and results to help you make a call. In the end it looks like the "big" 3582R will deliver a good spool up and huge mid range power - with enough head room to lean on it a bit harder later on if John gets bored.  :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 30, 2010, 10:03:59 PM
I very much doubt the power of this car will be boring....................... :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 31, 2010, 08:50:51 PM
Stripped the rest of the car tonight, mounted the body on a dolly I made years ago for my Beetle Convertible.
Just as well I kept it all those years, came in handy.
Going to try and hot waterblast the engine bay and wheel wells in the weekend and get rid of all the old wax so that the fun part of sanding can begin  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0060-1-3.jpg&hash=8023df1a03fd185d0b20ac39f92e17e93a74447a)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 01, 2010, 03:53:28 PM
It seems Phil wasn't kidding when he said he ordered my turbo  ;D Just a little fella  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0061-6.jpg&hash=5e12fadef3beaa3ea6a3eddd641b4571215871b0)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Simon* on September 01, 2010, 04:01:28 PM
Faaaaaaaaark look what it did to that coke can just by looking at it!!!


That's a healthy sized snail ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 01, 2010, 04:06:43 PM
LOL, the can is crumbling just at the sight of it  :laugh:
Back to work..................I was busy until this showed up  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VeeDub on September 01, 2010, 04:08:07 PM
 :o  :o  :o  >:D  >:D  >:D  ;D  ;D  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: JDVW on September 01, 2010, 04:31:11 PM
 :o
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SteveC on September 01, 2010, 05:09:30 PM
VW or Kenworth?   :o
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on September 01, 2010, 05:46:03 PM
And that's considered a "medium" size for a nice responsive turbo on 3L+ engines. I was looking at a 4088 (another frame size larger) as a good option but various factors ruled it out.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on September 01, 2010, 07:51:00 PM
Show off............................. ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 01, 2010, 08:00:58 PM
 :laugh:
http://www.youtube.com/watch?v=oqMfPxLYSYk&p=9DE60ECD7871F19F&playnext=1&index=43
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 04, 2010, 05:46:10 PM
Time to deal with the dirty stuff today, de-wax the engine bay and clean the wheel wells.
Chemicals sure are handy in times like these, sprayed Ripper on everything and let it soak for a while then hit it with a paint brush to dissolve most of the wax.

Once most of that was coming loose I hit it with a steamcleaner, soon as I got going it blew a hose  >:( Fixed that and 5 min later the hose blew again  >:(
Made a new hose up this time and got going again, that stuff just melts away with hot water  ;D
Got the whole thing clean as a whistle but it took most of the morning to get that far, drained all the water out of it and dried most of what I could get at.

Back inside I started the soul destroying sanding of the parts to be painted, MAN I hate sanding!  :D
Tried scuffing it with scotch pads but thats no good so back to the trusted wet & dry paper.
Got the whole engine bay done and interior up to the front seat mounts, no pics this time as it seems I have exceeded my allotted bandwidth on the photobucket account  ???
Going to have a go at building a makeshift spraybooth during the week and if all goes well I hope to be doing some painting next weekend  ;D






Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on September 04, 2010, 06:21:18 PM
Quote from: 80 Vert on September 04, 2010, 05:46:10 PM
no pics this time as it seems I have exceeded my allotted bandwidth on the photobucket account  ???

45,000ish views on VWVortex will do that!  :laugh: Sorry I wasn't there to lend a hand but next week for sure!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: deedub on September 07, 2010, 02:01:46 PM
I use picasa web albums, I don't think they have a bandwidth limit.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on September 11, 2010, 08:28:58 PM
John had been giving me the wind up during the week about some cunning plan for the first phase of painting (engine bay, interior, boot area, wheel arches.

I headed out there early this morning to see what he was on about. Had to laugh when I entered the shop to see a gazebo frame up by the roller door and a big roll of plastic sheeting on the floor.  :laugh: But after going over the plan with him I was thinking, "yep, this should work!"

Soooo here's how you make a DIY paint booth  :D

Erect Gazebo frame and throw a layer of plastic over the top. Attach with copious amounts of packaging tape in strategic areas.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05370.jpg&hash=c8be93df6b39e7d582065a6cfa3502135084e0ba)

Then start on the sides and wrap that sucker, ensuring she's thoroughly taped together to seal it off.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05370.jpg&hash=c8be93df6b39e7d582065a6cfa3502135084e0ba)

Roll out a final sheet for the floor and after an hour or so you should have something like this
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05372.jpg&hash=c8dbf3e173a2e3344d846642fac058fe5e8100a0)

Run the air lines out to the regulator mounted in the corner.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05373.jpg&hash=726c40da9dac02ad008c86c59f24322a8b77cf20)

Layout some cardboard for the floor and tape it all together
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05375.jpg&hash=1e4161be34158fa00e49daf20e300ead401e42ee)

Then add car  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05377.jpg&hash=0d283550e9d5733e0c84923a2e57f6d1b5026f3e)

Finally install vacuum fan and custom air outlet under the roller door
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05379.jpg&hash=e0d4541070f78e144983b5bba8bf1a2e656e4ec0)

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05381.jpg&hash=108da5af0b5b05c7bfe71e2f0481ab8bac71d749)

Seal the booth and start painting
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05386.jpg&hash=f981e6f305243406f00d03ef2d75fd55aa97d78e)

Pwnd! hahhaaaaaa
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05382.jpg&hash=a3129e5860a35aa62ffe55ded8745386221c9f2d)

Then on to the co-ordinated effort of painting the car, keepng lights in the right place, keeping the gun topped up, etc. John did a great job flowing on the R32 blue and copious amounts of clear. OK the gazebo didn't work perfectly, but was good enough for the moment and we'll refine the design for the next phase! Here's a few snaps of the results.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05395.jpg&hash=c83b2e4db0c5b318806c2ab9314c9d2d2425ec27)

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05394.jpg&hash=8841a57fc624ec5af4d3b3d8a7c4621a29bd154e)

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05393.jpg&hash=4a5c5a9f88f4566695e60ffb59a147e32b1cea94)

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05391.jpg&hash=899474bdb5681fa782f16508b1df0d60185bc081)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on September 11, 2010, 08:57:44 PM
Oh yes! Love that colour and I'm looking forward to seeing the whole car.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 11, 2010, 09:25:57 PM
Thanks again Phil for the help today, really is a 2 man job.
Biggest problem with the "booth" as is now is that the paint over spray very quickly fills up the air making it very very difficult to see in there.

The fan we had was only pulling air out as I thought all the spray gun air would kinda balance things but that wasn't the case, the fan caused the sides of the plastic to pull inwards far too much so phase 2 will be to paint the insides of the bonnet, boot lid and paint some smaller pieces.
For this paint run we'll construct a frame with a filter in it so that the fan can draw air through the whole thing taking the paint overspray outside, this way there's fresh air coming in and overspray going out.

Perfectly logical now that I think about it and can see why it didn't go 100% today, still next time it should improve again, takes time to get these things right  ;D
But..........................I'm still pretty fricken stoked with how today turned out!!  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on September 12, 2010, 12:25:01 AM
nice work guys the colour looks fantastic,and nice No8 styles on the booth 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on September 12, 2010, 10:29:45 PM
Awesome stuff there! that colour I will always Love!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: dubstar on September 13, 2010, 11:38:34 AM
Looking good.  Great job on the booth too.

I once had a regular customer at Ripco who was a backyard carpainter.  He set up his spray booth in a carport.  Sealed off the sides and floor with plastic, but left the roof as just corrugated iron (new carport, so not very dusty).  Unfortunately, there was an ants nest in the roof, so when he sprayed the car the solvent killed all the ants and they dropped down into the paint.  He ended up with a purple paint job with a black flake.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on September 13, 2010, 12:50:19 PM
Quote from: dubstar on September 13, 2010, 11:38:34 AM
Looking good.  Great job on the booth too.

I once had a regular customer at Ripco who was a backyard carpainter.  He set up his spray booth in a carport.  Sealed off the sides and floor with plastic, but left the roof as just corrugated iron (new carport, so not very dusty).  Unfortunately, there was an ants nest in the roof, so when he sprayed the car the solvent killed all the ants and they dropped down into the paint.  He ended up with a purple paint job with a black flake.

Bahaha!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on September 13, 2010, 06:57:24 PM
Quote from: dubstar on September 13, 2010, 11:38:34 AM
Looking good.  Great job on the booth too.

I once had a regular customer at Ripco who was a backyard carpainter.  He set up his spray booth in a carport.  Sealed off the sides and floor with plastic, but left the roof as just corrugated iron (new carport, so not very dusty).  Unfortunately, there was an ants nest in the roof, so when he sprayed the car the solvent killed all the ants and they dropped down into the paint.  He ended up with a purple paint job with a black flake.

:o NOW THAT'S CUSTOM!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 14, 2010, 08:20:30 PM
Looks like the engine build is back on, new pistons arrived today!  :laugh:
They even fit in the block this time round, looking forward to building it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 16, 2010, 09:50:49 PM
Santa came again yesterday with gifts for the next stage of the build, should have most of whats needed now to complete the car bar smaller bits and pieces.
One thing that was on the cards to get upgraded were the brakes, a heavy car with lots of power needs good brakes but I didn't quite realise how big these are  :laugh:
Paul and I both burst out laughing as I pulled a caliper out of its box  ;D This picture explains it very well
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on September 16, 2010, 09:53:04 PM
Thats a kool case holder but where is the caliper?  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: JDVW on September 16, 2010, 09:58:55 PM
inside that case  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on September 16, 2010, 10:51:20 PM
Those plastic caliper covers off TradeMe are getting really realistic, that almost looks like the real thing ;) ;) :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on September 17, 2010, 07:45:45 AM
Quote from: 80 Vert on September 16, 2010, 09:50:49 PM
Santa came again yesterday with gifts for the next stage of the build, should have most of whats needed now to complete the car bar smaller bits and pieces.
One thing that was on the cards to get upgraded were the brakes, a heavy car with lots of power needs good brakes but I didn't quite realise how big these are  :laugh:
Paul and I both burst out laughing as I pulled a caliper out of its box  ;D This picture explains it very well


Ive never seen blue Porsche calipers before John. Have they been repainted?

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on September 17, 2010, 07:46:31 AM
Quote from: Golfboy666GTI on September 17, 2010, 07:45:45 AM
Ive never seen blue Porsche calipers before John. Have they been repainted?



Cayenne?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 17, 2010, 07:48:56 AM
Yup, 6 pot Cayenne   :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on September 17, 2010, 07:49:06 AM
Holy moly - how wide are they? Going to test out that wheel fitment for sure!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on September 17, 2010, 09:13:07 AM
Jeez its gona be fast but those are BIG, you recon you will be able to fit them?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on September 17, 2010, 11:16:34 AM
Quote from: ballin on September 17, 2010, 07:46:31 AM
Cayenne?

Oh, OK, I guess a Cayenne has to be good for something . . .

John, what size discs are you using?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on September 17, 2010, 12:38:58 PM
its business time! 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on September 17, 2010, 01:26:47 PM
Holy Mackeral !! Why didn't you go for bigger brakes?  :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on September 17, 2010, 01:28:18 PM
John it seems you might be um......over compensating?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 17, 2010, 01:53:21 PM
Quote from: Golfboy666GTI on September 17, 2010, 11:16:34 AM
Oh, OK, I guess a Cayenne has to be good for something . . .

John, what size discs are you using?


The discs are 14.1" (360mm) so I figure that will stop when required  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Simon* on September 17, 2010, 01:53:30 PM
Quote from: tyz-fly on September 17, 2010, 01:28:18 PM
John it seems you might be um......over compensating?
LOL

You're gonna need more powahs to lug those brakes around!  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 17, 2010, 01:55:14 PM
Hahaaa, surprisingly they are no heavier than the stock stoppers that came off the R32 not that they are little by any means.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Simon* on September 17, 2010, 02:06:28 PM
Slots, holes and vents makes them lighter again too no? ;)


Talking cars here BTW

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 18, 2010, 06:11:36 PM
Been cracking on with putting the car together, I try and do at least an hour each day before I go home and as a result lots has been done.
Cleaning parts as I go before they get installed takes a bit of time but its beginning to look like a new car.

Main objective is to get stuff off the floor and back into the shell as there's parts literally everywhere right now and its becoming quite difficult to figure out exactly where it all is.
So far the wire harness is in, brake lines, rear subframe, tank, front subframe / susp, pedals, dash bar and lots of little things are done.

Its really enjoyable working on it because everything is nice and new unlike restoring a rooted old Beetle where you have to fix/rebuild everything that goes back into it.  ;D
I know these threads are worthless without pix so here's a few from this past week.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0078-1.jpg&hash=3bb97bbd7d13368cf425785e28210323ff1906a6)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0077-1.jpg&hash=10025c42a2179a194bf2a5d16e6b3bad6c06ad9c)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0076-1.jpg&hash=45e5de7a479d92580a654b6fb8c0f75d1227a659)
Since the pistons arrived and the weather was s**te I thought it would be a good day for engine building, soooooo answerphone on to deal with interuptions I got on with it.
Stripped the old pistons and rods from the block and cleaned up the cylinders with a light hone, cleaned up the rod bearing as these had virtualy no visible wear on them so they were fine to re use.
Checked the ring gap in the bores but as predicted they were fine so with complete piston/rod assemblies done I installed them one by one in the block.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0079-1.jpg&hash=3e9df8a03dd1549495550b5be52dd6a2d3e351e0)
Checked side clearance to the crank to make sure all is ok and torqued them down.
These high performance parts these days are pretty awesome, very nice machining and spot on factory specs.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0080-1.jpg&hash=919095c1243ac868b1d62faab425a1c59560efac)
Slugs and rods in  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0081.jpg&hash=aab33a4ac6cef1cf05d6a0a4fa833535f871d678)
Final part of the day I installed the raceware head stud kit, studs fitted fine however some of the nuts didn't fit well on the studs so I ran a tap through the ones that were tight.
Seemed to be some sort of coating residue in the threads, typical american imperial nuts while the block end of the stud is metric  :laugh:
Head will have to wait, more painting next week!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0082.jpg&hash=f1e04be1923a47f4b5c2a554beeaadd239c10a21)















Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GLIDN on September 18, 2010, 08:25:49 PM
Why not paint the block while it was apart?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 18, 2010, 08:39:35 PM
Doesn't need it, will degrease it when its back together. It still looks brand new under all the crap thats on it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on September 19, 2010, 09:13:51 PM
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi29.photobucket.com%2Falbums%2Fc284%2Fchrisbed%2Fn2ih5s.jpg&hash=aafcb46f6315f6f6076f6b73a8a62ff27300f3e6)

they should fit over with the LM's John, if that picture is anything to go by  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 19, 2010, 09:24:50 PM
Yup thats them alright, I do hope my wheels fit............. :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on September 19, 2010, 10:10:52 PM
Quote from: 80 Vert on September 19, 2010, 09:24:50 PM
Yup thats them alright, I do hope my wheels fit............. :laugh:

If they dont you will have nifty looking DVD/Xbox game holders!  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 25, 2010, 07:33:52 PM
Since my first attempt at a DIY spraybooth worked ok at best I decided that some improvements were needed in the MK2 booth paint extraction and lighting departments so over the last couple of weeks I sourced some downdraft spraybooth filter material and made an inlet filter.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05461.jpg&hash=a4c404bafbf6f0a0d2d80fd0def8bdb6971dd2fa)
Had a pile of furniture tube at work that hasn't been used for anything in the last 10 years so it was ideal to make it out of that, inner and outer frame bodged together and clamped the filter between the two.
Had a box of gate latches lying around also so they worked well to clamp the two frames together to be able to get the filter in and out easily.
With the filter sorted it was the lighting next in line, 2 strings of party lights with 100W energy savers  ;D
Total of 20 bulbs gave me around 2000 watts of light, lit that sucker up pretty good  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05459.jpg&hash=410f92770b404f8d1a332790271e1dc995ef4fb1)
One of the big problems last time was the plastic pulling inwards between the posts so the easy fix was more furniture tube and made some X braces that are zip tied to the gazebo, by the way tape and zip ties feature heavily in this home booth  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05460.jpg&hash=b840f04665db6dd91b8069adbe5a79ef5be83333)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05462.jpg&hash=69cccf9c75bf63aae601937608014fa074d53054)
Net result?
Awesome paint booth, worked beyond my expectations and a massive improvement from a couple of weeks ago  >:D
With the fan going at full bore all of the overspray got sucked out no problem, easy to see what you are doing.
The plastic just goes taught and it then allows the air to be pulled through the filter, so cool!
Results............................... ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05472.jpg&hash=7b3fded47372bc27c7e4c89b1a74999ed6f57fce)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05471.jpg&hash=ddbc0b7442cfe39eba198ebe0a9deb9775f1abbe)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05473.jpg&hash=7cd47aa093d87392a447c0091038d3edce4ea527)








Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on September 25, 2010, 08:29:20 PM
Looks great!! But can't wait to see engine results....  ;D :o ;D ;D ;D >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: badhabit on September 25, 2010, 08:44:36 PM
ahhhh the smell of fresh paint in the morning!
another BBJ achievement
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: gti vr6 on September 26, 2010, 08:17:22 AM
Mint, looking good!!

:)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on September 26, 2010, 08:27:29 AM
It's great to see you painting the car. Gives hope to the rest of us we might be able to do the same.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on September 26, 2010, 10:01:54 AM
Hmmm maybe i should block back the mk1 while you have the bug Vert ;D
Funds your way of course. Ive gotta get it sorted soon or it will rust away :-\
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 26, 2010, 11:30:19 AM
Hahaha funny Jem, I have 3 of my own cars to paint so that will keep me going for some time to come  :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on September 26, 2010, 01:13:08 PM
Looking good there guys! ......good to see the ole Honda Parts boxes getting a second use out of them!....
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 28, 2010, 09:59:13 PM
Good sturdy boxes those, good for painting car parts on  :laugh:
Will get back to the engine build hopefully this weekend, install the head and maybe start looking at building the short runner mani since those RMR components arrived yesterday.

Get turbo / exhaust manifold coated, Gearbox to come apart also..................soooo much left to do  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 02, 2010, 04:43:08 PM
Didn't do much on the project this weekend as i was helping a mate take the gearbox out of his 4 Motion but I did manage to bolt the head back on last week to get it to a longblock stage ready for all the ancillaries to go back on.
With a few spare hours this arvo I pretty much finished off putting the motor back together and modified the new injectors as they are too long for the VR6 head meaning the fuel rail won't fit anymore.

With the injectors done the plugs also needed changing so with some donor looms I cut the plugs off and soldered them on to the existing engine harness completing that part of the motor.
Can now start looking at doing the gearbox so that the whole unit can go back together for a trial fit in the car.
Also bolted the snail on  ;D to see whats what and did'n count on the turbo being the other way round from how i thought it was going to be, too early to say if thats going to be a problem so I'll just wait till its all together and test fit it.
Bit of head scratching with that one but we'll see, worst case is that I'll have to get a different exhaust manifold  :-\

Thinking about this some more on the way home it would be better if the turbo was flipped round the other way, maybe making an adaptor plate to do so might work.
The turbo can't be bolted on the other way round the way it is as the exhaust housing will hit the block but with some kind of angled adaptor plate that might just work........... :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0092-1.jpg&hash=78927ae58954c18dfed2ac3d16afb4fb44ab12bf)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0094-1.jpg&hash=d717a987366b445111f7b8cb658ac1f388ad2136)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0095-1.jpg&hash=8e751dd579a83ddd8928b5eb3835c0f846bca2b2)



Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on October 02, 2010, 06:37:39 PM
 :o :o :o :o :o

jesus christ that thing is going to haul........ i was scaring people in the Jetta but this thing  >:D :police:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on October 02, 2010, 07:02:29 PM
That exhaust manifold is really big out the back of the engine, plus the waste gate pipe as well.
Im really surprised these Yanks dont build something a little more compact, maybe only a NZ'r would think of fitting into another chassis.

If its too tight , maybe build yourself another manifold, or cut that one down, huge job though.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 02, 2010, 07:13:29 PM
Its not the size I'm worried about as it actually looks bigger than what it really is, with the VR6 leaning forward as much as they do there's quite a bit of room behind the engine but I think it would be better if the turbo was the other way round for RHD.
There are lots of smaller log style manifolds for these engines but those have the same problems as the Vento by placing the turbo too far on the RH side of the engine bay.
As always I'll end up changing it to suit......... ::)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FATP-VVW-200_450-3.jpg&hash=f3214c344945f6f0518a1c27ccf4e234e75fba68)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on October 02, 2010, 07:18:11 PM
Your manifold is the same orientation as my 1.8t, i like the exhaust being just a bend to flow out, otherwise its quite a bit of plumbing.

If size isnt a problem, then dont worry about it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 02, 2010, 07:34:12 PM
You don't have a prop shaft, transfer case and steering rack in the way  :laugh:
So............if the turbo was the other way round then the intake would come straight from the airbox on the LH side and exhaust would be 180 deg bend and out............but I'll just wait till the gearbox is ready and test fit.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on October 02, 2010, 07:48:15 PM
Oh................................forgot about you spinning all wheels, maybe you are right...............again.

Good luck John..... ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: fast4motion on October 02, 2010, 11:22:27 PM
My turbo is the other way around, and although it was a real mission to squeeze in a 3" downpipe (mainly due to my turbo sitting higher, so the downpipe had to clear the brake booster/master cylinder) I think it would've been even harder to fit it on the passengers' side. Because I'm pretty sure there's less clearance between the driveshaft and "transmission tunnel" on the passengers' side, plus you have the shifter cables to contend with.
But I think your biggest problem with the turbo facing that way, will be trying to fit your intake and intercooler piping past the brake booster/master cylinder.

Are you going to run a frontmount intercooler?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 03, 2010, 10:19:49 AM
Yeah the more I think about it having the turbo round the other way will be better, there's no way to get the exhaust out on the pass side of the tunnel and even on the drivers side there's only a small gap to get it through.

Yep going with a large front mount so at least having an SRI will make that job easier. The good thing about that ATP manifold is that you can retain the factory heat shield over top of the exhaust which will keep an awful lot of the heat away from the bonnet.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: fast4motion on October 03, 2010, 10:28:00 AM
When you build your SRI, are you keeping the throttle body on the passengers side, or moving it to the drivers side?

I'm considering moving mine to the drivers side, then the intercooler pipe can exit the turbo without crossing over the turbo "hotside" and run straight to the passengers side of the intercooler. Then it can exit the intercooler on the drivers side, and run straight up to the throttle body (with relocation/replacement of the washer bottle).
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 03, 2010, 10:32:47 AM
What I was thinking yes..............seeing as I'm building my own SRI, I may just have flanges at both ends to give me some options.
Thats pretty much how we set up the Vento which has worked out pretty well.
Ohhhh sooooo much to consider........... :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 09, 2010, 06:03:18 PM
Spent the entire day doing wiring, I'm still a bit puzzled why its taken all day to finish just the rear section of the car.  ???
I'm using the R32 harness in this car as its already set up for a 3 door and has more modern electronics than the Bora although this means adding the rear section of the Bora loom to the R32 one to compensate for the extra body length.

Frustratingly not all colors are the same so having to trace wires with the help of a diagram makes for painfully slow progress, after the wires are joined I do a continuity test to make sure everything is where it should be.
Next on the list will be the extra wiring for the dash vents and electric seats, have to prune those parts from the Bora harness and add them to the R32 one.

Working on the wiring in the boot I did realise there's a perfect spot behind the spare wheel for me to sink a custom made water/meth tank into the floor, should hold a decent sized tank and be completely hidden under the boot floor mat. ;D

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 14, 2010, 08:56:35 PM
Been trying to finish up the wiring over this past week, a few hours after work most days has pretty much got it sorted now.

Removed wiring as needed whilst trying not to butcher the Bora donor loom too much as I'll need it to get the 2.8 24V going again once its new owner is ready for it to be installed  ;)
So far the seats have been the most work by far, have added all needed wiring for memory power seats on both sides so hopefully that all works now.
Memory function also controls mirrors and dips pass mirror when selecting reverse for parking, no wonder modern cars have several km's of wire in them  :o

Found that our budget spec NZ new R32's don't even have cruise control so thats another thing I removed from the other loom and added to this one, hey its free so when not install it  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0064-5.jpg&hash=a95ae15633b507735107bb354a3ade21fffdaeb5)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on October 14, 2010, 09:00:47 PM
Quote from: 80 Vert on October 14, 2010, 08:56:35 PM
Found that our budget spec NZ new R32's don't even have cruise control
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0064-5.jpg&hash=a95ae15633b507735107bb354a3ade21fffdaeb5)

Surely not Vert, we all know that NZ New are the best cars in the World and anything else is completely worthless.  ;D

Great work, loving the attention to detail.  :o
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 14, 2010, 09:09:22 PM
Its just rubbish isn't it, 80K car and no cruise WTF?  ???
Anyways, quite enjoy wiring stuff from time to time so its all good.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on October 14, 2010, 09:11:28 PM
Quote from: 80 Vert on October 14, 2010, 09:09:22 PM
Its just rubbish isn't it, 80K car and no cruise WTF?  ???
Anyways, quite enjoy wiring stuff from time to time so its all good.

Time to time is a bit of audio wiring or central locking not bloody stitching two looms together!

;D :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 14, 2010, 09:16:09 PM
Hahaaa, you gotta do what ya gotta do to make it work  :laugh:
Hmmm what to do for a stereo, not much space left in the boot once water/meth tank is in...........hmmm engine bay going to be rather crowded too  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VeeDub on October 14, 2010, 10:30:56 PM
Wiring talk is all jibber jabber to me I don't understand! Looks like the least rewarding part of the project though?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 14, 2010, 10:33:21 PM
Quite the opposite, wiring is what makes it run  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on October 14, 2010, 11:21:49 PM
Yep I enjoy the wiring aspects of most of my work too. Quite sad and geeky but highly rewarding when it works.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: deedub on October 14, 2010, 11:33:56 PM
Quote from: M on October 14, 2010, 11:21:49 PM
Yep I enjoy the wiring aspects of most of my work too. Quite sad and geeky but highly rewarding when it works.

Amen. I'd far rather be splicing looms and studying wiring diagrams than trying to wrestle a dirty great motor into place. And it's sooo satisfying when it works.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on October 15, 2010, 12:46:15 PM
Being colour blind I'm screwed when it comes to wiring unless I have my 10yr old translator. :P
Give me a bloody great big spanner and oil up to my elbow any day. >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Omes on October 15, 2010, 02:36:28 PM
Quote from: 80 Vert on October 14, 2010, 09:16:09 PM
Hahaaa, you gotta do what ya gotta do to make it work  :laugh:
Hmmm what to do for a stereo, not much space left in the boot once water/meth tank is in...........hmmm engine bay going to be rather crowded too  :laugh:

Who needs a stereo when you're gona have an R32 and a turbo singing in harmony together...... ohhhhhhh pure acoustic porn!  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on October 15, 2010, 07:06:25 PM
Quote from: SOFTLAD on October 15, 2010, 12:46:15 PM
Being colour blind I'm screwed when it comes to wiring unless I have my 10yr old translator. :P
Give me a bloody great big spanner and oil up to my elbow any day. >:D
Bullcrap, I am colour blind and it has never stopped me, my old boss couldn't believe it when I told him after almost 4 years of working on wiring diagrams for him.  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on October 15, 2010, 08:36:25 PM
Quote from: M on October 15, 2010, 07:06:25 PM
Bulls**t, I am colour blind and it has never stopped me, my old boss couldn't believe it when I told him after almost 4 years of working on wiring diagrams for him.  ;D
Its never stopped me but I just make sure I have a good supply of fuses and always double check, and ask my boy what colour is what
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Alfashark on October 15, 2010, 09:46:27 PM
Planning, purchasing, setting up and diagnosing issues with a 9000V electric fencing unit I can do, playing around with 12V looms in cars however is another matter :-[

Hats off to you guys that have the knowledge and patience to do this  :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GTI's on October 15, 2010, 10:50:59 PM
I like the sticky crap that you get on your hands while stripping looms down. NOT!!!
Anton does  :laugh:  But I have felt it once...
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: chis on October 17, 2010, 07:05:01 PM
that loom snot is horrendous
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on October 17, 2010, 08:05:17 PM
Quote from: GTI's on October 15, 2010, 10:50:59 PM
I like the sticky s**t that you get on your hands while stripping looms down. NOT!!!
Anton does  :laugh:  But I have felt it once...

we still talking about the Loom?    :-* ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 17, 2010, 09:09:58 PM
Yeah, you know how VASK works  :laugh:

Anyway, getting this back on track I pulled the gearbox apart yesterday to install the LSD and also modify the shift forks as these can become a problem over 600wtq  :laugh:
Hopefully I'll get some time to work on it during the week so that by the weekend she's ready for a test fit.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 21, 2010, 07:47:09 PM
In the last couple of weeks work has SERIOUSLY been getting in the way of working on the car  :laugh:
But.............time to get on with it again.
One of the common problems seems to be broken rivets on the selector shafts/forks so here's how to fix them, I pulled the box apart last weekend and yesterday finaly got some time to sort this out.

On the shaft where the shift fork is riveted I drilled holes either side of the rivet and installed roll pins, then drilled the rivet out and threaded the hole with M8 thread and loctited them in place.
The bolts were just long enough to poke thru the other side so I secured them with weld and also welded the roll pins in.
On the other forks which use just a roll pin to secure them I punched the pins out, drilled 6.5mm and then threaded them M8 and again loctited them in.
Where possible I also welded them on the back side, I used 12.9 grade cap head bolts- don't think they'll come out now  ;D

A quick test assembly of the trans revealed that the heads of the bolts need grinding down to clear the case, once that was done it all goes back together easy as.
Still have to take it apart again to install the LSD but thats for later as this weekend the motor/box/turbo are going in for a test fit  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0069-2.jpg&hash=34cde7a806ec5a7676f76959ef924155a2b60c33)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0068-2.jpg&hash=fb4973a6a880891f52d87f08d4b6195618662edb)
Yeaaaaaaaaaaaaaaaahhhhhhhhhhhh  boooooooooooooiiiiiiiiiiiiiiiii  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 23, 2010, 09:27:25 PM
Back to the serious stuff today, The aim was to get the motor and box in to see if the manifold was going to be any good for its intended purpose or wether it was going to make a good boat anchor  :laugh:
started the morning with fitting the South Bend clutch and both laughed at whats in store for that poor unit, still the one in the Vento has been awesome so far!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05611.jpg&hash=3eebb0d99ed8954d6c3bd14cf72d90f2c759f780)
Also bolted the gearbox and transfer case on along with the turbo and manifold at which point we both said thats NEVER going to fit in that car!
Still after a couple of quick measurements I decided that the only way to know for sure was to throw it in and see.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05612.jpg&hash=7f95247c625809ca63edf01cd072a944c3aeefeb)
We had to put the car back on the ground to be able to use the chain hoist for the motor so we used the Vento's 17" track wheels to get it rolling again, just as well they were 17's as they only just fit over the rotors with no calipers on them  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05613.jpg&hash=79281086dceaf8a81030a746f627a0c75c3956ba)
Anyway with a bit of faffing around trying not to distroy the paintwork the whole lump went in and to my surprise it doesn't look too bad at all, the RHD sure makes things tight  :-*
Had the compressor outlet pointing up but soon realised that wasn't going to work so the next idea was to clock it downwards at the driveshaft.
With the driveshaft in there's enough room to put a 90 bend on the outlet and run the charge pipe out, along the RH rail straight into the intercooler- should work very very well!
Turbo inlet however is another story, not much room to go down past manifold and brake booster.
Did have a brainwave though and thought why not use a LHD booster (larger dia but much thinner) like I had in the other Jetta  ???
Of course I did have a spare one back then but binned it as I thought when will I EVER use that  :laugh:
so there you go, never throw anything away!
Will order one from the US as this will buy me at least 40-60mm of much needed room  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05620.jpg&hash=1c37d3b7b2d0ba4e713919834198f4dabf91c9b3)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05622.jpg&hash=08b9f1ee043dae8165b9e694c9cc9021ecfcb448)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05619.jpg&hash=d3f471ac740aaad605ebf0098729c4f629e76a8b)
Not counting my chickens yet but the exhaust doesn't look like it will be that big of an issue and yet I thought that would be the worst part.
Also had a play with the intercooler, looks the prefect size- BIG  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05618.jpg&hash=bedcf5dfdfad0efc36bad4a753420ac77eda0fe2)
To end the day we made some notes of what needs to be done in the engine bay and pulled the motor so I'll work on resolving those issues and order the LHD booster and hopefully then we can re fit the engine in 2 weeks time so that I can start plumbing ;D

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on October 23, 2010, 09:42:55 PM
Man I hate that rule, I have suffered that same fate so many time throwing stuff out.

Good work Vert.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on October 24, 2010, 10:16:28 AM
Holy crap those brakes are big. Awesome!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on October 24, 2010, 05:12:13 PM
Yea some rubber and those disks could double As space saver wheels  :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 25, 2010, 07:01:26 PM
With the impending intercooler piping having to be made I've finally decided that work really needs a AC/DC tig welder  :laugh:
Got a great deal on one today so let the fun begin, plenty of use for it to do the intercooler, short runner manifold, water / meth tank and I can also weld stainless with it for the exhaust.
Can't wait to get started............. 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on October 25, 2010, 07:08:50 PM
Quote from: 80 Vert on October 25, 2010, 07:01:26 PM
With the impending intercooler piping having to be made I've finally decided that work really needs a AC/DC tig welder  :laugh:
Got a great deal on one today so let the fun begin, plenty of use for it to do the intercooler, short runner manifold, water / meth tank and I can also weld stainless with it for the exhaust.
Can't wait to get started............. 8)

How different is it welding stainless and alloy? Is the intercooler stainless too? I went for 2.5" alloy that now needs colour coding

Excuse the noob question but why water meth?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 25, 2010, 09:45:28 PM
A DC tig welder will do steel and stainless steel however for Aluminium and other non ferrous metals you need a AC tig welder.
So most Tig machines are DC only, all my intercooler pipes are Alloy as is the intercooler.
The good thing about this welder is that it will do pretty much everything depending on thickness and unlike a Mig welder there's pretty much no grinding involved to clean up the weld afterwards.

Water / Meth keeps engine temps down, makes more power as you can run more ign timing without it knocking.
Will probably set up water / meth to come in over 15psi boost or something like that.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on October 25, 2010, 09:49:26 PM
Do they make a pulse welder, AC/DC?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 25, 2010, 09:56:58 PM
Yep, this one is. Also high freq start.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 31, 2010, 11:24:37 AM
With no firm plan of what to do not much got done yesterday just removed the brake booster and master cylinder in preparation for the LHD one coming from the States.
Made the brackets to mount the intercooler to the front panel so at least thats done, shame I can't cut the bumper support as it would easily take a bigger front mount but hey thats the law!  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0060-4.jpg&hash=5edadb3289cd302675b58861d17ef7b0e8263bf6)
Was quite keen to get home yesterday as I got a bottle of gas on friday for my new toy so I spent quite a few hours playing with the tig welder learning how to use it, aluminium is tricky stuff when you haven't done it much  :P
Just started out laying beads on flat 1.5mm plate and then tried welding a box together by fusion welding which was ok but with filler rod was another story  :-\
Still the more you do the better it goes, welder is nice to use at least so thats cool.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0062-4.jpg&hash=0357a00517172fe5d4efa01bdb5a9ecde6bf0692)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0061-7.jpg&hash=2cb8b49a7edd8c726d3b728d8fedaab68cedc5f2)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on October 31, 2010, 01:52:03 PM
That looks fun :) I think its easy enough to weld the nice clean stuff but worse when trying modify a old manifold etc. You will be a pro in a very short time vert.
Will pay for your welder in a few jobs. How much was it do you mind me asking?

I am happy to hear you are doing the water/meth injection as I have always thought that was a good thing and wonder why more people don't do it?

Get a smoke weld mask vert the fumes are bad, but you know that and probably have one.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 31, 2010, 03:36:23 PM
Yep it is quite good fun, just need more practise.
Once I get the hang of it better I'll get a foot pedal to back off on the power as the ali melts faster and faster the hotter it gets.
At the moment I have enough to contend with trying to keep the torch at the right distance / angle while moving along and feeding the wire in  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 06, 2010, 11:29:20 PM
After weeks of mediocre progress, today paid divedends- just when I thought I wouldn't have all the pieces organised for this weekend the LHD brake booster from the US arrived Friday afternoon  :laugh:
So this morning I was pretty gung ho to slap the engine in and get fabbing on the intercooler piping but Phil's cool head intervened and conviced me to fit the booster and master cylinder first so that we had everything in place before any piping got made.

Its an epic tight squeeze to get the LHD one in there but it does fit, some persuading is needed with a large knock o meter (read sledgehammer  :laugh:) but its in there!
Still have to re run a couple of the brake lines before the engine goes back in for the last time but since it wasn't going to matter today I just left them out for now.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05676.jpg&hash=69173cc84a07c9fcada7e8cd4983a85d2520fb25)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05677.jpg&hash=3f2b097caf2bc6bdfdad7731275f438c27d3200c)
With the pedal box back in place we lifted the engine and box back in, dogbone on, prop shaft on and RH driveshaft in only to find there's a clearance issue with the power steering line so that came out and also got modified  ;D
By now it was lunchtime and feeling seriously deprived of coffee we headed up to the cafe for lunch  :laugh:
On with the serious stuff, figuring out where to run the new pipes for BOOST  ;D
I'd gone and bought ali bends, ali pipe, couplers and clamps during the week so it was just a matter of cut to size and weld that sucker together, my welds don't really look like stacked dimes yet but I'm sure I'll get there as I do more of it.
Got the RH pipe running under the chassis rail to the IC, started on the LH pipe also but I have to wait till the short runner intake is done before I can finish that one.
Can't even begin to tell you how good it feels to finally be able to weld aluminium myself and finish things there and then on the spot rather than sending it out to be done.
A few shots of progress so far....... ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0066-3.jpg&hash=acf3d9f281dd58823c5aad22f92855306669adab)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0067-1-1.jpg&hash=beccab7ad6b8eb009d341cf81b1954967d6ac2bc)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0068-3.jpg&hash=9d9fa7834de617263d3ae86adc5cc37282249b67)








Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: chis on November 07, 2010, 10:14:51 AM
 8)

choice
so many shiny bits mmmm mmmm!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on November 08, 2010, 05:53:12 PM
 :o   Ooooh Can I touch it ???????
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on November 08, 2010, 05:58:24 PM
Remember to leave the intercooler outlet pipe clamp slightly loose to save the engine from destuction on your first test drive ;) :D :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 08, 2010, 06:16:09 PM
 ;D, better still I'll make sure the wastegate is hooked up  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 14, 2010, 12:41:05 AM
The aluminium bends I got a couple of weeks back turned out not to work so well for what I had in mind, the 4" 90deg bends were no where near tight enough to clear the exhaust manifold so that meant YET another trip out to Altech for a tighter silicon 90 straight off the turbo.  :laugh:
With that out of the way I got the first pipe in place, a little clearancing around the manifold has it sitting pretty nicely and has plenty of room around it.

Its funny how you think ohh yeah all I need is a 90 here, straight there with a 45 into the airbox- FAIL!  ;D  It never works out that way!
The parts you actually need are never at hand............... :laugh:

4" pipe is quite ungainly to make look nice but I decided that I'd like to retain the stock airbox although heavily modified, I cut off the original fitting that the MAF screws on to and opened up the hole to be able to fit the 4" pipe into the lid of the airbox.
With the airbox in place and lined up with the rest of the intake pipe that got made this morning I started to make some aluminium plates from 2mm sheet that will bolt the new MAF housing to the airbox.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0072-2.jpg&hash=6ff9a9af14501ba97c4a58eff728d1195138ccd2)
I'm going to use a B7 S4 MAF so I made an aluminium block in the mill and welded that on the short piece of pipe coming out of the airbox.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0071-2.jpg&hash=37967ff0f6d39c270b04bbead139af6411b0da2f)
Yet another day working on the car bites the dust however I'm quite happy with what got done today, still have to make a larger intake for the airbox once everything else is in place as I doubt the stock plastic pipe will be any good.
Hopefully I can extend the intake to the inner fenderwell or something like that but we'll see how much space I have left  ::)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0073-2.jpg&hash=4c5f75d120a85749e766d32aaa3e1810b5ec7528)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0074-2.jpg&hash=8d1ec8cd54dedcb90f2b14a3df8e8de7b92d4d7e)
On with the stainless next week making the downpipe, again the 90's I bought are not tight enough so I'll have to track down an stainless donut if there is such a thing, once thats out of the way the motor can come out again to make the oil and water lines for the turbo







Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GLIDN on November 14, 2010, 04:18:14 AM
Yes you can buy stainless in donut forum.
One of my customers build massive machines and they can only use stainless.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 14, 2010, 09:42:39 AM
Cool, thats good to know. Will track one down during the week  :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Period_Correct_ on November 19, 2010, 06:42:10 PM
what are the dimensions of the tube you need? i maybe be able to do something for you...
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 19, 2010, 08:22:45 PM
Cheers Nige, I managed to get one from Autobend earlier in the week so its all systems green for exhaust fab tomorow  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on November 20, 2010, 10:07:13 PM
So I headed out to John's today to get into the fun stuff of building the downpipe and starting on the exhaust. Downpipe was first task and we thought we'd knock it out in an hour or two............... turned out to be more like 3 or so hours worth. All the checking, tweaking, cutting, welding, rechecking, etc, just eats time. Also a small issue with the welder where it was either just a fraction to low heat, or a bit high meant John was battling the welder a bit as well which didn't help.

Basically it's a 180 out of the turbo, then a 90 past the driveshaft, then a 45 to start it pointing down and back towards the rear. In the end it turned out really well though, the only remaining clearance challenge is the proximity to the shifter cables but we tossed around a few ideas and John is confident he'll be able to resolve that issue. Anyway here's a couple of pics.

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05697.jpg&hash=c8141e5f70935afbd1f9eece52f5c2b7fc8db50c)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05699.jpg&hash=0b625f9a70e8acd02536d3f2a0dc2a812e15eba8)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05704.jpg&hash=101b52ae76fc71f4e2bf7bdce1279a65773252d3)

That's kind of as far as we got with that though as we struck an issue with the size of the 3" flexi so a shorter one will be needed. Also the original idea was to split into 2x2.5" pipes after the flexi flowing through the OEM CATs then merge again near the rear diff. But looking at it we'll probably just use one of the 3" race CATs I've got and keep it simple.

So then we started on the short tunner intake. This also created a bit of head scratching as there is no way a straight (horizontal) runner will clear the altenator bracket. Hmmmm - time to give this some more thought. Options are angled runners as per pics or curved runners would be the way to make this work. More research needed.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05706.jpg&hash=373caec3cce7fb99e47a6dc30b6cbe6672e1bf3f)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 21, 2010, 12:20:17 AM
The issue with welding the stainless today was that it wouldn't really get the molten puddle going very well however setting the welder just a fraction higher in amperage it melted things way too quickly, there didn't seem to be any way to control it, too little or far too much  ???

Have ordered a foot pedal for it so that I can use higher amperage to get going and then use the pedal to back off on the power.
Unless I'm doing something else completely wrong, will have to play around some more me thinks.
Aluminium in some ways is easier than what I did today, still all learning though so its all good.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on November 21, 2010, 10:11:50 AM
Hey John, my job now envolves Stainless Steel, if you email me some questions you might have, I can ask the guys at the company we use for a few tips that might help you
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 25, 2010, 08:53:21 PM
Onwards with the SRI manifold, didn't have much luck finding information on the net so once again I just firgured it out myself and forged ahead with a plan.
Had a head plate and oval tubing for the runners already so it was a matter of deciding how to go about it, I made one runner to begin with being mindfull of the fact that I only had about 600 odd mm of oval tubing so one damn up and its all downhill from there  ;D
Luckily measure 10x and cut once worked out just great!

I made the runners out of 2 pieces welded together with a flat tansition at the base of the runner instead of having a sharp V like I was looking at in the weekend.
Welded these to the head plate, you can see one of the runners in the background on the bench. Clearanced the alt bracket for it to fit around the #1 and 2 runners but there's more than enough material left in the alt bracket to be ok.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FDSCF0081.jpg&hash=23bd605e225a7dd53f8632d402c485c21bd4f44b)
Last night I milled the bellmouths to fit the runners, just had to mill the sides down so that they fit next to each other on the runners.
Here they are test fitted to the rest of it, will start making the base plate this saturday and hope to have all of that welded up in readyness for making the plenum next.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FDSCF0082.jpg&hash=a69a796aa85dd7edb93f0cc949404accafb3b121)





Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on November 26, 2010, 08:14:57 AM
Awesomeness.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on November 26, 2010, 10:31:16 AM
Wouldn't that make for two different lengths of intake??  The intake side of the block would have shorter intake lengths than the exhaust side...  If you catch my drift...
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on November 26, 2010, 11:31:28 AM
Quote from: 5-pot on November 26, 2010, 10:31:16 AM
Wouldn't that make for two different lengths of intake??  The intake side of the block would have shorter intake lengths than the exhaust side...  If you catch my drift...

Part of what makes a VR6 a VR6 :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on November 26, 2010, 12:14:46 PM
Well yeah, for sure.  i just thought he was going for the equal-runner thing... 
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: robh on November 26, 2010, 01:19:20 PM
I reckon with boost added the equal runner thing doesn't make much difference.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 26, 2010, 01:40:14 PM
Thats what I though too and from what I've read it appears that the 24V's have compensation built in to the cams for the uneven runner length anyways.
It seems that 12V engines have equal length runners built into the inside of the cast manifold but they didn't do that on the 24V's plastic manifold, instead compensating for it in the cams.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on November 26, 2010, 07:46:53 PM
classic Can-Am cars had staggered inlet trumpets, basically to spread the power band by tuning 4 cylinders for low rev grunt and 4 cylinders for top end revs

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fwww.hvmracing.com%2Fhvmblog%2Fwp-content%2Fuploads%2F2010%2F02%2Fm8e-12.jpg&hash=7847993dfdb4fa980aff4a3c6fd4236fb94c9796)

mind you, these were big engines, I remember reading a Denny Hulme quote that he preferred the "little" 427 engine because it revved better than the later 454s

so I wouldn't bust a gut to get equal length inlet tracts with the VR6, what might be worth doing is grouping the short/short/short and long/long/long exhaust ports together, so they each get the same pulses from the collectors
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 26, 2010, 08:43:28 PM
I would probably get more fussy with a NA car but since its turbo and the air is being forced in I doubt it would make much difference, main reason for the short runner intake is the plastic one blows apart beyond 12-15psi.
It also puts the throttle body on the front of the engine right where the nice short intercooler pipe comes up to it and also the intake doesn't run across the top of a hot engine.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 27, 2010, 06:05:36 PM
Carried on with the SRI today, welded the bellmouths on this morning which turned out to be quite tricky with the limited acces for the tig torch.
Once that was complete it got bolted on the head for a test fit and found that the alt bracket needed some more material taken out of it before that would bolt up.
I ground the inside of the runners smooth with a die grinder and flap wheel, mostly to take the sharp edges off.
Should be able to sucky sucky plenty of air through that lot  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0084.jpg&hash=d6ae724396e3a826dc1680cee1a593174c4f0ed1)
With that fitting and out of the way I set about making the plenum plate out of 5mm thick flat aluminium, marked out the holes to be drilled and cut them with a hole saw in the drill press.
Made short work of it, fit was pretty darn close with minor filing needed to slip the plate over the bellmouths.
On with the fun part, well the learning part for me..............welding  ;D
Got to say I'm pretty happy with that welder, does a nice job once the operator gets in the groove  :laugh:
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0085.jpg&hash=956baaf7198f992e354f51edac0476ce5083d715)
All I had for the plenum was some 4" pipe so I thought yep I'll just open that up and bend it into a C section which will be EASY enough, how wrong I was!  >:(
Holy crap is that stuff tough, 2 big bars levering the crap out of it managed to open it up enough for me to start getting it into the shape I wanted.
Wrestled with that for the best part of an hour before it could be welded together, really started to get the welding sorted out here so I'm pretty happy with the results.
Made a huge mess at 3 benches during the day, its amazing the amount of crap you drag out to do this stuff.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0086-1.jpg&hash=76376c0c667ce684ab2306d63f47ce95cd017cdd)
Last job for the day was to make one of the end plates, drill & tap a booster vac fitting into it and weld it together.
Fitted it to the engine and put the front panel on to make sure everything clears, just have to make the other end plate and throttle body elbow next week completing the SRI and intercooler piping  :-*
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0088-2.jpg&hash=382f73e29e201a883b97b8b42330ce67b384781d)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0087-1.jpg&hash=d469b90f2bf9a47ed54e02e52032a581cd8f9104)






Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on December 04, 2010, 09:26:56 PM
John and I cracked into it this morning with the goal of having the manifold and intercooler piping finished by lunch time. Hmmmm, the best laid plans eh.........  :D

The first task was to mount the throttle body and pipework back to the plenum. John had already machined up this O ringed throttle plate and welded it to the 3.5" elbow pipe.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05746.jpg&hash=57adb85836c1b44a7d1f934cab0a3f70b52de7a2)

So it was a matter of guestimating the best spot and cutting the pipe to length. But even that soaks up time while we worked through a bunch of different options and trial fits. The idea was to then re shape the other end of the pipe to fit into the throttle body opening and then add some end plates to seal it all off.

But finding room isn't always as easy as it sounds. We thought we'd better put the radiator and slam panel on to give us a good guide to how much space we had. Damn, the top of the larger fan shroud touches the bottom of the plenum.  :( The extra wide rad sure doesn't help make clearance any easier as well. But extra cooling is always good.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05747.jpg&hash=846cc94172856d7104aa9ead155f12c0d249b5f7)

So remove slam panel and look at the options. Booya, simple - flip the radiator shroud so the smaller fan is on the passenger side. Back on and it's better, but still fouls. Bugger! And now the larger fan fouls on the oil dipstick tube. Solution to that issue came with removing the dipstick tube, re-bending it and running it up between the runners of the SRI. Phew - one problem solved. The other issue was resolved with some persuasion from the famous knock-o-meter (aka panel hammer in this case)

John manipulated the plenum side of the pipe and after the usual (seemingly endless) trial fitting period we ended up with the below.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05748.jpg&hash=d784fa8481fd19680d937d0f9853535ddfa6e5ff)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05751.jpg&hash=d6f597c1b02bc788b805ccb42eb46642d40adef5)


I didn't get a good shot of the final intercooler piping but basically this was the final routing down from the t/b down to the chassis rail. Ignore the a/c pipe lying over the plenum as that will get changed
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSC05752.jpg&hash=581f2b4302f6589afc67ed22f47188af6f0ca4b8)

The original plan was to run the coldside intercooler piping up close behind the radiator but as we had to aim the throttle body back into the engine bay slightly to get it to fit it meant a slight extension of the piping down the LHS chassis rail before turning up into the engine bay.

We then pressed on with John doing the final welding of the pipework while I cracked on with making some little aluminium plates shaped to fill the gaps at the end of the plenum. John welded those on as well but I had to head home at that stage so didn't get any pics. I'm sure John will post a few though with a bit more of an update.

It was a really awesome day though - started slow and a bit challenging however came together nicely at the end. Still a long way to go for this project but days like today where you put a tick beside "finishing the intercooler piping and intake", really feel like progress.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 04, 2010, 10:43:32 PM
Feels awesome to have the majority of the fabrication done, awesome day to be able to get to the point of the motor coming back out for the final time and plumb it up  :laugh: Another step closer to fire up day!  ;D

When I was welding the TB flange during the week I noticed that my gas bottle was just about run out and being too busy at work to go get another one, rather than do full welds we tacked everything in place to be able to finish getting all the pieces in place but as it turned out I was able to fully weld all the pipework and plenum.
After Phil went home I carried on finishing the oil dipstick tube and made a threaded boss that I welded onto the SRI.
The radiator is about 1/3 wider in the core than a stock one which really didn't help me at all with space in the front and as a result I'll have to cut the AC line off and re direct it another way but like Phil said the extra cooling will be great.
Ended the day by putting all the completed parts on for a final check to make sure it all fits  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0090-1.jpg&hash=693e23ee21e0263bbc9800d769e7c5c4e0534cd7)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0091-1.jpg&hash=e4834ff6ccd205046a6f8cec25842a28992bcbfa)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on December 05, 2010, 11:58:36 AM
Fantastic work guys, looks amazing.
Sounds like a great excuse for a bring food & drink starting party
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on December 06, 2010, 10:17:55 AM
It's mighty cosy in there...  Looks awesome.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 11, 2010, 06:51:03 PM
Yeah its pretty cozy alright, lets hope I don't have to work on it once its finished  :laugh:
No real progress to speak of in this last week, been chasing the glass situation again after my guy in Aussie turned out to be a great big fat waste of 3 months  :(

Looked elsewhere in the world like US, UK, Romania etc but nothing solid that gave me any confidence.
Few places would make them for me but only in container loads and I don't need that!  :laugh:
Anyway I got pretty disheartened in the end with no real solution still and since I'm not painting the car till the windows are at least test fitted it forced me to keep on the hunt.
I called a guy who does my windscreen installs and he gave me a contact here to try, called them and set up a meeting last Monday  8)
Result? making the windows is apparently no problem  ;D He told me to make an aluminium pattern of what I want so that they can send that to their factory in China to produce it in glass.
They seem to get quite a few windows made over there, especially for models like Holden and Ford.

Jeez that english wheel I made came in handy again, started on monday after work and by thursday I had 2 patterns wheeled up. Made a box this morning to crate them up in and delivered them this arvo.
Its amazing to see how much shape there is in them but unfortunately doesn't show too well in pictures though.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0092-2.jpg&hash=fee809e1ccf8badfaaeed54de45087d16c2dd761)
Now I'm not getting my hopes up just yet as that's lead to dissapointment more than once but he's talking end Feb for 3 sets of glass so we'll see if persistence pays off  :-*
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 13, 2010, 08:01:33 PM
Got the OZ Superleggeras back from the acid dippers today, soooo clean!
No sanding, no messy paint stripper, no effort!  :laugh:
Kwik strip on Patiki rd did an awesome job, not a chip of paint left and only 45 a wheel to completely stip them.
Will have to decide on a color, may end up doing some painting this weekend  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on December 13, 2010, 08:16:11 PM
So this is going to be a show stopper.

I thought you were going to drive this car John........... ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 13, 2010, 09:12:07 PM
It will be driven daily  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on December 14, 2010, 10:09:23 AM
Quote from: 80 Vert on December 13, 2010, 09:12:07 PM
It will be driven daily  ;D

Cue tui billboard... :P
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 14, 2010, 12:07:04 PM
Wait and see............no Tui billboard!  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Simon MkII on December 25, 2010, 10:46:51 AM
Do you guys know this has been posted on jalopnik?

http://jalopnik.com/5717579/the-jetta-coupe-with-an-r32-heart-of-gold
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 25, 2010, 11:00:04 AM
Hey thats kinda cool!  ;D Its on Buildthreads.com too along with the Vento.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: JDVW on December 25, 2010, 03:02:33 PM
some pretty stupid comments on that page haha
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on December 25, 2010, 04:55:30 PM
Quote from: 80 Vert on December 25, 2010, 11:00:04 AM
Hey thats kinda cool!  ;D Its on Buildthreads.com too along with the Vento.

That is pretty cool. How many times did you ask them to pick up your thread? ;) ;D :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: p40lvw on January 03, 2011, 06:40:34 AM
a link for this build has just turned up on our forum back here in northern ireland i have just read the build from start to finish & have to say this is 1 epic build lovin it cant wait to see it finished our forum is www.gtini.com pop over & have a nosey
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on January 08, 2011, 07:53:03 PM
Much work done over Xmas? Or did you take break John?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on January 08, 2011, 08:36:39 PM
Pretty sure Verts in the US of A.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 17, 2011, 08:51:09 AM
Sadly the holliday is over and I'm back now  :laugh: Lots of new ideas and a new toy!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on January 17, 2011, 09:01:05 AM
Quote from: 80 Vert on January 17, 2011, 08:51:09 AM
Sadly the holliday is over and I'm back now

Yep reality bites!

Whats the new toy? xmas present to yourself?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 17, 2011, 10:33:26 AM
True that, still bummed that its over tho.
New toy will be revealed soon, sure why not call it a christmas present? have to justify it somehow  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 22, 2011, 03:09:59 PM
After nearly a month off I thought it better to get back on to this before I loose interest in it  :laugh:
I sent the exhaust manifold and turbo exhaust housing out to be coated hoping that they would be back by today so that I could start making the coolant and oil lines for the turbo.
That didn't work out so I pulled the motor and gearbox out to fit the LSD to the gearbox, with the gearbox complete and back together its back on the motor ready to go in the car.

Bolted the daddy brake kit on which all seems to fit very well, looks like my new wheels will clear the calipers where as the LM reps won't so those will be for sale soon.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0095-2.jpg&hash=a1f1e815f5d78c2d5bb85b6fb847b378d2342e84)
Finished off the brake lines for the LHD booster / master and installed the BFI mounts I got in the US which pretty much completes the engine bay bar some heat shielding for the turbo.
Once the oil/water lines are made the motor goes in for good meaning the engine bay will come toether pretty quickly.
Also sourced a nice small dry cell battery in the US that will fit under the rear boot carpet nicely out of the way.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0096-2.jpg&hash=8af8e8ce56df89c9ee3f2e1a363e449dbf538a8b)
Phil still had an alloy crack pipe so we installed that along with the Mocal thermo sandwich plate for the oil cooler, I already had a 4 cyl plate so with a little modification it fits easily on the 6 banger.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0097-1.jpg&hash=a73378a42ba6ea83cc12c0261318a5aea8bba6a4)
The coated stuff should be back early next week so the hope is to have the motor back in by the end of next weekend  :o
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on January 22, 2011, 03:17:05 PM
Good to see you back at it John, I,ve been missing my fix from your weekly update.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 22, 2011, 03:19:34 PM
Hahaa good to know there is still interest in it, its pretty easy to do nothing these days  ;D
Does feel good getting somewhere though.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on January 22, 2011, 03:35:39 PM
Did that new custom window guy come through or still work in progress?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 22, 2011, 03:41:46 PM
As far as I'm aware they are being made, he was talking the end of Feb before they would be in NZ.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 29, 2011, 08:12:24 PM
What an epic day on the car today, lots of progress in the right direction.
There comes a point where all the preparation and endless test fits pay divedends in forward progress, for me that was today.
I managed to steal a fair amount of time during the week to prep the motor by installing the manifold and turbo at which time the coolant and oil lines could be made, the easy way would have been to buy braided hoses and be done but ss hard lines look way better and making them myself wouldn't cost me anything exept time.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0101-1.jpg&hash=39a081a7768f94aec1c61481a3012375270291bc)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0100.jpg&hash=41b0dec8efc308aef54c0f20fc12b40001812bf2)
Getting the bends right so that they clear everything just eats lots of time but I'm super happy with the way they came out, the coolant lines were made from scrap stainless waterblast lances I had at work which were the perfect size for the job.
Pulled the oil pan off and cut one of the threaded bosses off to install a oil return line fitting on the pan.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0098-1.jpg&hash=a27bfc187d7a7179f4966388b7a463d83c928acc)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0099-1.jpg&hash=2a3ef10d105291a72e9ba3fcb548a5cd0e3d1eb4)
At the last minute I remembered to order a beanie for the turbo which turned up on friday, just as well because that was a tough thing to fit even with the motor out of the car!  :o
I even managed to re fit the factory heat shield back on the manifold, had to cut some holes in it for the 02 sensors and clearance it for the intake pipe and W/G but it still looks pretty factory bonus being hopefully it keeps some of the heat off the bonnet.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0104.jpg&hash=c0eb26358533c2bacd8f96ebfe21049dd85edb57)
That brought us to today!
With everything set and ready to go this morning the motor went in hopefully for the last time  :-\
Used the trusty hoist just to lift it into place and bolt er in!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0105.jpg&hash=e5252b0e35da7c9d92f482f4471b84de2418a2b2)
Spent the rest of the day installing the driveshafts, electrical and re routing endless stuff like heater core hoses, shifter cables, power steering lines, header tank hoses, etc etc to clear other  stuff which is there in their place and get them away from sources of heat.
Things are getting busy in there again, next major task will be to get the intake side of things done and get the front panel on...................
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0106.jpg&hash=6ded003a351ec6ebb17dff6685274b77f07575b6)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on January 29, 2011, 09:15:33 PM
Looking good John, starting to take form now  8)

What wheels are you going with now?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on January 29, 2011, 09:27:36 PM
what a donk! 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 29, 2011, 10:39:52 PM
Going with another set of OZ 18x8 Superleggeras, the LM reps won't clear the brakes  :'(
Being that they are 8's & 9's was no good either as they will require a different size tyre front to back which the haldex will not like at all!

A guy from vwwatercooled actually emailed me to advise against it as even a small difference (like 5%) in rolling diameter makes the haldex do bad things  :o
Ohhh yeah, gotta love big engines............... ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Omes on February 01, 2011, 10:14:02 AM
Quote from: 80 Vert on January 29, 2011, 10:39:52 PM
Going with another set of OZ 18x8 Superleggeras, the LM reps won't clear the brakes  :'(
Being that they are 8's & 9's was no good either as they will require a different size tyre front to back which the haldex will not like at all!

A guy from vwwatercooled actually emailed me to advise against it as even a small difference (like 5%) in rolling diameter makes the haldex do bad things  :o
Ohhh yeah, gotta love big engines............... ;D

Very true, Ive read about that too.

Loving the engine install Verty, very tidy and attention to detail like fixtures and fittings goes a long way  8)  re-name the project beast to: Verty's Frankenstine monster  :laugh: R32 Turbo 4wd is going to be mental!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on February 01, 2011, 10:26:06 AM
Superleggera's are still the sexiest wheel around  ;D ;D ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 01, 2011, 06:16:38 PM
Yup, looked pretty seriously at other wheels but kept coming back to these.
May try some Grids in the future for a change but those too may bot clear the brakes.

Been looking around to get satin black wrinkle coating done on the intercooler piping and intake mani, HPC and Pro coat don't do it but found out today that my local powder coater does it so hopefully I'll get all that stuff off to be coated this week.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on February 02, 2011, 03:29:30 PM
Is the wrinkle coat just for the look or is it Tec?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 02, 2011, 06:31:51 PM
Yeah, purely decoration.
Finished off the welding on the intercooler piping and dropped it off at the powdercoater, should have it back by Saturday.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on February 02, 2011, 06:33:29 PM
Bling Jeremy, just Bling. :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 04, 2011, 04:34:08 PM
Booyaa, bling is back from the powdercoaters....................install time tomorow  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on February 04, 2011, 05:14:12 PM
Niice. Pics please :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 05, 2011, 07:20:05 PM
Picked up the powdercoated parts yesterday, not 100% the finish I wanted but it will have to do.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0110.jpg&hash=88995ba3e51bf39da659935edd20a293745de2c1)
Mixed bag of results today, not as much progress as I had planned but at least she's heading in the right direction besides it was just too damn hot to work!
Started making a gasket for the inlet manifold and then found I couldn't bolt it on without first
removing the whole accessory bracket DOH!  :o
That took care of the first couple of hours, carried on with making some coolant pipes to link the overflow tank to the rest of the cooling system.
The factory lines didn't really suit anymore with the big inlet pipe in the way so this tidies it up well and at the same time it gets rid of the SAI too.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0115.jpg&hash=8653015f93120d72e9e6c1a8b624c4424ef969a7)
The SRI didn't allow enough room for the top A/C hose to run its normal course so I welded on a MK3 A/C coupling to be able to turn the hose upside down the clear both the rad panel and SRI, worked out pretty good.
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There just seems endless hoses and associated parts the need new homes or to be re run somewhere else, quite amazing how much time this eats up!  ::)
With the A/C done, SRI bolted on, T/B on, coolant hoses sorted I was going to throw in the towel for the day but then started thinking about bolting the slam panel on  :P
Sun was beating down still so a quick clean of the intercooler got that ready for some black from the ole rattle can, left that baking in the sun while I got on with the front panel.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0113.jpg&hash=2fce6debd5b721aeff62a4312100c121246d9e1b)
Slam panel in place ready for the I/C to go on I thought surely I could bolt that on while its still wet'ish????  ;D
Yep, sweet! It worked a treat, finished the day with the inlet pipe and BOV in place..............sure is busy in there.
Need to go shopping for an oil cooler now and make the hoses for that, finish exhaust and tidy up odds and ends before it can be started!
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Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on February 05, 2011, 07:38:25 PM
Loooooking good there!  8).......Hows the glass comming along?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 10, 2011, 08:46:15 PM
Called in to see the glass guys today, looks like they will come a couple of weeks late due to delays in shipping their container, ETA now mid march.
Wouldn't mind them sooner but its not like I have nothing else left to do  ::)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 12, 2011, 08:08:35 PM
Today reminded me of why I hate making exhausts, spent a big part of the day in the summer heat fighting with the downpipe and wastegate pipe.
Having a steering rack in the way doesn't help at all and as such things are pretty tight down there between the rack and the prop shaft, made the W/G return back into the downpipe and welded as much of that with it mounted in the car as the downpipe is a complete nightmare to get out  >:(
I'll get it HPC'd and heat wrap it as its pretty close to a few things and no doubt its gonna get mighty hot!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0121.jpg&hash=9ee25b622e90864241230ca96b6f8702ef68f586)
Bought a Trust oil cooler on friday so I also mounted that along the chassis rail and I'll make a bit of a duct for it to direct some air through it, its a pretty decent size so hopefully it will take some of the exess heat out of the oil.
Now that its got a home I'll measure out the oil lines and get them made up which completes yet another job, its getting closer and closer all the time but I'm constantly amazed how long the little details take.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0122.jpg&hash=9ec615117e7b4dca80af1f39c51977c449b82f51)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0124.jpg&hash=96dba4f709f82d126ec2fd45156a1088a107f5d3)
On with the bumper......................brand new OEM bumper, sure felt bad making that first cut
Just a LITTE trimming needed to fit  :-\ :o
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Its even pretty cool just to start seeing a face on the car again, been looking around at other cars to get some ideas on what to do.
Found something that I liked the look of today so next week I'll see if I can find a crashed bumper off one of those to cut some pieces out of.................let the plastic welding begin. >:D
Quite nice to be able to get on to doing something else as I'm kinda over engine bay stuff for a while.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0125.jpg&hash=144a88484e950216a4dc585c6d3d1ad97fa9b870)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on February 13, 2011, 06:22:35 AM
Man it sure is rammed in there!
Do you think you will get severe heat issues? I hate to say it but I almost think that like RobH  who strongly didnt want to I think you may need a bonnet scoop to let the hot air out and cold in?
Or the slight lift of the rear of the bonnet?
Anyway would hate to see it  all catch fire after a few test boosts........

Also interested in what you think you will do with the haldex issue? Im thinking you can't use differnt sized wheels with Haldex it will be undriveable and then probibly break with all that power swaping around badly?
I put the question mark there because i don't really know much about Haldex at all but i have been in Rex car when his was swapping around all funny when something was wrong at taupo in the wet.....plus he was going way to fast :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on February 13, 2011, 06:54:51 AM
Great work John, she's really taking shape now!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on February 13, 2011, 09:22:09 AM
How low are you planning to have the car, as the intercooler sure hangs low. Speed bumps and small animals beware !
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 13, 2011, 10:14:41 AM
Yeah will wait and see in regards to heat issues, will be on low boost to begin with and go from there. If it needs a vent in the bonnet then that will come when required.
Car won't be that low, our roads are not kind to it anyway but the engine oil pan is quite a bit lower than the intercooler so thats all good, it looks a lot lower in the picture than what it really is  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: fast4motion on February 13, 2011, 11:53:19 AM
Hi John, would you be able to forward me a copy of the info you were sent regarding different size tyres affecting the Haldex system? I'm just interested in hearing about the guys experience, as I saw he mentioned it on Vortex.

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on February 13, 2011, 08:43:38 PM
Regarding the bumper...... Just a thought i had some time ago.....Ford XR6 front bumper....cut the bottom half of and weld that under the Bumper moulding line of the Jetta .... you will have air ducts for your oil cooler and what ever and a diffrent look??
This bumper or similar??
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi888.photobucket.com%2Falbums%2Fac87%2FGolfMini%2F9541_p.jpg&hash=70ef3ac2ed7bd4a8c38b9a3af2f23694c39a5a18)
Maybe someone can photoshop it onto a Jetta?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 13, 2011, 09:39:33 PM
Yeah looked at that but nah, thinking current shape Commodore SS right now........
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on February 13, 2011, 10:20:02 PM
ohhhh fair enough...... ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 13, 2011, 10:26:15 PM
It all depends on what I can find in the coming week, SS VE Commodore is still quite new so..........
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on February 13, 2011, 10:31:24 PM
Ive seen some of the new R8 bumpers on trademe so the posibility is there.....good luck
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 17, 2011, 10:00:12 PM
Some more little pieces coming together, had the guys at Hydraulink make up the oil lines this afternoon- whew! what a relief to get trade pricing on those puppies ;D
Going to move the oil cooler to the RH side as I realised this week that the air intake will be right above the hot oil cooler with it mounted on the left which isn't really ideal.

Also the oil feed to the turbo has been bugging me as it should have an inverted taper nipple instead of a banjo fitting but changing it meant having to have a longer hose made  >:(
Anyhow while I was at Hydraulink I called into Greenlane speed shop and got one made, much better now.........all those "little" parts sure do start adding up, best not to think about it  :'(


Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 20, 2011, 02:22:31 PM
Not much of an update guys, faffed around a lot yesterday with very little getting done  ;D
I guess I just couldn't be bothered in the end.............
Did re locate the oil cooler to the other side and installed the hoses I had made.
Started looking at where to mount the surge tank..............................hour later still looking..................might have to go right at the back behind the haldex as thats pretty much the only option right now.
I'll run the factory pump supply into the tank as well as the regulator return and also the return line to the main tank, what that means is that the surge tank will be full at all times with exess overflow going back to the main tank.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0126.jpg&hash=42968b4f07e112d563153bbe515c77c2bcb05034)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0127.jpg&hash=83e164b3f6eafb043aefd466c33886a31bf940e7)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on February 20, 2011, 06:37:17 PM
boso it 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 27, 2011, 01:06:38 PM
Another hot day working on the car, we measured the Vento for its new strut brace thats going to be made up and once that was out of the way I cracked on with the fuel system on the beast, decided that I should run a AN-6 line forward so that I don't have any issues later on.
Went and got all the fittings and some hose and let the fun begin, wit the mounting tabs cut off the IE tank is a perfect fit between the boot floor and frame rail so that couldn't have worked out better  :o
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0140.jpg&hash=5eb5f04312cfa2976fb1aaadd89aad67e1d4bde5)
Made a few mounting points for the hoses to attach to, still have to tidy them up a bit but at least everything is cut to size and fits pretty nice.
Still have to pull the main hose back out to get the fittings swaged on. GSS did have re useable fittings but at 70 bucks each I think i'll just go with swage on!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0142.jpg&hash=dea087b05cb76aa32e987aae1546292b8618cff4)
Moved to the front to get on with what I wanted to avoid! removing the fuel rail with the SRI in place, not easy and not something I'm particulary interested in doing again  :-\
Machined a fitting to fit in the end of the rail and welded it in place.
Putting it back on was even worse, but at least there shouldn't be any fuelling issues now.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0138.jpg&hash=b1bd89ae59470e33435f2c5433779f373e443053)
Final part was to make the line to the engine, I have a swept 90 where the fuel lines come up the frame rail and then a straight line to the rail, still need to get those fittings swaged on also and then re install everything for good.
The line even fits the factory bracket to hold it in place  8)
Only one more thing to make before start up time.......................the exhaust! >:(
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Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on February 27, 2011, 01:04:57 PM
good luck on the exhaust John, i hope it doesnt take you like a million times to find one you are happy with
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 27, 2011, 01:10:32 PM
Yeah same here!  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 05, 2011, 08:09:39 PM
Wasn't able to put it off any longer so it was exhaust time today, even worse had to make it lying under the car instead of having it up on a hoist  :-\
Have I mentioned before I don't like making exhausts?  ;D
Anyway the header I made a while ago put the Vband right above the steering rack which 1, made putting the clamp on very difficult and 2nd left no space around it for movement.

Looked at making the header longer a few weeks ago but that meant I couldn't get the header back in the car  so I left it again >:(
Had to deal with it today so after looking at it for a while I dropped the front half of the driveshaft out and boom! enough room to be able to put a 40mm longer header in putting the Vband clear of the rack.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0145.jpg&hash=ecb8db13b133404033dec4f32355fcfcf275b4ba)
Building the rest from there went pretty well, flexi and high flow cat welded in place pretty quickly.
Still had 70% of a 3" exhaust left over from the many attempts of the last Jetta so it made sense to use that on this car, hopefully the turbo chops up the soundwaves on this one because I don't want a repeat of the last one.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0148.jpg&hash=53583dbf41fc8471ec71a2f0d67bd292ed1dfa56)
Had the header, flexi, mid section and rear mufflers set up by lunchtime which surprised even me  ;D
Found I needed a collector to fully finish the rear section but since all the exhaust shops would be closed I didn't want that to stop me so I made one instead, welded as much of that as I could in place.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0152.jpg&hash=be2931b7ec7839175745eaea590d918d8a87e026)
Finished the day with 95% of the exhaust done, 2 dump pipes hidden behind a caractere lower lip like the last one, still have to remove the whole system and finish welding it.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0151.jpg&hash=e4996890c7f0b6b9f2bd791316be681a73f3bd57)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on March 05, 2011, 08:16:19 PM
That's a good day's work!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 09, 2011, 10:00:14 PM
Thought I'd be smart and prime the engine for oil pressure last night, filled the oil cooler and as much of the lines and oil filter housing as I could before cranking with the plugs out.
I also left the oil pressure gauge sender out to see when the filter housing was full and to bleed out any air, didn't expect to see NO oil at all coming out  :'(
Not wanting to keep cranking and cranking it with only assembly lube on the bearings I wondered what the f&^k could be up with it, came to the conclusion that either I forgot to install the oil pump drive shaft (very unlikely) or there's an air lock in the oil pump, only one way to find out- dropped the sump and removed the oil pump.

Pump drive shaft in place so that wasn't it, took the pump apart and presto hardly any oil present!
Now my golden rule has always been to grease the oil pump gears for better priming but obviously in my exitement to put this thing together I neglected to to do that on this motor and paid the price for it.
With the gears greased and everything back together tried again, primed right away this time.
So..................my top tip is grease the oil pump gears to avoid what I just went through. 
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: JDVW on March 09, 2011, 10:57:00 PM
vasolines good when your ready to pump
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 12, 2011, 08:45:11 PM
With most of the mechanical bits in order it was time to play with wheels!  ;D
Was going to get spacers made as I was too lazy to make them myself, in the end I just bought the aluminium and got started on them.
Spent the whole day behind the lathe and the mill and they are still not finished as I'm yet to machine the center bores and press the studs in :'(
Got going on the lathe this morning facing all the billets and machining the hub centric locators on each side, I could then figure out how wide to make them which ended up being 25mm to push the wheels out to the edges of the guards and clear the daddy brakes!  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0143.jpg&hash=9f5cee7e139968eb54332c0e760efaba35959290)
With the lathe work complete just after lunch, the mill with the rotary table was next.
Set that up to drill them 10x100 and got to work drilling and spot facing for the press in studs I'll be using, for the other side I'll machine some factory bolts from a ball seat to a 45 seat and cut the heads down a little which makes them prefect for bolting the spacers on the hubs.
I'll use Porsche closed end wheel nuts on the wheels  8)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0144.jpg&hash=0529845d29576c7533ad0b58ee930db0ac0fd115)
We all know stance is everything so as a last thing for the day I bolted a spacer on and looked at the days efforts  8), with the susp compressed on the ground the rims will sit right at the guard edge.
Have to say I LOVE Superleggeras!  You like?  :P
Hopefully I'll get to painting the wheels next weekend!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0146.jpg&hash=85284c31a7a823b99da1992c91766a53e117c68b)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0147.jpg&hash=0b7554fa29d5e2b22f0028a6d80ffcff22516f03)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0148-1.jpg&hash=d950d6d88a1c337b004a822bf3fdf372d23062e2)
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So this is what a whole days work gets you, 4 spacers  :o
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Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: The Truth on March 12, 2011, 08:49:38 PM
Delicious. My hat is off to you sir, this thread is so epic to follow.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on March 12, 2011, 09:36:29 PM
If you can do 22 you'll stay inside regs. Will you mount a tire before you press everything together?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 12, 2011, 09:46:19 PM
Regs are 27 so I'm already inside that.
Nah I don't think I'll bother mounting tyres, will just whack it together  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on March 12, 2011, 10:08:39 PM
soooo jealous!!!! Love those wheels John!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on March 12, 2011, 10:42:45 PM
Quote from: 80 Vert on March 12, 2011, 09:46:19 PM
Regs are 27 so I'm already inside that.
Nah I don't think I'll bother mounting tyres, will just whack it together  ;D

Just checked; you are correct re 27mm - don't know where I got 22 from. Stretch? I think so ...
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 12, 2011, 11:23:16 PM
Quote from: tyz-fly on March 12, 2011, 10:08:39 PM
soooo jealous!!!! Love those wheels John!!

Yeah they are the right wheels for this, will paint them dark silver / anthracite
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on March 13, 2011, 11:34:39 AM
Man those front brakes are epic!  >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Nick on March 13, 2011, 02:06:45 PM
very nice! 8) I'm impressed with those good work John.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on March 13, 2011, 05:13:29 PM
Is there anything you can't do John?! Awesome, brakes and rims look like the business! Who are you using to paint the wheels?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 13, 2011, 05:12:29 PM
Quote from: Poonmobile on March 13, 2011, 05:13:29 PM
Is there anything you can't do John?! Awesome, brakes and rims look like the business! Who are you using to paint the wheels?

I try and have a crack at everything Ash, that way if and when it turns to custard I can only blame myself and hopefully I would have learnt something new.
I'm using that guy 80vert to paint the wheels  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on March 13, 2011, 05:19:36 PM
Keen on painting a prepped set I have ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 19, 2011, 07:05:39 PM
Phil was kind enough to pick the downpipe up from Pro-coat during the week so armed with those and some heat wrap we set about wrapping the downpipe and secured the wrap with hose clamps.
We did buy (at huge expense  :laugh:) some stainless cable ties and at first these seemed ideal for the job but it wasn't to be as you just couldn't pull them tight enough so back to the tried and tested hose clamps  :(
Bit of a mission to get the downpipe back in the car but with the prop shaft out of the way it worked out, pipe in and VBands secured and prop shaft bolted up the rest of the exhaust could be bolted up.
Fingers crossed thats pretty much the whole underside of the car completed now, after lunch on with the fun part of the day PAINTING WHEELS!!!!!  ;D

I was going to get some paint during the week but my painter only had base coat/clear coat available but I didn't want to mess with clearcoat on the wheels so kept looking for some 2K instead.
Found about 1/2L of 2K left over silver in my paint stash and thought I'll just mix some black in with that to darken it up a little  ;D, well............. ran out of black and still not dark enough for my liking so I also had some satin black left over and thought what the hell...................mixed that in too until the 1L tin was full.
By then the colour started to look pretty good so I left it at that, not bad for left over paint.

Set up a temporary paint rack outside and epoxy coated the aluminium first 2 wheels at a time then swapping them over to the drying rack, worked out pretty well.
As always painting stuff outside sucks, flies and crap landing in the paint but hey thats how it goes............... ::)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdate19March2011003.jpg&hash=ef454eb663a3006915064de600d6ff3d2399459b)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdate19March2011005.jpg&hash=994fa580c139647d99626e82a781ce00ffb7a844)
Let that flash off for about 45min at which time we finished off bolting the rest of the exhaust on.
Once the epoxy had flashed off the top coat went on......................booyaa now there's a bangin set of wheels!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdate19March2011010.jpg&hash=40bc6fc498fe9cbc8a65ad6c7e980ad8c17e9776)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdate19March2011009.jpg&hash=ac2a9266cff0a2995c1254a982c3ab9cf418dc36)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdate19March2011008.jpg&hash=53f254df5ea062bd8902bca8a94efeb52f59bba9)









!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VeeDub on March 19, 2011, 07:08:06 PM
They look dope! Nice and dark = nice and aggressive! Can't wait to see the car sitting on these in the flesh!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on March 19, 2011, 07:11:05 PM
You should offer that VERT guy a job John, he looks like he knows some stuff.. :D :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on March 19, 2011, 07:16:34 PM
Pretty cool colour for leftovers!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 19, 2011, 07:19:10 PM
Quote from: qta4 on March 19, 2011, 07:11:05 PM
You should offer that VERT guy a job John, he looks like he knows some stuff.. :D :D

Yeah don't know about that..............experimenting mixing left overs, bit dodgy that  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on March 19, 2011, 07:20:51 PM
You are so modest, and i was complimenting you too.
Just accept it, you are good........................... :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on March 19, 2011, 07:31:23 PM
Quote from: qta4 on March 19, 2011, 07:20:51 PM
You are so modest, and i was complimenting you too.
Just accept it, you are good........................... :D

One word ....... Photoshop ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 19, 2011, 07:34:07 PM
Quote from: VeeDub on March 19, 2011, 07:08:06 PM
They look dope! Nice and dark = nice and aggressive! Can't wait to see the car sitting on these in the flesh!


I love the colour, they have a bit of a bronze look to them in the sun.
Should really pop with the blue on the body......................need tyres...............where are my tyres  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on March 19, 2011, 07:59:37 PM
as always, nice work, good finish
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on March 19, 2011, 08:17:24 PM
Bit of a tired old cliche but pics don't do the finish of the wheels justice! In the sun you get the pop of the metallic and they have a slight gold/bronze sheen to them. I was inside finishing off hanging the exhaust and wandered out to see the first few coats done. Truly one of those "wow" moments that seeing things painted sometimes gives you when the result far exceed your expectation.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on March 19, 2011, 08:25:57 PM
Nice, only a issue if you have to remix the paint. Also I spy a Rocco in the rolla door
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on March 20, 2011, 11:02:10 AM
Poppin!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M M on March 21, 2011, 12:33:30 PM
I can't believe I haven't seen this thread before. Awesome! Will be following. :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: p40lvw on March 31, 2011, 11:12:33 AM
any updates on this joined this forum just for this build thread its pure porn



Thanx Paul
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 01, 2011, 04:55:54 PM
Nothing has been happening to this in the last couple of weeks as its easier to do nothing these days, steadily loosing interest :(
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on April 01, 2011, 04:57:39 PM
the new toy too enticing, John?   ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 01, 2011, 05:08:19 PM
Yeah that and also not having all the other parts like tyres, windows, software etc.
There are plenty of other things I can do on the car but I just can't be bothered these days.
Will try to make an effort tomorow but I don't hold out much hope..............
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on April 01, 2011, 05:43:56 PM
What are the next steps John?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: wilco on April 01, 2011, 06:01:41 PM
April 1st right?  Yeah whatever, John.  :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 01, 2011, 06:04:37 PM
Nothing to do with april 1st but yeah like you say, whatever.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on April 03, 2011, 08:55:40 AM
Hey hey hey, thats not the John Kanter we all know and love!
But I totally understand. People just don't realize how hard you have to work and the money you have to pay to make this stuff happen.
If there is anything else going on in life thats getting you down then that sort of project is very hard to push on with.
But I have faith that you will get back to it in time John.
Well I hope you do.

Im stuck with my old truck, all the bits are there but its just so insanely hard to work on the thing, nothing fits right and I just don't know where to start and I always have other jobs that people are screaming at me to finish.

  All the best John and hope it sorts itself out.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on April 03, 2011, 08:20:22 PM
You really understand........... :(
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on April 04, 2011, 07:37:09 AM
Do I?
Well I work on cars all day too, so to have a project as a car as well kinda gets tiring.
Its even harder for me cause Im poor and got no room but john works very hard and his work must cost a fortune so in the end its about the same.
Hes got so many vask projects to do I can't see how he gets to do his own stuff.
Same here :(
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Skilfil on April 04, 2011, 11:50:09 AM
Its good to have a break from something like this, coming back later with a fresh mind. If you keep trying while you've got no motivation then there is a possibility (doubt you'd do it but it happens) that something doesn't get done right and you forget about it then pay for it later on down the track.

When it does get done however, thats going to be one awesome day when you get to drive it.  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Turbo on April 04, 2011, 02:36:46 PM
if i knew anything about anything i'd offer to help. but i don't, so i'll just send you some good vibes instead.

*thinks hard about vibes*
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on April 09, 2011, 09:05:54 AM
Yea I would like to help in some way as well but what can you do?

Hopefully we get to see the finish of this.
Good things are never easy, John never does easy.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on April 09, 2011, 04:07:32 PM
Some good progress today boys - more to come later.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 10, 2011, 04:21:38 PM
So...................Filx forced me to work on the car yesterday!
No just kidding  ;D, the great thing about positive people like Filx is that it rubs off on you so thanks for that mate and appreciated your help and input once again!
My shipment of parts arrived on friday so I booked some time with Lance at Arrow wheels to fit the tyres in case we could fit these on Saturday.
Saturday came, not much enthusiasm until Phil turned up who just about went weak at the knees when he saw the new rubber!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0146-1.jpg&hash=15fe2ff50848b4c4c96b125d1ff40e07238b6f5a)
Figured out that the rims may stick out too far last time I worked on the car so thinking about the problem I realised that the disc and caliper could easily be moved inwards 5mm and that allowed 5mm to come off the adaptor narrowing the front track by 10mm over all.
Vask member Nick was kind enough to CNC some rings out of 5mm ali plate (damn I love CNC machined stuff!!) so we cracked on taking the front brakes apart and fitting the new rings between the hat and rotor, first one took a while but once a few issues were sorted out the other one was easy.
Took the Vento up the road for lunch as I had not driven it yet with 20+psi  :P................well!  That's just lunacy on the street so I'm seriously wondering how a R32 turbo is going to go  :police:

After lunch we machined the adaptors down 5mm and fitted those, I could see Phil was getting keen to see the car with its new shoes sitting on the ground so the wheels went on and dropped it on the ground for the first time in what seemed like ages.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdate09April2011001.jpg&hash=0ec155166731fe65e9364b5819b51bbf7678b382)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdate09April2011002.jpg&hash=7f634ad7baf53294015311b1220ea5715b3a69ca)
Also got the new Caractere rear lip with that order so we fitted it along with the bumper then Phil had the bright idea to roll it outside for a few snaps.
Must admit I really like where its heading, starting to look exactly how I want it.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdate09April2011014.jpg&hash=263991c384d58e5fef98a297c5945b4dc12f2131)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdate09April2011010.jpg&hash=27d37777bed68022e50391baf22db751cdd04bbe)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdate09April2011009.jpg&hash=474111879b7be554ff590e51df6856fae0a2440c)
Once Phil left for the day I carried on fitting some New South gauges with one of their gauge pods that sits directly behind the steering wheel, the double sided tape they supply barely sticks to the crubber so I just ended up screwing it on for a better fit.
Did most of the wiring for them before I called it a day.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0148-2.jpg&hash=d29139f02df60bc45cae8fc2c6bfe4a12b0626a3)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0147-1.jpg&hash=30320ad1afd95c80771f7de975ff7ff2bb27e107)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Skilfil on April 10, 2011, 04:37:20 PM
Nice! Looks good, I was interested in those Superleggeras you had a while ago but wasn't sure on the repair of that damaged one. Awesome looking rims, they suit it thats for sure.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on April 10, 2011, 06:32:20 PM
Thats some exciting pics there1 ....very gooood!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on April 10, 2011, 06:37:52 PM
Very nice, perfect et on those wheels. Is that the final ride height or tweaking to come?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 10, 2011, 06:38:59 PM
Yep the rims are pretty flush!
Plenty more weight to come so ride height will decrease some more, will also fit my coil overs to cert that way I'm set either way I go.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on April 10, 2011, 07:11:14 PM
have you decided on the front bumper yet?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on April 11, 2011, 11:12:10 AM
r32 i reckon ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VeeDub on April 11, 2011, 01:01:16 PM
Good on you for getting stuck back into it! You're making huge progress on every update, it's great to see! This thing is starting to look suuuuuuper tight  8)  8)  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on April 11, 2011, 03:59:44 PM
the MK5 GTI steering wheel looks right at home there, John didn't even notice it at first

was missing the nice chunkiness of the GTI wheel coming back from Sulphur City in the MK4 yesterday
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on April 11, 2011, 05:08:36 PM
Flix is a cool and really positive person.
Glad to hear your back on it Vert.

And 400hp through the front wheels lunacy, no................. >:D :laugh: :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on April 11, 2011, 06:35:44 PM
A W D there Jem :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Pristle on April 11, 2011, 07:06:37 PM
Be interesting to see how much she weighs. Looks very light without the rear doors.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 11, 2011, 07:34:14 PM
LOL, looks light but it aint!
Phil and I struggled to push it back inside, will be at least 1500+ kg.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on April 11, 2011, 08:00:16 PM
Quote from: AngleBox on April 11, 2011, 06:35:44 PM
A W D there Jem :)

This car is, the vento isn't.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 12, 2011, 08:22:10 AM
I wonder what is in here?
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0149-1.jpg&hash=96f9edbe84346984f66466a60499a6eb0e1ab3a7)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on April 12, 2011, 08:41:44 AM
my pick is windows!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on April 12, 2011, 09:12:26 PM
small furry animals?  :P  ......windows X2
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on April 12, 2011, 09:55:25 PM
Dry cell batteries for the hybrid conversion
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 13, 2011, 08:02:06 AM
YES!!!!!!!!!!!!!!!!!!!!WINDOWS  ;D ;D ;D
I owe a HUGE thanks to Glenn Bishop of windscreen distributors NZ for making these happen as without his help I would still be looking for a solution 10 months later.
At any time he could have given up on that crazy idiot with his coupe windows but he didn't do that, instead he found a solution and got to work.
The windows are awesome, fit perfectly and dot matrix looks completely OEM.
Will probably have to come up with another solution as far as seals but thats minor detail, this glass is laminated but I still intend to make the pop outs work so watch this space.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0152-1.jpg&hash=54d43f80e57c37414643497ec9e64baa57fc1323)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0153.jpg&hash=925ed55712d7d3bb95e8ff631957362fba04f364)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on April 13, 2011, 08:06:43 AM
Nice when people go the extra mile like that eh.
They look really pro John.
Glad to see the magic happening again.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 13, 2011, 08:09:42 AM
It sure is Jem, not many people do anymore though sadly.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on April 13, 2011, 08:26:59 AM
They look fantastic. Get them IN!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on April 13, 2011, 08:46:57 AM
Quote from: 80 Vert on April 13, 2011, 08:09:42 AM
It sure is Jem, not many people do anymore though sadly.

dunno, I often come across good keen people who are happy to do a job well and like a like a challenge, Milford Auto Electrical come immediately to mind
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on April 13, 2011, 09:43:34 AM
Nice, looks like it's coming along well, good to see you back into it :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on April 13, 2011, 12:57:22 PM
I sure hope these window never get broken
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 13, 2011, 02:39:52 PM
Not worried about that, I have spares  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Turbo on April 13, 2011, 05:02:05 PM
good thinking.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on April 13, 2011, 08:40:19 PM
that looks great! Cant wait to see them 'poppin' out! good to see you back into it too :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on April 13, 2011, 08:42:41 PM
Quote from: 80 Vert on April 13, 2011, 02:39:52 PM
Not worried about that, I have spares  ;D

Great planning as always
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 13, 2011, 08:44:41 PM
Thanks guys, enthusiasm is well and truely back!  >:D
Got a call from Glenn today with the final bill, top bloke couldn't reccommend him high enough!
I know they are only dumb bits of glass but they are the last big piece of the puzzle.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on April 13, 2011, 09:26:11 PM
Put the bloody puzzle together already :P ....heheh.....goodstuff guys!  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on April 14, 2011, 08:40:12 AM
are you going to have to drill holes for mounting hardware, or is it all glued on?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 14, 2011, 09:19:11 AM
Yep is all made to be glued on, Glenn decided I was better off gluing the pop out latch to the glass.
Front hinge is a channel that the glass slips in to which will also be glued, thats the theory anyway.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 17, 2011, 02:47:57 PM
Ok, mixed bag of results yesterday.
One thing I did manage was to break one of my side windows  :'( Still, lessons learnt were that the existing hinge idea sucks and needs to be changed in order for it too work.
Don't mind one set of glass being the gunnea pig to make the pop outs work, if that turns to sh#t too then I'll be gluing them in for good.

The existing seals also were too thick so I had a look at Para rubber and tried a few different rubber extrusions but none were ideal so again back to the drawing board on that too.

Looking at my existing seals that I made from Sharan ones a while ago they would be ok as long as they were a bit thinnner so I managed to cut the pinch welt part from them meaning they are now 2-3mm thinner so they will now work fine, just have to urethane them to the body instead of relying on the pinch welt.
Thought of different ways to do the hinge at the front and one was just to urethane it and let it flex on that which should work fine but being able to remove the windows when called for would be better so this morning I headed back to Pick a part and found the ideal thing on a Toyota people mover thing.
Again same idea as before, glue the hinge to the glass which in turn bolts through the B pillar.
Nothing else needs changing body wise so Easter weekend will see 180 grit block sanding to get her straight for paint.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on April 18, 2011, 09:06:49 AM
Bummer on the breakage :-[
Good ol pickapart.
And that would have been a Toyota Estima.
I had one it was great!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 18, 2011, 05:21:42 PM
Yep certainly a bummer but thats the cost of progress sometimes, just as well there's another 14 sets coming in a container  ;D
Anyhow I spent quite a bit of time completely re thinking the whole hinge idea so therefore the Toyota hinges which have turned out great, in many ways this is a much better solution which I should have done first time round.

Everything is held in with tape at this stage to sort everything and get the alignment just right.
Can finaly move forward with bodywork and paint!!!  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0146-2.jpg&hash=df383f45a6c4247d7568cb699430589958c15476)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0147-2.jpg&hash=ff3d250f6f4430688571fd4fc456a3dc1dc3a3f7)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on April 18, 2011, 05:34:33 PM
14 more sets :o
Did you have to get a certain order for them to make them?
Nice work John.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on April 18, 2011, 06:02:24 PM
Think bigger Jem - production line of R32 Jetta 2-dr for export market
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on April 18, 2011, 06:21:48 PM
Aaaaand... the enthusiasm is well and truly back by the looks of things ;)  Awesome work!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on April 18, 2011, 06:33:17 PM
Didn't really take that much eh.
I guess he enjoys what he does.
And hes got a good work shop. Its a dream shed really.
Good shirt John.
Crankin out the hot VWs.
Why not.
I don't think we as car users are wasteful.
Ok we burn gas a bit, and no we don't have to do it to survive but its the endevour of man to create and we really look after and build stuff to last mostly.
Its all the morons with half flat tyres and no oil in their engines who do the damage and waste.
And yanky scrapping laws ::)
Which we adopt ::) ::)
So lets never let this beconing doom and gloom re cars and oil stop us doing our best.
From the resident cloth eared greeny.


Not that John would have ever had this at the back of his mind burning away >:D
Hes too petrolhead for that  :laugh: :laugh:

Yea but nah, I think we all do really enjoy seeing what John gets up to and are so glad he does bother to share and post pics.
Top Vasker.   
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 18, 2011, 08:38:59 PM
Yep, 15 set minimum. Just wouldn't have happened otherwise.
Fark it s soo cool to have glass in there! Bring on colorisation!

Its amazing how something small can make a great day go bad, same thing with building cars.
Something small like side windows sparks new intrest........................ >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on April 18, 2011, 09:00:36 PM
Wohooo ....let the motivation role!!!!!!!!  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on April 19, 2011, 09:24:29 PM
Quote from: 80 Vert on April 18, 2011, 08:38:59 PM
Yep, 15 set minimum. Just wouldn't have happened otherwise.
Fark it s soo cool to have glass in there! Bring on colorisation!

Its amazing how something small can make a great day go bad, same thing with building cars.
Something small like side windows sparks new intrest........................ >:D

You know what would really get you going?? R32, AWD Mk1 Rocco !!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 21, 2011, 08:40:16 PM
Hope you all have a pleasant weekend planned?
Starting tomorow I'm sanding, then I'll do some more sanding plus some more sanding later in the weekend  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on April 21, 2011, 08:54:22 PM
Coming on Sunday ?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 21, 2011, 09:05:03 PM
Nope, hopefully I'll be re priming everything on Sunday.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 22, 2011, 08:05:26 PM
Good thing about having this 4 day easter break? Gonna get lots of sanding done thats what  >:D
Did the last of the filler work around the window frames during the week so thats ready for 180 sanding.
Started the prep on the doors and side skirts today.....................fun fun fun  :police:

The RH door had a very average blow over at some point so I ripped that down with some 150 grit to cut all the nasty bits down quick followed up with 180, once both doors were ready I masked the insides, did some small repairs on the side skirts and primed them up again.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0148-1-1.jpg&hash=e6633d0492ff5f0a6ebf22b9f41ecd18217c0d28)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0149-1-1.jpg&hash=5ad01fe68165b47b3590f2734828c055ca09c02f)
Tomorows job is to block sand the rear quarters and jambs with 180 grit and re prime them.
I'm not a pro at this body work stuff by any means so things probably take me a lot longer to do but thats the way it goes.
Also masking the whole car is a pain but the delays in sourcing the windows has meant this was the only way to carry on building the car, not my prefered way but its working ok so far
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0150-1.jpg&hash=63699d5ad98291c361daf32b981af83e0878b48b)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 23, 2011, 08:38:22 PM
Had an awesome day working on the car again today, great tunes on the stereo and things worked out well sanding. Probably been the best day working on the car for quite a while!
Got both rear quarter panels blocked out with 180, re masked the whole car and shot some more durepox primer on it.
Still have the bootlid to do but that can wait till next week, was a long day today so having the next 2 days off is kinda nice before going back to work.
Going to have to install those coil overs too, that ride height is just rediculous  >:D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0152-2.jpg&hash=3300763ce4a434f384ee746b494036eb877a0b40)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0151-1.jpg&hash=6091f87da11644787f47eb1f3bb3f4255a10248f)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on April 26, 2011, 08:27:15 PM
Looking good there....WOW.......that blue is going to be awesome on it!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: vonripsnorter on April 26, 2011, 08:32:49 PM
looks REAL good John, but I wouldn't expect anything less from you,

Liking this thread alot & always watching ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 26, 2011, 08:43:48 PM
Cheers guys,
Bootlid is all done now too, never could get the hole for the boot release quite right until tonight.
Found a piece of pipe a few mm smaller than the hole in the lid so wrapped some sandpaper around the pipe and presto! Easy way to make a hole round  ;D
Sounds easy to make a hole look round to the eye but it isnt, took me quite a few goes but the pipe trick did the job in one go.

Got that primed up with durepox and re hung the doors to final gap the guards before paint, going to also fit the side skirts so they can be painted with the doors and body as I'm a bit nervous painting major parts seperatly with pearl colours.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on April 26, 2011, 10:35:47 PM
Quote from: 80 Vert on April 26, 2011, 08:43:48 PM
Cheers guys,
Bootlid is all done now too, never could get the hole for the boot release quite right until tonight.
Found a piece of pipe a few mm smaller than the hole in the lid so wrapped some sandpaper around the pipe and presto! Easy way to make a hole round  ;D
Sounds easy to make a hole look round to the eye but it isnt, took me quite a few goes but the pipe trick did the job in one go.

Got that primed up with durepox and re hung the doors to final gap the guards before paint, going to also fit the side skirts so they can be painted with the doors and body as I'm a bit nervous painting major parts seperatly with pearl colours.


If you are nervous, i'll be excited for ya ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 28, 2011, 06:24:20 PM
Should I mold the Caractere lower lip into the rear bumper and make it all one piece or leave seperate as factory?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on April 28, 2011, 06:26:13 PM
If you are making a 1 piece front bumper/lip, I'd do the rear to match. 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on April 28, 2011, 06:55:14 PM
Nothing about this car is factory, no point starting now, DO IT!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RevHappy on April 28, 2011, 06:59:21 PM
Quote from: tyz-fly on April 28, 2011, 06:55:14 PM
Nothing about this car is factory, no point starting now, DO IT!
+1
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on April 28, 2011, 08:53:43 PM
Quote from: 80 Vert on April 28, 2011, 06:24:20 PM
Should I mold the Caractere lower lip into the rear bumper and make it all one piece or leave seperate as factory?


Factory - you've made the rest OEM  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 01, 2011, 04:41:05 PM
Molded the lower lip to the bumper, the lip is urethane and the bumper is plastic so there's no way to plastic weld this as far as I'm aware, doesn't seem like bondo sticks to the urethane super well either so there's always the possibility of it cracking meaning I'll probably get some extra paint made in case I need to re visit this down the track.
There's a LOT of screws holding the 2 parts together though and also made brackets for the ends where the guard liners go to stop things moving and cracking so fingers crossed  :-\

Finished up with the final coat of bondo yesterday and primed it up, will let that set and 180 block it before I re prime it again.
Got to say I'm likin the one piece look
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0153-1.jpg&hash=b901d05f7b41d79ff4eb01d81b92c9a2055d85fd)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0156.jpg&hash=2b22734233b9e6cefff2369b43e934477a21e143)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0157.jpg&hash=2ad1f1a19cec36e665a771da408fb4d16c025c2e)
Must say I'm well over doing body work and sanding for a while so I moved on to making the air intake pipe for the airbox, had to move a bunch of stuff out the way to clear a path to be able to pick up air from the inner guard area.
Started out making cardboard templates and then cut those pieces out of aluminium, had a problem with the welder which in turn ruined most of what I had already made aarrrgggghhhh!!!!!!!!!!!  >:(
By now it was 3.30pm and feeling like s**te that things had gone wrong I was going to throw in the towel for the day but I managed to figure out what the welders problem was so game on again!
Re made my parts and welded them together successfully this time, quick test fit which looks ok.
Still have to trim one end and make attachment points to the airbox but so far so good.
Once this is complete I'll start on the water meth tank for the boot and do the wiring for the boot mounted battery.........................getting closer, a LOT closer  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0154.jpg&hash=0c38db9a6f152fbe551faebc21601dd2ebd32b49)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on May 01, 2011, 06:14:57 PM
Looking good John, looking at the exhausts did you use a similar layout (i.e. resonators and boxes) for the exhaust as the S/C Jetta?

So as not to get drone is there a number of resonators required??

just thinking about my exhaust options on my mk4
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 01, 2011, 06:21:23 PM
Ummm yeah the exhaust, here's hoping it won't drone too bad.
The SC jetta had the 2x 3 into 1 factory cast manifolds on the head with everything custom from there, didn't get rid of the drone till I fitted the R32 back box.
This one however has a 6 into 1 ATP manifold going through the turbo and a 3" from there into a high flow cat & resonator then splits at the rear axle in to 2x 2.5" triple flow mufflers.
Turbo's are supposed to break up the soundwaves also so like I said.......here's hoping!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on May 01, 2011, 06:27:01 PM
Just turn your subs up bra :P
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 07, 2011, 09:12:55 PM
Righto another saturday bites the dust, lots of little stuff done!
Finished off welding the water meth tank so that's as far as I can go with that till I decide what kit to buy and also waiting on the flush fit cap to arrive.
The tank is held pretty securely by the foam tool tray and still have space left over next to tank to mount the pump when I get one.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0166.jpg&hash=682281db9f151c7045654999701e75104999404b)
Mounted the Odyssey battery in the boot, simple bracket bolts it to the foam tool tray using the center hold down pin as an earth terminal.
Got some chunky battery cable on friday but with no clear plan of how to run it forward I spent quite a bit of time looking at the best way to run it, in the end the best solution was out through the bottom of the tyre well and under the car.
Also finished up the wiring for the secondary fuel pump, relay off the battery with a signal wire from the stock in tank pump ensures that it should all be trouble free.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0167.jpg&hash=f92b270272ef9541b2504258d327ac68f2d8382f)
Made a power point for the front out of some bakerlite so that the cable from the battery, starter cable and battery fuse box power can all come together.
Also made the starter cable and earth cable to the motor at the same time.
The battery fuse panel neatly mounts to the air intake pipe I made last week, quite happy with that!  :)  Good to have the motor cranking over on its own battery which is nicely hidden under the boot carpet.

Been thinking about the side trim for a while and since paint is pretty close now it meant I had to get a bit more serious about a solution, I intended to always retain the stock chrome trim on the bumpers and side moldings but of course with the 2 door conversion it meant that the 4 door trim was the wrong length, rears too long and fronts too short  :-[
Looked at all kinds of ways to solve it but nothing grabbed me till I thought of incorperating an R badge on the door trim where the join would be.
Cut the rear trim down to length but unfortunately I fooked that up by cutting it wrong!!! D-OH!
As luck would have it I had a spare one off another door, phew!
Measured a bit more carefully this time, marked out where the badge would go and put it in the mill to machine a recess in the trim for the R to go..................went better than I expected  ;D
Bit more fiddling with a file and knife to look like this.................................now to repeat everything for the other side, devil's in the detail!  >:D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0168.jpg&hash=aae09da259f4dc4932ef53cc57410f59fc7858c2)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0169.jpg&hash=bc770f54308cc28c2158bf61899e8ec97b1d8b93)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on May 07, 2011, 10:37:52 PM
That was a damn good idea.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on May 07, 2011, 10:48:40 PM
great solution! down there for dancing 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on May 08, 2011, 09:15:11 AM
The R badge looks really good John.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on May 09, 2011, 02:51:41 PM
it'll be known as the pirate ship now.  the JettaRRRRRRR...

sailin' the blacktops of New Zealand, plunderin ricer boys and intimidatin the posers...  Arrrrr.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 17, 2011, 04:50:28 PM
Bit of a belated update from the weekends action, not much to report but I did manage to do some more painting  >:D
Painted the guard bolts areas and the door openings, mainly did it this way so that I can paint the whole car with the bonnet, doors and bootlid in place to make sure there's no issues with the pearl effect.
Can carry on this weekend sanding the outside to get this sucker ready for paint.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0164.jpg&hash=8f046592377e1dc4fbecb6a22e431334f57523aa)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0165.jpg&hash=e9b5bbe12885db9fadc7c9f14487484189b8cd8e)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on May 17, 2011, 09:26:22 PM
Coming together nicely!
I like the idea of painting it like that, hopefully it will give a more consistent finish
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: itsagthing on May 20, 2011, 01:46:41 PM
Looking so fresh this.....Keep up good work.;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 22, 2011, 10:09:48 AM
The plan was to do a full days blocking yesterday to get this prepped for paint but as soon as I was about to start on the roof I realised that I hadn't made the roof moldings or modified the gutter seals, didn't really want to be doing that when the car was painted.

Modifying the 4 door seals turned to s**te because of the pinch welt molded in to them so it was back to the mangled R32 ones that I'd kept off the wreck, managed to resurect those luckily.
The moldings were pretty easy in the end, just a bit of hand bending and curving them in the shrinker has them fitting really nice.
The moldings essentialy cover the join in the roof where it meets the 1/4 panel, normaly held in with a rubber seal but I'll urethane these in as it keeps dirt / water out better.
The rest of the day was sanding, sanding and then some more sanding  >:D got the roof, bonnet and front guards finished  :o
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0145-1.jpg&hash=17f4b3de7007846c5aa8411fcafd9cb01c919b89)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 25, 2011, 10:41:54 PM
Been adressing the software for this car again, did have a solution set up already which looked very promising but it wasn't to be and being let down again by another USELESS american company it forced me to look elsewhere.
Growing more and more tired of the usual slackness of US companies I started looking around.

Reading about LeMans's great eperience with Viper tuning for his RS4 map led me to contact Richard who was more than happy to jump on board to work on a solution to get this thing running!

End result is that he'll write a custom map for my car, LeMans was kind enough to pop over and do an ECU read which Richard has confirmed to be what he tought.
Bit more mucking around set up wise but in the end I should have a much better suited solution for my car.
Hopefully things will work out so that once painted we can work on getting it running  >:D Looking forward to THAT day!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on May 25, 2011, 11:27:47 PM
BBQ for the fire up?  :P

Would have thought getting it all talking would have been fairly simple being essentially all Mk4?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on May 26, 2011, 08:06:55 AM
Take it that's someone local?, which would make it easier when you upgrade to and even bigger turbo some day. Not sure how of it would physically fit in though.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on May 26, 2011, 08:14:57 AM
Rich from Viper is from some channel island somewhere in the UK. The technology today supports getting your ECU tuned from anywhere in the world which is cool. A local person would still be great but there isn't anyone with the experience or capability for this kind of work.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: itsagthing on May 28, 2011, 09:14:44 AM
Quote from: Filx on May 26, 2011, 08:14:57 AM
Rich from Viper is from some channel island somewhere in the UK. The technology today supports getting your ECU tuned from anywhere in the world which is cool. A local person would still be great but there isn't anyone with the experience or capability for this kind of work.
*100
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 05, 2011, 06:30:53 PM
 ;D ;D ;D ;D ;D more later!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2Fozzy003.jpg&hash=38f33b2d759e6f80ef676f70d07dbbf278b8f659)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VeeDub on June 05, 2011, 06:58:33 PM
YES!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on June 05, 2011, 07:58:09 PM
baptised in blue!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on June 05, 2011, 09:21:45 PM
Awesome John! 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on June 06, 2011, 07:48:12 AM
Quote from: 80 Vert on June 05, 2011, 06:30:53 PM
;D ;D ;D ;D ;D more later!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2Fozzy003.jpg&hash=38f33b2d759e6f80ef676f70d07dbbf278b8f659)

You decided to paint it yourself John?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 06, 2011, 10:15:26 AM
Yep always intended to right from the start, still needs some cutting and polishing but for a home job without a spraybooth i'm 85% happy  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 06, 2011, 10:58:52 AM
Ok so the paint is on, another tick in the box!
Was a huge couple of weeks leading up to yesterday with sanding and body prep, masking off and setting up my temporary paint booth.
Since all the insides were painted and I seriously dislike overspray it meant I had to mask EVERYTHING which was a huge job in itself, by no means a pro at this so I just took my time.
Once set up on stands I masked a skirt down to the paper on the floor to stop overspray getting underneath the car, a lot of effort but it worked out great.

Spraying the car sure showed the shortcomings of the temporary spraybooth, at only 3m wide it doesn't leave a whole lot of room down the sides to move around which made spraying a lot harder than it should have been with hoses getting in the way and trying to not touch the car as I moved around but hey its done now and I can say I did it  >:D :laugh: 
Bumper and all small pieces to be done next weekend all going well.
Will flatten down the sides, roof, boot and bonnet in the coming week and buff those out which should make it much flatter and pop a lot more, anyway enough talk now for the pics.....................
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapaintingJune2011001.jpg&hash=49f605734c2d9190b8c8d9017d0d73a5b3a226ce)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapaintingJune2011004.jpg&hash=af55d1eb05d838d5c57314f50b67644f98767f34)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapaintingJune2011012.jpg&hash=a62f88f438662a6d54f26defb4e5a6ce17be2bdb)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapaintingJune2011016.jpg&hash=4cc47ff4bf7b32cbba9c3c13d54adfff9bf485e0)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapaintingJune2011018.jpg&hash=ace38107880db0db6f937a2ad459509c66e98973)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapaintingJune2011021.jpg&hash=019226230ce75c09633dcf2a24b3d77ca37d1300)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapaintingJune2011022.jpg&hash=2ddd181165ac118fcaee94e3423da3a66ca87d95)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapaintingJune2011032-1.jpg&hash=1e18a63001ba31bccb06b55a3f7b68c356517d63)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapaintingJune2011031.jpg&hash=4ce7829670439ef022f7a27c5a867023c06eeb96)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapaintingJune2011029.jpg&hash=d5e478134871edd54fa9891dd56a6d37bc9c7dad)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapaintingJune2011028.jpg&hash=23887a0bb3c66821aa1fbf6aaa6bdb0d775f76ab)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on June 06, 2011, 11:05:01 AM
Looks great John.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on June 06, 2011, 01:19:40 PM
That looks awesome! What was 15% making you not so happy?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 06, 2011, 03:35:38 PM
The amount of rubbish in the paint (dust, dirt) and the amount of orange peel.
Both just about unavoidable but a 2000 grit cut & polish will solve those  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on June 06, 2011, 04:42:52 PM
That's a beautiful colour, nice!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on June 06, 2011, 05:18:11 PM
What is really impressive about this paint job is the amount of work and gritty determination just to get through the prep for the paint stage. There's serious hours in the prep work which is pure hard slog. I was very impressed when I say the standard of the pre paint finish - no corners were cut, nothing left half done.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on June 06, 2011, 05:22:21 PM
But, did we expect anything less from John?  :) :P

Looks sweet so far dude!

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 06, 2011, 10:12:56 PM
Yes yes I know I'm too fussy & obsessive  ;D  :police:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on June 06, 2011, 10:11:39 PM
Loving that colour, can't wait to see it with bumpers etc! 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: uero-jet on June 06, 2011, 10:34:39 PM
 ;D i is very excite
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: le mans on June 06, 2011, 11:03:25 PM
Brilliant!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Period_Correct_ on June 07, 2011, 07:28:47 AM
damn John, you should get a TV slot.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: gti vr6 on June 07, 2011, 09:46:43 AM
looks great!!

even the lady of the house approves of your colour choice....

nice work with your warewhare spray booth

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M M on June 07, 2011, 10:07:06 AM
Awesome colour choice and great result. Brilliant job!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 07, 2011, 11:39:59 AM
Cheers guys, now to get it finished and running................ >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on June 08, 2011, 08:20:45 PM
Sometimes its good being away with no web time.....you get a wack load of awesome blue jetta pictures! ......loooks great!  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on June 08, 2011, 08:54:12 PM
Gee look at all that respect 8)
I'm a pale imitation now :laugh: :laugh:
TOP WORK.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: vwrally on June 08, 2011, 09:07:00 PM
Quote from: 80 Vert on June 06, 2011, 03:35:38 PM
The amount of rubbish in the paint (dust, dirt) and the amount of orange peel.
Both just about unavoidable but a 2000 grit cut & polish will solve those  ;)

Great Work and a Great colour I admire your patience and attention to detail, Im sure neither of things are in my gene pool

I used to work with a guy who did some amazing paint jobs in his garage and he always told me two things that will help

1  keep your paint warm

and

2 attach a steel chain to the chassis that reaches the floor and water the floor down,

you get a lot of static electricity blowing all that paint around that it starts attracting dust from all over your work environment and the chain along with the wet floor will keep your car grounded.

Might help with the parts you have left to do
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 08, 2011, 10:16:15 PM
Great tips VWrally, I'll be sure to give those a try.
Makes sense when you think about it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on June 09, 2011, 01:55:59 PM
Looks great! Well done.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: xring on June 09, 2011, 07:47:37 PM
When the car is finished, I think you need to take a road trip ...... calling on every town that has a vask member so that we can all see the fruits of your labours in the metal and have a few drinks. You drive, we will shout you the drinks.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on June 09, 2011, 07:52:22 PM
 :P Not sure how that works with the drink driving laws an all Xring, but it would be great to see John go around NZ in it!
It costs a lot tho, it really does when you add everything up.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on June 11, 2011, 07:20:41 PM
Hope the rest of the painting went well this afternoon John  :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 12, 2011, 04:57:45 PM
Yeah cheers mate, phase 2 of the painting went awesome!
Annoyingly the paint laid down much better than on the car itself but thats how it goes sometimes and you just have to take the good with the bad.
What a mission setting all that up, hung the parts as they would be on the car to hopefully paint them the same direction minimising any potential for the pearl effect to look different.
Everything bar the front bumper (which isn't even made yet) is painted now, feels good to have that big step out of the way and over with.

I'll make a start on the polishing of the body this week, hopefully I can get a little done each night so that it can start to go back together.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapainting2June2011001.jpg&hash=c28cb57671695d829fc179ce9b41b76e6a592a55)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapainting2June2011004.jpg&hash=7485e6968fd012e0a1ff7bbbee3266d9f9a6b269)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapainting2June2011005.jpg&hash=9bd06c20798a08306f6e5ac5fd036fe5a6e9b54d)
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Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on June 12, 2011, 06:05:15 PM
Daaayaum that's shiny. I shoulda taken those pics in the nudz for some reflecto pr0n.  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: JDVW on June 12, 2011, 06:16:59 PM
i didnt know party central was a spray booth to. looks good
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on June 12, 2011, 09:51:12 PM
That is so cool - well done mate.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on June 12, 2011, 10:09:32 PM
Loving the one piece rear bumper... looks great!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on June 13, 2011, 10:51:45 AM
I can not wait to see this rolling John! Love your work!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GTI's on June 13, 2011, 04:46:01 PM
Paint job looks factory flash!  Very nice colour too!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 13, 2011, 09:49:30 PM
Paint should improve a lot more by the time I'm done  :), had a go at using the polisher tonight.
With no idea of how the whole deal works I watched a couple of youtube vids and got to it, flatted down the bootlid with a block and 2000 grit then masked up the edges so I wouldn't burn through which seems to be easy to do.

Gave it the bada bing bada boom with some 3M cutter  ;D which seems to work quite quickly bringing the shine back again, I'm not taking all the peel right out just most of it.
Seems to take a few goes to get all the scratches out but works pretty well, the fluro lights work really good to highlight areas's that still need work.
Finished off blocking out the rear 1/4 panel so I'll give that a crack tomorow night  >:D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0149-2.jpg&hash=2580ffa7bde990965241e8bbb42aa4871eab1797)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0148-3.jpg&hash=121b1df2c016b54a2f603ef4997877a9f1bfba73)

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VeeDub on June 13, 2011, 10:02:45 PM
Mega respect for all the time and effort you're putting into the prep & paint work on this project!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 13, 2011, 09:59:05 PM
Paint job makes or breaks the look of a car and paint prep is everything to get a good finish, besides with all the work gone in to this it kinda deserves it I think  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on June 13, 2011, 10:25:37 PM
So how much is Kanters paint and panel shop  :P

Looking good though
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on June 14, 2011, 09:06:04 AM
He don't muck around, couldn't call the dude lazy.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on June 14, 2011, 06:15:20 PM
Good on ya mate! step by step! TWO-thumbs up! ......i wonder how that .:R badge would look if the blue of the badge was Red?...
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: John Stone on June 14, 2011, 06:55:23 PM
Benchmark stuff John, bloomin marvelous
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 14, 2011, 10:09:07 PM
Been thinking the same thing myself Arno, will look into that!
More effort tonight, the polishing is just plain hard work but you just have to turn the radio up and get to it!
At least it beats sanding by a slim margin  ;D So far both rear 1/4'rs and boot lid are done, also sanded the roof so I'll hopefully finish that tomorow meaning I'll be nearly half way LOL!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 00quattro00 on June 14, 2011, 11:00:14 PM
Quote from: Filx on June 12, 2011, 06:05:15 PM
Daaayaum that's shiny. I shoulda taken those pics in the nudz for some reflecto pr0n.  :laugh:

like this tv >:D

http://www.trademe.co.nz/Electronics-photography/TVs/Standard/CRT/22-32-56-81cm/auction-383692820.htm
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 18, 2011, 09:08:30 PM
Bada bing bada boom!!
This is what you get for around 20hrs hard graft with a polisher  >:D more tomorow................. ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapainting18June2011003.jpg&hash=57f6d19fa5abe1a04a740be3b5df29e924a393f5)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Omes on June 18, 2011, 09:17:14 PM
I saw this up close and personal the other day, Kanters you are a Wizzzzzzard!  Paint has come out mint after that cut and polish, superb  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on June 19, 2011, 03:27:29 PM
You gotta have balls to wet and dry your freshly painted car eh!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 00quattro00 on June 19, 2011, 03:22:18 PM
Quote from: coons on June 19, 2011, 03:27:29 PM
You gotta have balls to wet and dry your freshly painted car eh!

you just need to know what you are doing, quite easy to cock it up
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 19, 2011, 04:43:09 PM
Quote from: coons on June 19, 2011, 03:27:29 PM
You gotta have balls to wet and dry your freshly painted car eh!

Well I'd be lying if I said I wasn't a little nervous in doing so but its turned out better than I could have imagined.
Main thing was to tape up ALL the edges as its super easy to burn through them! and the other thing is to spend the bucks on the right gear like 3M cutter and buffing pads.
Even the sandpaper makes a huge difference, I bought some 2000 grit on TM which was absolute garbage and the scratches it left behind were almost impossible to remove  :'(, again more expensive 3M paper was night & day difference!
After having done this car I wouldn't hesitate to do the Ghia when I paint that as apart from being mega time consuming the results kinda speak for themselves.
Anyway finished up polishing out the jambs yesterday and started some assembly, cut some vinyl for the B posts of the doors and put some door related stuff on.
Trying to stay away from putting too much stuff on the fresh paint till it hardens up a little more so this coming week I'll get myself set up to do some upholstery  ;D
Got some headliner material some weeks back so thats next on the list along with the A,B&C pillar trims, quite looking forward to some upholstery work as its been a while since I last did some.
Here's some pics Filx took yesterday...........
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapainting18June2011018.jpg&hash=4f2b26b75aa4dc37c4d853f1db666a80e16094e7)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapainting18June2011014.jpg&hash=883e520c8f03b62bc6d46040f4f1431b4373302d)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapainting18June2011002.jpg&hash=f3813493927ac0aa8bbb25ee8e810e328976359f)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBorapainting18June2011020.jpg&hash=3f45c6506095adfcb129ab1a271ac17765fe272c)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on June 19, 2011, 05:09:21 PM
Damnnnnnn :).....thats looking incredible! That 3M stuff works miracles. Keep it up guys!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on June 19, 2011, 05:45:48 PM
WOW! 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on June 19, 2011, 06:25:05 PM
Winding me up with those Jetta badges John! ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 19, 2011, 06:36:21 PM
Quote from: RS ZWEI on June 19, 2011, 06:25:05 PM
Winding me up with those Jetta badges John! ;)

How so Nik?  ;D
Bora sounds so.................well.........ummm boring!  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on June 19, 2011, 07:00:48 PM
Jetta is the right moniker. Bora is a MEXICAN car :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on June 19, 2011, 07:24:02 PM
Lucky I took my togs and a towel when I was out there on Sat as I dived in and swap around in the paint, didn't even touch the bottom!

This thing is nuts - can't wait to see it fully assembled and rolling. Seriously mind blowing!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M M on June 19, 2011, 07:46:59 PM
This is definately something else. Awesome work! Can't wait to see it in the flesh. :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on June 19, 2011, 07:53:57 PM
Quote from: 80 Vert on June 19, 2011, 06:36:21 PM
How so Nik?  ;D
Bora sounds so.................well.........ummm boring!  :laugh:

Cos it's only in the stupid US (maybe SA) that they are called Jettas
The Germans who designed them call them Boras so that's what I call them ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 00quattro00 on June 19, 2011, 07:53:09 PM
they should have called them all jetta's, mk1, mk2 were jetta;s then they changed to vento then bora and back to jetta, wtf with that
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on June 19, 2011, 07:58:56 PM
Quote from: 00basil00 on June 19, 2011, 07:53:09 PM
they should have called them all jetta's, mk1, mk2 were jetta;s then they changed to vento then bora and back to jetta, wtf with that

They wanted to change the image.
I remember a stat (no bull) that gay males most popular car was a Jetta.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 19, 2011, 08:06:18 PM
Quote from: RS ZWEI on June 19, 2011, 07:58:56 PM
They wanted to change the image.
I remember a stat (no bull) that gay males most popular car was a Jetta.

Hahaaaa thats hillarious, let me guess it was an american stat?
Sorry Nik, the Golf sedan is and always was a Jetta.
Globally the MK5 went back to being a Jetta, nuff said.
Anyhow its just a badge, one that I prefer but still just a badge  ;D Gay or not  >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on June 19, 2011, 08:33:10 PM
It's a one off car so John can pretty much call it what he likes......  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 19, 2011, 08:35:49 PM
Quote from: M on June 19, 2011, 08:33:10 PM
It's a one off car so John can pretty much call it what he likes......  ;D

Haha I like that reasoning, +1 respect from me  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: phil on June 19, 2011, 08:54:16 PM
Awesome mate :-)

Did you wet and dry by hand or with a buffer ?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on June 19, 2011, 09:05:38 PM
Quote from: RS ZWEI on June 19, 2011, 07:58:56 PM
They wanted to change the image.
I remember a stat (no bull) that gay males most popular car was a Jetta.

Pretty sure that's an Audi TT ?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 19, 2011, 08:56:20 PM
Quote from: phil on June 19, 2011, 08:54:16 PM
Awesome mate :-)

Did you wet and dry by hand or with a buffer ?

Yeap wet & dry 2000 grit then polished with 3M cutter / wool pad and lastly again with same cutter but black foam pad.
Had I pre sanded it with 1000 grit then 2000 grit it would have been flatter still but I'm happy with this for a first try  :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on June 19, 2011, 09:09:19 PM
Quote from: spooln on June 19, 2011, 09:05:38 PM
Pretty sure that's an Audi TT ?

It was something I heard in the early 90's
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on June 19, 2011, 09:18:29 PM
Quote from: RS ZWEI on June 19, 2011, 07:58:56 PM
They wanted to change the image.
I remember a stat (no bull) that gay males most popular car was a Jetta.


Mazda Miata will always be the number one hairdresser car.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on June 19, 2011, 09:36:38 PM
Quote from: 80 Vert on June 19, 2011, 08:56:20 PM
Yeap wet & dry 2000 grit then polished with 3M cutter / wool pad and lastly again with same cutter but black foam pad.
Had I pre sanded it with 1000 grit then 2000 grit it would have been flatter still but I'm happy with this for a first try  :)

Did you buy all that 3M gear locally or overseas?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 19, 2011, 09:30:31 PM
Got it all here, easy to get locally
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: gti vr6 on June 20, 2011, 08:41:09 AM
Gay guys usually have great taste in most things, just ask the Queer eye blokes

And yep pretty sure they prefer orange TT's
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on June 20, 2011, 09:05:06 AM
Jetto?  Venta? there's some room for creativity here  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on June 20, 2011, 12:05:15 PM
Vajenta?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on June 20, 2011, 12:04:05 PM
Great Results John, colour is so glossy and wet
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Skilfil on June 20, 2011, 08:46:58 PM
Well theres nothing gay about a Jetta Coupe with an R32 motor in it  >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: LVDUB on June 20, 2011, 09:02:07 PM
Looks great mate :D when u wax it use a foam pad on ur D/A sander then buff off by hand, alot easier than applying by hand and definitely more consistant too :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 20, 2011, 10:13:37 PM
Cheers, will do LV.
Some of you have asked about another BBQ so I spoke to GTIVR6 today (who was the master chef last time) and it looks like thats a go at some stage.
I'll probably get the car a bit further along and then organise one once the weather is a little better.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 26, 2011, 05:45:27 PM
Time for some interior stuff to get done, been thinking about the headliner quite a bit and did seriously consider going with black but the difficulty in getting all the matching black lights, sunvisors and sunroof controls meant I gave up on that idea pretty quickly besides the fact I'm quite partial to a 2 tone interior anyway.
Started with covering the headliner which was pretty difficult, I'd done quite a few before but never a sunroof one.

Things didn't go quite as well as I'd hoped with some lines still visible where I'd extended the headliner in the rear and at the front the matrial didn't want to stretch the way I wanted around where the sunvisors go, so after getting all pissed off about it I decided it wasn't going to cut the mustard the way it was so I ripped all the material off again to re do it  :'(
$150 worth of material down the toilet and a days worth of work wasted I ended up with the below  ::)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0146-3.jpg&hash=f2150c480153000d711e04e4e7a20032d1be08d5)
As a pure fluke Ian Goodwin suggested a guy he buys material off so I went and saw him, waaaaaayyyy more stretchy stuff at nearly 1/3rd the cost of what I had so it wasn't so much my lack of expertise rather the material was just utter crape!!!  >:(
New stuff went on much nicer and actually looks like a professional job now which is the way it should have been in the first place.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdateJune2011004.jpg&hash=4e1484abf9ec48e62f6accb8908e0d48c7fe2e12)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdateJune2011003.jpg&hash=78d6b17384a178755b4cd42f9147eb5d35f3be88)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdateJune2011008.jpg&hash=0d93ea565a461bf25e2408027c7c3d5c3642ac73)
Urethaned the side window seals to the body during the week which was also an epic fail  :P as the urethane didn't stick to the rubber seal, with a lot of searching finally found a type of urethane that stuck to EPDM rubber so those are also sorted now.
Phil gave me a hand getting the headliner in on Saturday, all looks pretty good and seems to fit quite nice.
Getting a bit stuck for things to do I had the bright idea of fitting the front & rear windows for which I got quite a blank worried look from Phil  ;D with my reply how hard could it be???  ;D ;D
Glenn Bishop to the rescue for advise and some borrowed tools, so armed with no experience and all the gear we needed we gave it our best shot.
Front screen went it without any significant problem, would also have fitted the rear one but I want to get the window tint on first so that will have to come during the week sometime.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FBoraupdateJune2011006.jpg&hash=32c0269eb8dd3ec97b31f57a3d7ec22e1fabf70b)







Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on June 26, 2011, 05:44:59 PM
Wheres all the dirty finger prints Vert :P
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 26, 2011, 05:53:13 PM
I'm not a monkey so there isn't any  >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on June 26, 2011, 07:08:32 PM
Ur a magician ;)
I can't help myself :-[
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VeeDub on June 26, 2011, 07:09:41 PM
Headliner looks glamour John, and the paint looks really stunning seeing bits of the car all come together. How did you make the back window rubbers?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on June 26, 2011, 07:18:58 PM
I love it. Don't finish it too soon - I won't have anything to read about!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on June 26, 2011, 07:22:35 PM
That front screen was stressful, we gingerly carried it up over the bonnet and basically lined it up in position with about a cm to go my suction handle thing let go. Luckily it plopped into place perfectly with just a gentle wiggle to line it up square. Phew (now, where's that "wipes forehead" emoticon?)  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on June 26, 2011, 08:09:32 PM
Right here:

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fmelantrys.net%2Fwp-includes%2Fimages%2Fsmilies%2Fnew_phew.gif&hash=0fa74682133b1313aa837ead51add32d9a98fde4)

Nice work again John and Phil.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 26, 2011, 08:23:02 PM
Quote from: VeeDub on June 26, 2011, 07:09:41 PM
Headliner looks glamour John, and the paint looks really stunning seeing bits of the car all come together. How did you make the back window rubbers?

I made them out of Sharan rear side seals, cut and glued as needed  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on June 26, 2011, 08:37:47 PM
Dude, you are so slick it's almost unbelievable.

That headliner really turned out well eh!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M M on June 26, 2011, 09:28:54 PM
Man thats looks so professional! Great job. :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 26, 2011, 09:35:43 PM
Quote from: 5-pot on June 26, 2011, 08:37:47 PM
Dude, you are so slick it's almost unbelievable.

That headliner really turned out well eh!

Hahaha don't forget it took 2 goes though! Glad I re did it though as it looks heaps better.
The whole idea of this project has been to try and do everything hence me having a go at installing the windows too, never done that before so hopefully they don't leak!  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on June 26, 2011, 10:08:16 PM
Nice work! you wrapped the pillars too by the looks of it?
Would be really interested in knowing where you got the fabric - is it proper headliner fabric still?

As you say finding all the black bits and pieces are hard, I've been trawling eBay for a few weeks now looking for Mk3 bits
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on June 27, 2011, 08:48:43 AM
What you guys don't understand is just how hard it is to muck around on a car and install a head lining without getting even one dirty finger print on it!
For me it is impossible, but then I have only worked on ones that are broken and they have dirty tracks and sliders etc.......but Vert would still do it without finger prints and this is the part that really impresses me about this dude.
Cars are such dirty things unless they are brand new like this beast.
Awsum job on that head lining John Awsum.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Turbo on June 27, 2011, 10:43:35 AM
Quote from: the phantom on June 20, 2011, 09:05:06 AM
Jetto?  Venta? there's some room for creativity here  ;)

Betta
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on July 02, 2011, 01:31:40 AM
Quote from: 80 Vert on June 26, 2011, 09:35:43 PM
Hahaha don't forget it took 2 goes though! Glad I re did it though as it looks heaps better.
The whole idea of this project has been to try and do everything hence me having a go at installing the windows too, never done that before so hopefully they don't leak!  ;D

Only 2?!  I'm with BB.  I don't know how you get all this done so quickly and to such an impeccable standard.  No show ponies here, this one's got plenty of tricks up it's sleeves!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 02, 2011, 10:29:15 PM
Hmm don't know about quickly..............going pretty slow from where I'm standing  :laugh: The original plan was for a year but i'm well past that now.
Moved the car to a capeted area at work next to the Vento, much nicer to work on carpet  ;D

The last couple of nights and all of today has seen the biggest visual jump forward yet, Its quite cool to see all the little ideas of what I wanted coming together with the trim going on.
On thursday I urethaned the first side skirt on with the aid of a multitude of clamps and even a big steel block wrapped up in a rag to hold it on the body while the urethane dried, all looked great on friday morning so did a repeat of the same for the other side friday night.

With the skirts on the boot and roof spoiler next, 3M VHB tape for that and holy s**t does that stuff stick!  >:D
The boot spoiler is a BMW M3 one, curvature isn't quite the same but its a pretty flexible piece so I just stuck the ends down and then pulled the center outwards to the curve I wanted and stuck the sucker down.
Pics came out crap but you'll get the idea...............
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FIMG_0258.jpg&hash=398a7040996905b4596941f1e8babd65da092706)
Same thin VHB tape for the side moldings, used masking tape as a guide for a nice straight line on the body and stuck them on.
Really only get one shot at this as once that VHB tape sticks down they aint coming off again without ruining them.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FIMG_0262.jpg&hash=b9d12b51decc2f11fecbd521851c4b71eb834c4f)
Also assembled both doors, ran extra wiring for the indicators in the mirrors and installed the glass.
A while ago I scored a nz spec stereo for next to nothing but I hadn't been able to get it to work for some reason so I tried plugging it in to the wife's Polo and no problems, made a note of the wiring finding I had it wrong on the Jetta so that's also sorted now.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FIMG_0260.jpg&hash=ddf65ca000c86b67aa26bd7c8d88594e92e42f0c)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FIMG_0259.jpg&hash=43c3500853b93d5a190a69928ec231a72f37c52b)

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on July 02, 2011, 11:34:08 PM
Quote from: 80 Vert on July 02, 2011, 10:29:15 PM
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FIMG_0262.jpg&hash=b9d12b51decc2f11fecbd521851c4b71eb834c4f)

This is off the scale mate, looks fantastic, the R side trim really makes the blue pop.
I love this shot with the jetta coupe reflection 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Toro on July 03, 2011, 12:33:51 AM
2 Hrs spent reading this.

Absolutely brilliant.

Do you get Freeview HD with that antena ? lol
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on July 03, 2011, 07:29:34 AM
Quote from: SOFTLAD on July 02, 2011, 11:34:08 PM
This is off the scale mate, looks fantastic, the R side trim really makes the blue pop.
I love this shot with the jetta coupe reflection 8)

About to post the same thing. Nice shot indeed.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: JDVW on July 03, 2011, 10:38:10 AM
all while listening to the breeze...nice relaxing work on your car music
looks fantastic
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M M on July 03, 2011, 11:49:13 AM
Quote from: spooln on July 03, 2011, 07:29:34 AM
About to post the same thing. Nice shot indeed.
X2. Awesome work!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 03, 2011, 12:48:20 PM
Its getting close now, the MAF and associated parts have arrived at Viper for flow testing so that will allow Rich to get started on writing the software, quite a relief to finaly have a good solution for that.
Once the rest of the wiring is done the interior can go back in, added the sunroof wiring yesterday along with the interior monitoring for the factory alarm, should have thought about that before as its a BIG PITA to add it now  ::)


Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on July 03, 2011, 01:32:20 PM
with the mirror indicators, what happens to the repeater light holes in the guards?  another R badge?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 03, 2011, 04:49:48 PM
Nah there's smoked side repeaters goin in there.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: itsagthing on July 03, 2011, 04:41:23 PM
Looks BEA- utiful i must say.Hats off John.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on July 03, 2011, 05:03:06 PM
The breeze :P
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on July 03, 2011, 07:05:56 PM
Quote from: BB on July 03, 2011, 05:03:06 PM
The breeze :P

Haha i spotted that too......The test radio station ....lol
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 03, 2011, 08:40:16 PM
Hahaaa DEFO the test station  >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on July 03, 2011, 09:05:32 PM
Looking real good there! You must be proud of the outcome!  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 09, 2011, 09:41:01 PM
Cheers Arno, yep I'm really happy with how its turning out,
Righto another update from this past week and today, lots of little things done and out of the way.
The taillights have been an ongoing saga, wanted them tinted so I sprayed them with some Tamiya smoke paint a while ago followed up with a coat of clear which made them go really milky!
But! once the clear dried the milkyness went away, how weird...............................but that's not the end of it ;D  Wasn't quite good enough for what I wanted so I flatted them down a little and sprayed another coat of clear over them which ruined them completely, reacting with the layer underneath >:( :'( F%&K!
What to do, chuck them in the bin or sand all of it off and try something else?
Being a dutch tight arse I spent a few hours sanding  >:D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0143-2.jpg&hash=2d4e8ec0010d01458acd6447b0874cb99cbcc9c5)
This time I just mixed a tiny amount of black in the clear with a much better result! Happy at last, not sure it was worth all that effort but no one said modifying stuff was easy  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FOZVWNats004.jpg&hash=7f4328c9c8741a89b336914be9c71f55e55943de)
Slowly been working away at the wiring too, modified the mirrors to install the memory motors that work in conjunction with the seats and figured out how to make the actuators work for the pop outs, MK4 switch just wasn't going to work as the actuators only have 2 pins and the current needs to be reversed to close them.
In the end MK2 Golf switches have double contacts in them which do exactly that, ran all the wiring and installed them in the center console by the handbrake and also took them apart to paint the bulbs red so that they match the rest of the illumination, details details   :P
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0149-3.jpg&hash=d57aa7abb0dece0a62ec7549a0613908224bac0d)
The rest of the interior is also coming along, drivers door completely finished and center console all done.
Installed the Weitec coilovers in the rear, fitted the inner guard liners and took the calipers off to paint them.
Been scratching my head trying to figure out why I couldn't get the boot lock to work properly and today discovered that the Golf CCM operates it differently to a Jetta one so once the correct CCM was in there and a key coded to it that all works too with the MK5 handle, very cool!  :laugh:
Still its left me with another problem that I've yet to figure out..............................it never ends! :'(
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FOZVWNats003.jpg&hash=40ee310b8249e70f11cc7688b6129166a33f8996)






Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on July 10, 2011, 12:51:07 AM
That paint looks so glossy and wet- amazing job! I like the popper switches in the centre console, looks so oem!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on July 10, 2011, 11:14:58 AM
Coming along really well!  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on July 10, 2011, 11:30:40 AM
did you wire up the puddle lights in the mirrors as well John?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M M on July 10, 2011, 11:36:13 AM
Nice work on the lights!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 10, 2011, 03:29:19 PM
Quote from: the phantom on July 10, 2011, 11:30:40 AM
did you wire up the puddle lights in the mirrors as well John?

For some reason I didn't bother but I'll probably do it before the car is done.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on July 10, 2011, 04:25:33 PM
from experience, the puddle lights  don't work very well in practice, so probably not worth the effort, it would be interesting to see if the MK5 mirrors mean less wind noise on the MK4 as the MK5 had pretty low wind noise
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on July 10, 2011, 07:50:00 PM
Puddle lights are pretty easy to wire up.

You will have a 1C0 xxx xxx CCM;
positive goes to CCM T23 / 20 (red / blue wire).
negative goes to CCM T23 / 21 (blue / grey wire).
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on July 10, 2011, 07:56:48 PM
This is the thread that should help you with the interior monitor coding: http://forums.tdiclub.com/showthread.php?t=160960

Lots of reading, but definitely helpful.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 10, 2011, 08:23:23 PM
Thanks Cam, still thinking about wether I can be bothered pulling the drivers door and dash apart again for the wiring but maybe..................
Yes I found that thread also and been speaking to Graeme in Brisbane about it, he's offered to do it for a small fee if I send the CCM over to him which I'll probably do.
Ranton also seemed confident he could do it but unfortunately he's away for a few months  :'(
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 13, 2011, 05:05:07 PM
Been having a play with my latest toy, actually I've had it since the beginning of the year but until now hadn't used it.
Since I want to repaint the rear calipers red to match the front I thought I'd give em a quick blast in the cabinet to prep them, should have bought one years ago!

It must be powdercoat that's on there as its tough as nails so just roughing up the surface will be enough.
Also tried some heavy rust on a piece of steel and it just vaporises it!  >:D will be handy, VERY handy indeed  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0146-4.jpg&hash=4ac08c2e2a07c2a1a40c088d02a6f17ea62acc16)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on July 13, 2011, 05:00:58 PM
MMM nice sandblaster 8)
I get to use my mates one at the reco shop.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 17, 2011, 05:38:53 PM
Managed to paint the calipers on Thursday so that they could go back on this weekend meaning I could finally bleed the brakes and clutch, somehow feels that its a lot nearer to fire up day!
Wrote myself a to do list which quickly filled my whiteboard but a lot of items are just little things that won't take a lot of time, still there's quite a few lines!  ;D

Cleaned up the adjustment rings of the Weitecs in the lathe as some idiot obviously used vise grips in the past to adjust them, fitted them to the car and the wheels back on.
Won't bother setting final ride height until its on the road and settled, I doubt it will end up much lower than it is now though, our roads just don't cater for it!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F17_07_2011025-1.jpg&hash=e52bff816a22cbd711dd773f02d6684bd81e30ab)
Its little things that eat time for example cutting a hole in the drink holder cover that will go over the boost controller, 3 hours work right there!
You try to cut and file a square hole in something as thin as that  >:D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F17_07_2011012.jpg&hash=84fde8ee0805a8d96bdf19e35c0b15eac06c86cd)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F17_07_2011028.jpg&hash=a2461607cf1505055ac3b2a5aae72b7373dae084)
By the time that was all said and done it didn't leave a whole lot of time to look at the bumper, a few weeks back I managed to find a VE SS Commodore bumper which I'm going to try and do something with, very very early stages so far but I've got some ideas now.
Can't see too much of what its going to end up like from these pics but it might just work.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F17_07_2011015.jpg&hash=b964f52ad25b0ffd5f06dbbb5eb06646fd35c1d2)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F17_07_2011016.jpg&hash=fbf5dca9167141694bea3cff1a70508106594c95)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on July 17, 2011, 06:23:49 PM
how about a Falcon XR6 dam as a starting point?

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fdigiads.com.au%2Fcarsales%2Fused-cars%2Fcar_ad_photos%2Fdigiads_car_ads_102701_1.jpg&hash=421b5623c558a57a2b85e4ab1f562ed1baf28004)

edited to use a smaller image
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: deedub on July 17, 2011, 06:46:54 PM
Quote from: 80 Vert on July 17, 2011, 05:38:53 PM
Its little things that eat time for example cutting a hole in the drink holder cover that will go over the boost controller, 3 hours work right there!
You try to cut and file a square hole in something as thin as that  >:D

But it's the little things which make an incredible build into an absolute stunner! That looks so tidy and factory.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GTI's on July 17, 2011, 06:54:32 PM
The car looks stunning John!  No drinks inside I take it  :angel:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 17, 2011, 10:05:59 PM
Quote from: GTI's on July 17, 2011, 06:54:32 PM
The car looks stunning John!  No drinks inside I take it  :angel:

Hahahaaa it looks that way doesn't it. May look at getting a US spec center console with cup holders, the one in the SC Jetta was pretty handy and way better than that stupid thing above the radio.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: gti vr6 on July 18, 2011, 05:37:18 AM
Nice work John!!
8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on July 18, 2011, 08:13:06 AM
 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on July 18, 2011, 06:12:27 PM
what a guy!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on July 18, 2011, 09:40:48 PM
Quote from: 80 Vert on July 17, 2011, 05:38:53 PM
as thin as that  >:D
By the time that was all said and done it didn't leave a whole lot of time to look at the bumper, a few weeks back I managed to find a VE SS Commodore bumper which I'm going to try and do something with, very very early stages so far but I've got some ideas now.
Can't see too much of what its going to end up like from these pics but it might just work.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F17_07_2011015.jpg&hash=b964f52ad25b0ffd5f06dbbb5eb06646fd35c1d2)
[img width=700 height=525]

Looooking great Mate, outstanding work! should buy a big warehouse and set up shop and museum of past accomplishments in the car word......

Regarding the bumper shrink by cutting a section out of the middle and match the angles of the lights and grille with the edges/angle of air-dam of the ss bumper and you should be sweet
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Pristle on July 19, 2011, 10:47:39 AM
Quote from: 80 Vert on July 17, 2011, 05:38:53 PM
You try to cut and file a square hole in something as thin as that  >:D



I'll leave that to you J, if I didn't break it, it'd be scratched to buggery and I'd be close to requiring stitches.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 23, 2011, 09:56:45 PM
Couldn't be bothered with the bumper this morning so I did some other stuff, as luck would have it the Passat memory mirror from the States arrived on Friday as did the recoded CCM from Aussie!
Tore the mirror apart and installed the inner workings in the Skoda ones, not a bolt in but then nothing ever is.
Pretty cool to have all that memory stuff working, with the mirror switch on L the mirror dips down for you when putting the car in reverse- very handy when getting old!  ;D
Mirrors have been a complete headache to fit but that's the price you pay for doing something different and I have to say they look way better than anything non factory.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0155-1.jpg&hash=96df578a656017ab2b2ba3f4e0ba44ba41d9411b)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0156-1.jpg&hash=dda267506f2b437dbd2f213ba4120a62d9f289ff)
With that done the passenger door could finally be finished off, Since that took most of the morning to complete and Badhabit, Tbag and Coons arrived at lunchtime that only left a few hours in the afternoon to play around  :P
Had already urethaned a hinge to the one good window I had so I test fitted that which all seems to look pretty good, pictures came out crape but that's life!
Found that the hinge seemed to flex a little too much so I decided to take it off the glass only to find the urethane hadn't completely cured, in any case its re done now to be left over the weekend to dry.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0153-2.jpg&hash=f09892c3dfdd82131fce1f04300599f8f88e6d2e)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0154-1.jpg&hash=46027bb3c495268ba79b565e06b622721f1beea7)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: elliott2705 on July 23, 2011, 09:53:36 PM
Looking really good mate! Love your work.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: gti vr6 on July 24, 2011, 05:48:29 AM
looking BAD ASS John  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on July 25, 2011, 08:49:51 AM
Very nice John, Need to come around and have a perv some time  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on July 25, 2011, 07:56:18 PM
thats some top quality german style of things going on there.....
I have to say i keep on looking at that damn bumper picture and itching to weld that shizz together!...... :P  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on July 25, 2011, 09:44:17 PM
love the (ironic?) 8 ball on the aerial!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on July 26, 2011, 06:43:09 PM
John you could start your own little coupe club and be the only member and still have a whole of cars in it!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 28, 2011, 05:14:31 PM
IT WORKS!!!!  8)
Passenger memory seat is a go, been an epic struggle with this one.
Installed memory motors and control unit from a LHD car into my passengers seat but it would only work if you held the button down all the time which for me was a not good enough!
Object was to use pos 1 to roll seat forward to gain access to back seat (these seats have no release levers being from a 4 door) and then use pos 2 to roll back to seating position.
In the end (after a lot of trial and error) I found out the that under seat control unit was an earlier version which operates differently to the drivers seat.

With another control unit sourced from the US I realised that it also needs a canbus connection to it for the memory to work.
Graeme86 did some coding on my CCM which was awesome and in a few emails to him he advised against connecting 2 control units with the same adress to the canbus network so rather
than try, and possibly fry something I installed a switch to be able to switch the canbus between driver and passenger seats for the memory! Works awesome and adds a touch of class!
So now you just open the door, press 1 and the seat rolls forward  ;D all that work just for that but like they say the devil's in the detail!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0159.jpg&hash=1746cfb2034358e43ba43785186ade312a9191fa)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: The Truth on July 28, 2011, 05:41:34 PM
This car just continues to grow in awesomeness. You should really be consulting for VW after this!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on July 28, 2011, 07:01:58 PM
Another great feature, fighting it out with a heap of other awesome bits to be the best part of the car
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on July 28, 2011, 06:49:14 PM
legend! i started getting stressed out just reading the post! you obviously thrive under pressure 8).
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on July 28, 2011, 07:00:21 PM
RAD
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on July 28, 2011, 07:19:21 PM
Quick question, if your in the seat and you accidenally hit the 1 button, would you get mashed onto the dash?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Alfashark on July 28, 2011, 07:17:11 PM
I'm loving this build!
One of my much older brothers has been doing hotrods and customs since he left the UK nearly 40 years ago and is blown away by the attention to detail you put into what he calls "a generic appliance"
Same goes for mates of mine that are JDM worshippers.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on July 28, 2011, 09:08:52 PM
Quote from: spooln on July 28, 2011, 07:19:21 PM
Quick question, if your in the seat and you accidenally hit the 1 button, would you get mashed onto the dash?

They don't adjust to memory position when the ignition is on, well at least not normally.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 28, 2011, 09:10:01 PM
Correct, memory only works with ign off and if you are dumb enough to fiddle when sitting in the car with the ign off then suffer!!  >:D
Currently looking into rear parking sensors, apparently it can be completely cobbled together from OEM parts so I've started looking for the needed bits to make it happen..................more electrical  :-[ :P
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on July 29, 2011, 06:11:13 PM
Rear parking sensors!
HARD 8) :) :laugh: :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on July 29, 2011, 06:42:03 PM
Quote from: 80 Vert on July 28, 2011, 09:10:01 PM
Correct, memory only works with ign off and if you are dumb enough to fiddle when sitting in the car with the ign off then suffer!!  >:D
Currently looking into rear parking sensors, apparently it can be completely cobbled together from OEM parts so I've started looking for the needed bits to make it happen..................more electrical  :-[ :P

ahh come on ...you know you love it !  8)  8)  Looking and sounding like this is going to be a VW collectable with all the goodies going into it!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on July 30, 2011, 07:26:46 PM
Just a few small steps forward today, was a bit busy helping young Tbag fixing an alloy sump that some turkey had already "fixed" with fiberglass  :( (you did well T, I was impressed!)
Much the same story on the headlights, some monkey before me obviously decided that the up/down adjusters needed cutting off, I have absolutely no idea why but there doesn't seem to be any limit to some peoples stupidity  :'(
Looked at the problem for a few minutes and decided to make my own adjuster which worked out pretty well and doing the second headlight was even easier.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0160.jpg&hash=a9fd45f49b47394ac6208654d6d858fa32a3ddcd)
Once we finished up with T's car I worked on the bumper for a few hours before calling it a day, still a long way to go on this and as it stands its still to low to be useable every day also keeping in mind I want to lower the car some more  >:D  Hahahaaaa I want I want  ;D
I'm still not 100% sold on the look but I'll get the other side roughed in and screwed together for a better picture of whats what.
For now the left side is just screwed on to get an idea of where I'm heading, the Bora bumper I bought brand new aint lookin so new anymore- Oh dear what have I done...................... :-\
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0162.jpg&hash=f92a51161c80a71370fd28f08262d62a9f18bf9c)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0163.jpg&hash=c030262dd31fe09caf021afe13cd40c9ae36f46b)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0164-1.jpg&hash=22ba346e85ab4b691e1fc4ffde461484d03b71dc)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on July 30, 2011, 09:19:38 PM
looks promising!  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Toro on July 30, 2011, 11:52:07 PM
Oh, yeah.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on August 02, 2011, 08:10:43 AM
Would a modified r32 bumper be another option John?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Turbo on August 02, 2011, 11:51:45 AM
bora r ?  http://forums.motivemag.com/showthread.php?4479767

from the link above:

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fgallery.me.com%2Fevildub%2F100151%2FDSC_2281%2Fweb.jpg&hash=57f08867a16a2b864e63bb893cc0d3bf995ec035)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Heino on August 02, 2011, 12:15:54 PM
1+ for above! thats deff the way id go.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 02, 2011, 12:10:59 PM
Yeah its ok ish I guess but everyone has those and to be honest I'm looking to do something no one else has.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Turbo on August 02, 2011, 12:13:56 PM
ah, righto. i just read the first link saying "rare" and thought that'll be right up vert's alley.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on August 02, 2011, 12:27:48 PM
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi29.photobucket.com%2Falbums%2Fc284%2Fchrisbed%2F1505d832.jpg&hash=be13834422a4370a9c25419f54d5effe09e1c7c7)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Turbo on August 02, 2011, 12:23:39 PM
bit too ricey?



would a new model bumper fit your shape with mods?

maybe something like a cleaner version of the rgt?

http://www.netcarshow.com/volkswagen/2005-jetta_r_gt/800x600/wallpaper_04.htm
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 02, 2011, 03:08:48 PM
Quote from: Ballin on August 02, 2011, 12:27:48 PM
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi29.photobucket.com%2Falbums%2Fc284%2Fchrisbed%2F1505d832.jpg&hash=be13834422a4370a9c25419f54d5effe09e1c7c7)

Mate are you on crack? thats terrible  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on August 02, 2011, 03:41:50 PM
you said something that no ones done before? LOL

its that bad no one would do it!  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on August 02, 2011, 03:47:25 PM
^^ ahhahahaha thats pretty fugly right there... :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 02, 2011, 10:10:33 PM
Too Sharky :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on August 02, 2011, 10:22:46 PM
Quote from: Ballin on August 02, 2011, 03:41:50 PM
you said something that no ones done before? LOL

its that bad no one would do it!  ;D

seidl tuning did it before! that's barry boys territory, that one
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on August 02, 2011, 10:20:03 PM
How good does that Bora up the top look though  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on August 02, 2011, 10:54:06 PM
r32 bora bumper looks good but to tie in with the chrome topped rub strips  you need it to run into the front bumper and r32 bottom with bumper rub strip will look odd.....I for one know what Vert is wanting...diffrent but it has to work and look good and something that could of been factory!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 03, 2011, 10:38:30 PM
You're on the money Arno!
Started on something different tonight, cut up a MK5 R32 bumper so we'll see what the next few nights and the weekend bring.................
Intake testing is done by Viper tuning, results good as expected and on its way back here along with a water meth injection kit!  ;D Start up is very much closer now!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Dub_luver on August 06, 2011, 01:53:48 PM
my mate got a awsome front bumper that will fit ur intercooler and everything real nice,think it might be made by reiger and its in plastic with the headlight washers etc, way nicer than that boras one. when u over the shore next hit me a message and u can have a look as he hardly uses the car, u could always make a mould or something
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on August 09, 2011, 09:49:46 PM
http://www.youtube.com/watch?v=F372PsRE7pY (http://www.youtube.com/watch?v=F372PsRE7pY)  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on August 09, 2011, 10:04:41 PM
great work guys looks cool  :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on August 09, 2011, 10:06:44 PM
 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on August 09, 2011, 10:29:13 PM
she's lookin' good!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 10, 2011, 07:55:02 AM
Pitty I'll have to glue the windows in now as the laminate is not up to the job of opening and closing....................................... >:(
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on August 10, 2011, 09:20:51 AM
No don't do that! Just go back to the drawing board. You can't write them off after all that work.
What's wrong with just using conventional hinges on the leading edge like most pop out's use?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on August 10, 2011, 12:19:54 PM
Agree with Sam. keep at it as its a very good idea
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on August 10, 2011, 01:11:09 PM
Damn, hope you come up with another cunning plan, Id like to see this retained as well.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 10, 2011, 09:45:19 PM
Yup, more than a little annoyed about it.
Have decided to shelve this for a while and concentrate on getting the POS going!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on August 11, 2011, 08:36:57 AM
Quote from: 80 Vert on August 10, 2011, 09:45:19 PM
Yup, more than a little annoyed about it.
Have decided to shelve this for a while and concentrate on getting the POS going!

shiniest t*rd on the block!   ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on August 11, 2011, 08:55:54 AM
Go before show?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on August 11, 2011, 09:19:41 AM
Quote from: Fizz on August 09, 2011, 10:04:41 PM
great work guys looks cool  :)

Definitely cool, all none of my work though so I can't take any credit (aside from videoing it for posterity  :laugh:). I'm confident sooner or later a solution to get them working will present itself, but in the meantime I agree with John - glue them in and keep progressing the car overall.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 11, 2011, 09:11:47 AM
Whos ever going to go in the back anyway?
Move on and get it going. Can always do it later.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on August 11, 2011, 10:42:50 AM
what's aircon for anyway?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 14, 2011, 03:36:28 PM
Decided to forget about the bumper and windows for now and press on with getting the sucker going! After all that's the most important bit!
The rear bumper chrome turned up so that also completes the back of the car and once that was installed I carried on with engine bay stuff again.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F05_08_2011003.jpg&hash=b55086920167502d9997adba3ceeda88ecf899b9)
First job yesterday was to fill it with coolant only to find both inlet & outlet fittings leaking right away, seems the mishimoto radiator fittings are slightly smaller than its OEM counterpart! what is it with aftermarket JUNK!!! I mean just make the thing the same FFS!!
Slightly thicker o rings seems to have sorted it for now so we'll see how that goes.
My intake system came back from Viper tuning in the UK, they flow tested the new MAF / airbox and 4" intake for the custom software.
I'm yet to speak to Richard again to see what the next step is for start up which we are not that far away from.

Since plastic water fittings lemon out on a standard car on a regular basis and seeing as there's 3 of them right in the line of fire from exhaust heat I thought it better to make these from aluminium so I quickly knocked them out on the lathe and installed them along with some extra heat wrap to hopefully keep most of the heat away from the hoses etc.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0143-3.jpg&hash=55f7635e26cd0d4ae17f96d157c101298d3acf7f)
With those in place the whole airbox, inlet and cold air intake could be installed and BOV return pipe made, certainly looks pretty full in there now.
Where to put a puke tank?  >:D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0147-4.jpg&hash=0fdabd5e5da20d23fd9699f1fa0c1c5c061e6904)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0146-5.jpg&hash=b6e2bc9eb26eb1066c550694567aa933b2dc3611)
Last job for the day was a puke tank, decided to make my own from some scrap aluminium laying around the shop, its not a very big one but it will do.
Its got the ingoing pipe going right to the bottom with holes drilled in the sides and then an oil separator plate about 3/4's of the way up.
Didn't have any steel wool type material to put on top of the seperator plate before I welded the top on but that can still be shoved in through the vent hole later.
Also made a fitting in the lathe so that the factory plastic vent pipe clips on to it, found a little spot right near the brake booster for it to hide in so made the bracket to mount it with and presto! another job off the list  :o
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0144-2.jpg&hash=6f45cd2d8852c42286e8423ea911b596c27a9ed3)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0145-2.jpg&hash=853a897a2456a87a7307869ce2d2f00bcaaecf7f)
The water meth kit also came in with the other parts from Viper so I can get to work next week mounting the pump and finishing the water tank, will also try and test the fuel system for leaks and maybe even fire it so see if it will start! ;D

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 14, 2011, 05:38:38 PM
Waiting for the hour of power :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 16, 2011, 07:14:13 PM
The hour or power is pretty close Jem!
Done a couple more things since the weekend, changed the way the fittings seal on the radiator again which meant draining the coolant for the 4th time  ;D
Filled the gearbox with oil, cranked it with the plugs out to build oil pressure and tested the fuel system for leaks.
That 044 pump sounds pretty serious and loud! I wonder if it will be thrifty on gas  >:D :o
Pretty much just need the map loaded now to fire it up!!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on August 16, 2011, 07:26:58 PM
Quote from: 80 Vert on August 16, 2011, 07:14:13 PM
The hour or power is pretty close Jem!
Done a couple more things since the weekend, changed the way the fittings seal on the radiator again which meant draining the coolant for the 4th time  ;D
Filled the gearbox with oil, cranked it with the plugs out to build oil pressure and tested the fuel system for leaks.
That 044 pump sounds pretty serious and loud! I wonder if it will be thrifty on gas  >:D :o
Pretty much just need the map loaded now to fire it up!!!

Is the 044 external then? There is an option for a pump that fits in your standard tank spot you know.  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on August 16, 2011, 07:31:35 PM
ohhh brooom brooom time!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on August 16, 2011, 07:41:29 PM
My car also has an 044 fuel pump and makes a hugh noise, makes me think my lines are too small for it.
They will flow enough fuel for 700 hp given big enough lines.
My fuel lines are std mk1, so maybe they are compromised.
Maybe these lines need to be much bigger to shut it up.

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on August 16, 2011, 07:53:08 PM
I am not sure you will quieten it down with larger lines but imagine trying to blow through a straw. However if you haven't had trouble by now then standard fuel lines must be enough for your power.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 16, 2011, 08:48:46 PM
Quote from: M on August 16, 2011, 07:26:58 PM
Is the 044 external then? There is an option for a pump that fits in your standard tank spot you know.  ;)

I have the std R32 in tank pump feeding/filling a surge tank which houses the 044, seems a little quieter than the external 044 on the Vento but not by much.
They just seem to be a noisy pump, pretty much everyone you talk to says they are noisy.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 18, 2011, 09:11:08 AM
I guess it could be working harder than it needs too with too small a hoses?
The original mk1 fuel lines are very small.

So whens the map arriving for the H O P!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: monni27 on August 18, 2011, 06:35:35 PM
im delayed vert,but one word for u,RESPECT,an well done on the project
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on August 20, 2011, 10:04:01 PM
I found your thread on Vortex while surfing, man some of the comments from those Americans lol
The response in that thread shows how world class this is though
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 20, 2011, 10:14:07 PM
Last few mechanical bits done today,
Man, buying that tig welder has paid off big time, finished the water tank off by making a filler for it from a motorbike tank cap so that its a nice flush fit deal to hide nicely under the boot carpet.
Mounted the pump to the side of the tank which worked out great, the kit comes with a nice fitting that has a strainer in it already making it pretty easy.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0143-4.jpg&hash=778f439da6dd91567315a6d358bf5d580183d214)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0145-3.jpg&hash=96f2fd6273719b850b77629a8f425f4fa6f53823)
Made sense to mount the relay and the pressure switch close to the pump since the battery is back there in the boot which meant running a pressure hose forward for the nozzle as well as a vacuum line to the back to activate the pressure switch at the desired injection pressure.
The pressure switch is adustable from 6-30psi which is a dead simple way to do it, easy to get at too being under the rear carpet.
Drilled / tapped the intercooler pipe before the throttle body and mounted the nozzle with its non return valve, will be interesting to see how well it works.
Have read a lot about water injection and how its supposed to reduce temps and make more power.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0146-6.jpg&hash=11ee8ad804efb57b43373af1873d5be0bad75e99)
Last job for the day was to make the upper rear arms adjustable, when you lower these AWD cars the rear camber goes to sh*t so by having the top arm adjustable you can dial the factory camber back in even when lowered.
Got some stainless turnbuckles yesterday so it was just a matter of cutting a section of the arm out and replacing it with the turnbuckle, they have a 4000kg breaking point so I think they'll be ok but the certifier will get the final say.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0147-5.jpg&hash=3ee90107f477534ac12d5c1d07c53d9eb56df384)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0149-4.jpg&hash=572741540adc5255fe016d4a3f6ca7a38d9b1133)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 20, 2011, 10:21:13 PM
Quote from: coons on August 20, 2011, 10:04:01 PM
I found your thread on Vortex while surfing, man some of the comments from those Americans lol
The response in that thread shows how world class this is though

Yeah over 200,000 views now, can't believe how positive they all are about it seeing as so many threads get ripped to shreads on there.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on August 20, 2011, 10:36:52 PM
Quote from: 80 Vert on August 20, 2011, 10:21:13 PM
Yeah over 200,000 views now, can't believe how positive they all are about it seeing as so many threads get ripped to shreads on there.

Yea exactly, you have to do something pretty impressive to impress that forum..

Imagine if you opened up a custom VW body shop over there, crap you would be run off your feet! Not to give you any ideas though.. we want you here!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 21, 2011, 10:06:20 PM
Quote from: coons on August 20, 2011, 10:36:52 PM
Yea exactly, you have to do something pretty impressive to impress that forum..

Imagine if you opened up a custom VW body shop over there, s**t you would be run off your feet! Not to give you any ideas though.. we want you here!

Well that thought has crossed my mind more than once.................
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on August 21, 2011, 10:42:54 PM
Even if you did it hear you would keep pretty busy.. you already are!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 00quattro00 on August 21, 2011, 11:12:27 PM
lol at the last comment on vortex
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on August 22, 2011, 08:17:43 AM
read the vortex thread last night, they're pretty impressed, even if a lot of them can't figure out that there's a world outside of the States

but you're getting a lot of respect up there in Ak=Alaska, John  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on August 23, 2011, 10:27:53 AM
Anyone got a vortex link??

Nevermind, found it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 23, 2011, 07:02:23 PM
Quote from: 5-pot on August 23, 2011, 10:27:53 AM
Anyone got a vortex link??

Nevermind, found it.

So can you put the link up I can't find it. :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Pinkmaggit on August 24, 2011, 09:22:36 AM
http://forums.vwvortex.com/showthread.php?4800868
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 24, 2011, 10:15:04 AM
Yea I'm with fu#kyouwhore!.................................Not.

They all go on about how they wish they had as much money as you Vert. Ha ha little do they know your not that rich and its just your hard work and utter skill and dedication that gets these done.

If you got paid for all the work you have done this car would be worth half a million Id guess.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on August 24, 2011, 11:25:52 AM
Well, he does have a nice workshop that most of us won't be able to afford, thanks to his business.  I think that's what most people are suggesting...
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on August 24, 2011, 11:28:58 AM
Quote from: BB on August 24, 2011, 10:15:04 AM
Yea I'm with fu#kyouwhore!.................................Not.

They all go on about how they wish they had as much money as you Vert. Ha ha little do they know your not that rich and its just your hard work and utter skill and dedication that gets these done.

If you got paid for all the work you have done this car would be worth half a million Id guess.

Haters gonna hate Jem...
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on August 24, 2011, 02:04:58 PM
Quote from: 5-pot on August 24, 2011, 11:25:52 AM
Well, he does have a nice workshop that most of us won't be able to afford, thanks to his business.  I think that's what most people are suggesting...

That's because its his business to have a workshop. If anyone wanted to make the huge commitment and develop the skill base from time up invested, I'm sure they could achieve that as well.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on August 24, 2011, 03:10:25 PM
But that's what I'm saying.  His business provides that workshop.  Most of us aren't professional mechanics and thus, can't afford a workshop like that.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 24, 2011, 04:41:22 PM
This whole car has only been able to happen because I've done 98% of it myself, if I didn't know how to do something then the object was to learn and have a go at it.
Over the years I've become used to having to do everything as that's what makes it fun and you end up learning something new in the process, too many times have I paid someone to do a job only to re do it because its not good enough, be that on cars or otherwise.
This project has had some very very difficult aspects to it and some have been a huge PITA to resolve but at least there's light at the end of the tunnel now, not finished yet but she's close.

Cost? I have an idea but don't really want to think about it.......... ;D but its no where near what some might think........I'm dutch remember  :P
The next few months will be the most exiting ones, driving and tuning!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 24, 2011, 06:41:47 PM
None of us can do what Vert does.
As you can see by the number of amazing cars there are others than can pull off some pretty cool stuff I mean check out all the yank builds and stuff and racing cars etc.
There are many people at a very high level in NZ and around the world.
But Vert is pretty much the top of the VW scene in NZ I recon.

Its a pretty epic car, and so are most of the cars he does.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on August 24, 2011, 08:50:58 PM
most of those american teams will have a kiwi mechanic/engineer.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on August 24, 2011, 10:43:16 PM
I just read all the pages on vortex....so funny...all of them are like teenagers seeing boobs for the first time regarding the fresh paint ...fair enough but they are hooked like a drug.......Bloody good stuff comming from Nz showing the world how to do it rite!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 27, 2011, 05:16:58 PM
Hee hee heee its alive!!!  >:D ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on August 27, 2011, 05:20:35 PM
ripper!!!  but only a heee heee heee? not a whoop whoop?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on August 27, 2011, 05:49:23 PM
Video >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Turbo on August 27, 2011, 06:08:59 PM
awesome. well done.
now hurry up and upload the vid that i'm sure has been flimed...


edit. didn't see the new page. so yeah, what coons said. ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 27, 2011, 07:56:17 PM
Cool, did you just plug the ECU in and she started and idled sweet like it should do 8).
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 27, 2011, 11:58:18 PM
What a day, filled with excitement and nervousness all in one.
It all started earlier in the week when pretty much everything was close enough for me to see if it would start, fired up right away even on the factory tune.
Only ran the engine for a few seconds then turned it off, good enough...........or so I thought!
For some reason I thought it prudent to do a vagcom scan which came up with a rather disturbing code...............injector electrical circuit failure cylinder 2  :o WHAT???
Ran some tests on the wire back to the ECU and the ground wire also both were fine, ohm test on the injector didn't reveal any problems either.....................what now?  :-[

Richard over at Viper had my map ready to go but me being clueless about computers couldn't get the MPPS software to load on my laptop so we made a time that suited Rich which saw me going in to work early on wednesday morning at which time he took control of my laptop over the internet and installed the software! How good is that!!!  ;D
Armed with the right tools it was as easy as pie to load the map...................10 minutes later I had programming completed!!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0156-2.jpg&hash=b3e480ff05c0c2f2a97f758ae82a2c67a6d3a852)
Started it up again but the dreaded injector #2 code was back, still wasn't really convinced that it was actually only running on 5 cylinders as it wasn't rough or anything like that but not wanting to risk anything the only option was to pull the injector rail to see for sure if injector 2 was spraying.........................UGH pulling the rail out...............not a fun job......... :(
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0158.jpg&hash=692b743d13bb5ba6164450dbd95eca427bee6b22)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0157-1.jpg&hash=1eab5ee8326a5a072faeeffe02b7f7e1e2b074bf)
With the rail out and hooked up I cranked it on the key and whadda you know, injector 2 is working  ;D
Being so focused on #2 I failed to notice #4 not working till I cranked it again later on, hmm that's odd.......................code for # 2 yet #4 doesn't work WTF?
Traced the wires for #4 and sure enough, broken wire which got me thinking are #2 and 4 the wrong way round? Nope, all going to the right place so that must have been the problem.
Put it all back together again on Friday which brings us to today............

Last few bits this morning, welded an 02 bung on the exhaust to be used later on for further tuning along with tightening the last few odds & ends.
Did throttle body alignment, checked and topped off fluids etc.......................nothing further to stall time with, Phil nudging me along the moment of truth was at hand.................. >:D
Backed it out of the shop and took it for a ginger drive down the road, Rich had been very specific that it was ONLY to be light throttle driving so 3K rpm was about its limit but even at that its easily apparent that this car will go VERY well when driven in anger!
Just doesn't seem to feel all that weight at all, so my first impressions are

..............Ride from the Weitecs is firm but very good, tyres are quiet just the way I like them and the engine mounts from black forest ind are something I rate very highly indeed!
Ohh and that R32 burble............................SO GOOD.
Yes Phil did take video, will upload soon.   
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on August 27, 2011, 11:57:41 PM
F >:D >:DK Yeah!!!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: mark2 golf on August 28, 2011, 07:58:39 AM
good work boys.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 28, 2011, 09:00:09 AM
So why did vagcom ay inj 2 when it was inj 4?

A big turbo on a 3.2L V6 go well.............never ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: le mans on August 28, 2011, 09:08:00 AM
Awesome, well done!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 28, 2011, 09:34:36 AM
A vid to prove it actually happened............. ;D
http://www.youtube.com/watch?v=hJ6cYkDM17A
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: slowmo on August 28, 2011, 09:50:56 AM
that car looks awesome!  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on August 28, 2011, 12:44:00 PM
Very carefully backed out past the doors into the yard:). And then straight to a side road for "testing"
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on August 28, 2011, 02:10:42 PM
that exhaust note has some menace!  note that the recent "constructive"  :o comment on vortex has been removed
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on August 28, 2011, 02:26:26 PM
That paints just glossy wet!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 28, 2011, 04:38:00 PM
Quote from: spooln on August 28, 2011, 12:44:00 PM
Very carefully backed out past the doors into the yard:). And then straight to a side road for "testing"

Hahahaaa yeah cunning eh!
Came within 5mm of clipping the mirror on the sliding door too!
Here's another vid Phil took
http://www.youtube.com/watch?v=6hgPXOS3rgY
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on August 28, 2011, 04:56:44 PM
Quote from: 80 Vert on August 28, 2011, 04:38:00 PM
Hahahaaa yeah cunning eh!
Came within 5mm of clipping the mirror on the sliding door too!
Here's another vid Phil took
http://www.youtube.com/watch?v=6hgPXOS3rgY

where is my box of tissues....
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: slowmo on August 28, 2011, 05:52:07 PM
I want one!  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GLIDN on August 28, 2011, 10:22:07 PM
Well done John,

Looks great
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 29, 2011, 09:32:20 AM
Looks like we'll do a BBQ on the 17th september, GTIVR6 will be the chef of the day again.
Will do a lunchtime one starting at 12-12.30? let me know who's keen.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VeeDub on August 29, 2011, 09:32:46 AM
Keen beans!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on August 29, 2011, 10:12:41 AM
Looks great John. Cant wait to see it finished, and what your planning for the bumper.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Pinkmaggit on August 29, 2011, 10:25:10 AM
That paint looks pretty amazing. Great to see the attention to detail that went into this thing.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on August 29, 2011, 10:41:10 AM
keen as John
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Pristle on August 29, 2011, 10:52:03 AM
Meneer, dit is heel erg mooi
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on August 29, 2011, 10:44:57 AM
Last two  8)

http://www.youtube.com/watch?v=ct0W3PZEJaY (http://www.youtube.com/watch?v=ct0W3PZEJaY)
http://www.youtube.com/watch?v=K-DzMlplTHE (http://www.youtube.com/watch?v=K-DzMlplTHE)

The ride around was very interesting - though common sense says the car will be brutally fast it does take a ride to start to really appreciate it. Even on tiny throttle openings it is making 1-2psi of boost instantaneously and accumulates speed in the subtlest manner. I think it'll one of those cars that has that "hand of god" feeling, where it feels like laws of physics don't apply and some higher power is just effortlessly shoving you down the road.

I can't wait to see this thing hit the rollers at TP when the tune is dialled in!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 29, 2011, 10:53:46 AM
Quote from: Pristle on August 29, 2011, 10:52:03 AM
Meneer, dit is heel erg mooi

Ja dat denk ik ook!  ;D Nederlands is bijna het zelfde he?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on August 29, 2011, 11:51:53 AM
Quote from: 80 Vert on August 29, 2011, 09:32:20 AM
Looks like we'll do a BBQ on the 17th september, GTIVR6 will be the chef of the day again.
Will do a lunchtime one starting at 12-12.30? let me know who's keen.

In  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on August 29, 2011, 12:08:04 PM
would the longer US spec front bumper give more room for the FMIC?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Pristle on August 29, 2011, 04:36:14 PM
Quote from: 80 Vert on August 29, 2011, 10:53:46 AM
Ja dat denk ik ook!  ;D Nederlands is bijna het zelfde he?


Close, but as the Dutch would say, "we're more refined......" As if!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on August 29, 2011, 05:28:45 PM
Do the buttons on the wheel all work witht he dash?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on August 29, 2011, 06:32:25 PM
Looking Fantastic there guys!!!!! I stand up and go clap clap clap clap!........Keen for the BBQ.....i need to see this up-close and personal!.... 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RevHappy on August 29, 2011, 09:40:39 PM
Wish i could come and see. So proud to be kiwi seeing this!!!! Its amazing!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 29, 2011, 09:53:18 PM
Quote from: spooln on August 29, 2011, 05:28:45 PM
Do the buttons on the wheel all work witht he dash?

Nah, still have to get blanking plates for them.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 29, 2011, 10:05:05 PM
Quote from: Pristle on August 29, 2011, 04:36:14 PM

Close, but as the Dutch would say, "we're more refined......" As if!

Yeah they would say that, but after all you can't argue with the truth.  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on August 29, 2011, 11:04:15 PM
I'm in for BBQ too!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: gti vr6 on August 30, 2011, 07:38:07 AM
Quote from: tyz-fly on August 28, 2011, 04:56:44 PM
where is my box of tissues....

Are they happy tissues or sad tissues?  >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on August 30, 2011, 07:50:14 AM
Quote from: gtimanik on August 29, 2011, 09:40:39 PM
Wish i could come and see. So proud to be kiwi seeing this!!!! Its amazing!

I bet John is proud to be Dutch too.  :P
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 30, 2011, 05:15:08 PM
Can I've a drive mate?    ;) :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on August 30, 2011, 08:01:28 PM
since you have gone through the lengths you have to make this thing look so amazing, i think most of us are expecting it to go something like this....

http://www.youtube.com/watch?v=2PbTmjLfZnM



no pressure or anything >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on August 30, 2011, 08:30:00 PM
I was thinking more along the lines of this:

http://www.youtube.com/watch?v=4Id2O0vC7Lk
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on August 30, 2011, 08:34:59 PM
Quote from: M on August 30, 2011, 08:30:00 PM
I was thinking more along the lines of this:

http://www.youtube.com/watch?v=4Id2O0vC7Lk

I can't help but get a school boy grin when I watch that. Looks bonkers  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 30, 2011, 08:42:52 PM
I wonder how many of those other guys build there cars 98% themselves and do it on the back of running a water blaster business in recession struck NZ tho :P
They would all be trust fund bunny's ::)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 30, 2011, 08:43:34 PM
Quote from: M on August 30, 2011, 08:30:00 PM
I was thinking more along the lines of this:

http://www.youtube.com/watch?v=4Id2O0vC7Lk

Haha yeah I've seen that before, nutty as!
I don't see how EIP would have got 750hp out of theirs with that plastic manifold, we all know they pop around 15psi.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 30, 2011, 09:03:24 PM
Hopefully the weather is good this weekend so that I can do some more logs for Rich @ Viper, will need to do idle logs now to get fuelling spot on.
Filx did a log with vagcom while we were driving around the other day so that will be interesting to hear back on.
Isn't it amazing what is possible these days with modern cars!

I mean here's a guy on the other side of the globe writing one off software for a car he's never seen and the fact you can just use something like vagcom to log how the thing is running and make changes as you see fit is just awesome.
Lets not forget the fact that the R32 was never turbo'd from factory and now idles at 7-800 rpm with 630cc injectors!
(can you tell i'm exited?  >:D)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on August 31, 2011, 07:04:16 AM
Quote from: BB on August 30, 2011, 08:42:52 PM
I wonder how many of those other guys build there cars 98% themselves and do it on the back of running a water blaster business in recession struck NZ tho :P
They would all be trust fund bunny's ::)

pull your head out, not everyone with money is a 'trust fund bunny" some work for it. That S3 is from Greece and built by a tuning company, so 98% their work too.

Quote from: 80 Vert on August 30, 2011, 09:03:24 PM
Hopefully the weather is good this weekend so that I can do some more logs for Rich @ Viper, will need to do idle logs now to get fuelling spot on.
Filx did a log with vagcom while we were driving around the other day so that will be interesting to hear back on.
Isn't it amazing what is possible these days with modern cars!

I mean here's a guy on the other side of the globe writing one off software for a car he's never seen and the fact you can just use something like vagcom to log how the thing is running and make changes as you see fit is just awesome.
Lets not forget the fact that the R32 was never turbo'd from factory and now idles at 7-800 rpm with 630cc injectors!
(can you tell i'm exited?  >:D)

The first thing I noticed on EIP car was the plastic inlet too.  ;D

I agree on the modern tuning bit, I remember spending hours on dyno back in late 90's with a very smart engine guy doing mapping on my old race car with quad throttle bodies. Probably a full day and a half just on rollers. The net result was a car that was poor to start cold, idle terrible even when hot but went like stink when hot and on song.

It wasn't his fault but to get everything mapped perfect would have taken him days and days and wasn't worth it for a race car.

Makes me laugh when building mine, everyone here says "You going with a Link?". They look at me funny when I say I am sticking with standard management to get perfect cold start and idle, add to that the retaining of fault codes.  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 31, 2011, 07:47:02 AM
Yeah don't understand why you'd go aftermarket when factory stuff is so tuneable and usualy free with the engine.
Coming to think of it M you could look at a Viper map maybe? Richard has been fantastic in every aspect with my car so far.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on August 31, 2011, 07:53:30 AM
My only issue is that being a race car I want to be able to tinker at the track if I have to. That was my reason with going Maestro, as usual though they are not quick to deal with.  :(

Might have a chat with Richard and see what he can do.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 31, 2011, 08:01:53 AM
Yes although once its tuned (Richard is pretty fussy) I doubt you'll  need to change anything, we are still running the same map as it came from Chris Tapp and made no changes so far.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 31, 2011, 08:49:31 AM
Put your head back in M, most trust fund bunny's start a tuning company so they have something to do instead of just spending.

  I know not everyone with money is a trust fund bunny but there are plenty of them out there, that's for sure.
I was just trying to pay Vert a compliment.
I think the majority of high end cars are built by people who are loaded.

Most of us work for our money don't we yet we could never make something like this happen so get stuffed.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on August 31, 2011, 10:07:33 AM
Quote from: BB on August 31, 2011, 08:49:31 AM
Put your head back in M, most trust fund bunny's start a tuning company so they have something to do instead of just spending.

  I know not everyone with money is a trust fund bunny but there are plenty of them out there, that's for sure.
I was just trying to pay Vert a compliment.
I think the majority of high end cars are built by people who are loaded.

Most of us work for our money don't we yet we could never make something like this happen so get stuffed.

Just words of a jealous idiot. To simply assume someone with a nice car had a trust fund is just plain childish. In fact many of the most well off people I know started with nothing, me included(not that I am considerably well off).
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on August 31, 2011, 11:49:13 AM
I don't want to start a slinging match with you M.
I'm not a jealous idiot.
I wasn't intending to do anything really other than pay Vert a compliment, I think most people who would even dream of making such a car would have loads of money, plenty do.
There are so many trust fund bunny's around.
But your right I made some assumptions and I'm sorry if its pissed you off.

You yourself make a few assumptions at the end there too you know, most well off people I know started off with plenty.

Sorry to do this to your thread Vert :-\

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: KARTS on August 31, 2011, 02:23:04 PM
Saw a good bumper sticker the other day. "I started with nothing and I've got almost all of it left"
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 03, 2011, 10:52:55 PM
Not much to report on as Filx kept me busy working on his 3 door...........but now that the interior is finished my job is done and annoyingly its come out better than my own one  >:(

Some time ago a guy on VWwatercooled suggested I get a rear body brace for my car, he'd got one for his Bora 4motion and absolutely raved about how good it was.
Did some more research and it seems to be one of THE best mods to do for a MK4 or MK5.

It installs behind the rear seat tying the rear strut towers / body together pretty much eliminating any rear body flex.
A Jetta / Bora is already quite a bit stronger there so a Golf would especially benefit in this area even more so with lowered / stiffer suspension.
The big hatch opening creates a big weak area in the back and a guy on Vortex had removed his and found he wasnt able to re install it until he parked the car back on a level surface as otherwise the bolt holes wouldn't line up  :o
Having got the brace I drilled the holes to mount it and installed nutserts to bolt it in with, obviously it does limit boot space once the seats are down but its dead easy to remove with 4 bolts.
I'm going to get mine powdercoated black in the coming days and decided to order 5 more for anyone that might be interested, 1 is spoken for already but PM me if keen.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F27_08_2011018.jpg&hash=93f480ae56bad1880c94c5859f263f35965590bf)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F27_08_2011023.jpg&hash=146891626d8548e22ea527a780d16e2ff3b1774d)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F27_08_2011022.jpg&hash=a93332825a0e5289b9a723f43ccf63b5d66aa312)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on September 04, 2011, 08:37:56 AM
R logo ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 00quattro00 on September 04, 2011, 08:40:55 AM
How much are those braces? And how thick are they?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 04, 2011, 09:10:09 AM
Plate is 8mm thick, I'll know total cost once I've powdercoated this one.
There's also a 1" box section still to go on along the top edge as well which is getting powdercoated seperately.
R logo is inlayed with either red or blue acrylic.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 04, 2011, 10:22:21 AM
Just a reminder too that the BBQ is still a go for the 17th Sept, 12 onwards.
Thanks to those who have expressed intrest, helps to plan for food etc.
Will provide soft drinks but if ya'll want something stronger feel free to bring it along.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Nick on September 04, 2011, 10:26:44 AM
that brace is cool as 8) ill take one for sure :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 06, 2011, 06:28:32 PM
Got my brace back from powdercoating today and couldn't really wait till the weekend so I attached the upper bar and fitted the logo tonight, bolted in easy as with 4 bolts.
Has come up well I think, pricing has worked out to $349+gst raw finish with logo or $385+gst powdercoated.
Rivnuts and stainless bolts supplied with the brace.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FDSCF0159.jpg&hash=6c0f05cd8c8d18f84fc190db5c83086789a799ba)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FDSCF0161.jpg&hash=4005b01e7de7cc2c5f1db1caeeac186cd09f5582)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FDSCF0160.jpg&hash=3a8dbd9c2f6d3d6c74c16d6e1eb4f00a7805f401)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on September 06, 2011, 06:33:01 PM
That looks great!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: KARTS on September 06, 2011, 06:39:45 PM
Mean!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on September 06, 2011, 06:50:55 PM
Your gona need that at the speed you will be biffing it through the corners at the Hampster.

All 4 wheels smoking as you come out the sweeper after going in way to hot 8)
God I'm a bogan at heart.

Watch the Dahlback golf 4 wheel drift for inspiration.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Nick on September 06, 2011, 07:07:03 PM
WOW thats a really good price you would pay $500 at least any were else for something like this :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 00quattro00 on September 06, 2011, 07:08:54 PM
I could make them pretty cheap and could cut what ever you wanted in it
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 06, 2011, 07:18:41 PM
I'm pretty happy with my current supplier but thanks all the same Basil.
The powdercoating does add a little but I think the final product speaks for itself, I'm fitting one to Filx's 3 door week after next and we plan on doing some testing to see how much stiffer these make the Golf body.
The rest of the braces coming will have blue R logo's regardless of powdercoated or not.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on September 06, 2011, 11:45:34 PM
Quote from: Nick on September 06, 2011, 07:07:03 PM
WOW thats a really good price you would pay $500 at least any were else for something like this :)

Did you make it Nick?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Nick on September 07, 2011, 04:47:02 AM
no i didnt make them im not sure who did but they are very well priced as high grade 8mm ally is around $800 - $1000 dollers a 1200 x 2400 sheet :o its going to be cheaper for me to buy one from john then for me to make one for my self.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on September 07, 2011, 07:39:52 AM
That is a great deal then! It always amazes me how much raw material can cost, especially considering nothing has been done to it yet! Is there a mk2 version John?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on September 07, 2011, 07:49:36 AM
Mk2 don't really need it I don't think, tho some put a bar across the shock tops.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on September 07, 2011, 08:01:33 AM
that came out really well John, has it made much of a difference to the jetta from what you can currently tell?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 07, 2011, 08:09:45 AM
Quote from: BB on September 07, 2011, 07:49:36 AM
Mk2 don't really need it I don't think, tho some put a bar across the shock tops.

Really Jem?
MK2's would have a much weaker body than any MK4.
Doesn't look like anyone makes them for the MK2 Poon, doesn't mean that it can't be done but I don't think there's really anything to bolt it to in a MK2, would be interesting to have a look at one.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 07, 2011, 08:12:01 AM
Quote from: Fizz on September 07, 2011, 08:01:33 AM
that came out really well John, has it made much of a difference to the jetta from what you can currently tell?

I haven't driven the car yet since putting it in, we'll get Filx's one installed in the coming weeks and run some tests  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on September 07, 2011, 08:19:42 AM
Well as I say some put a bar across the rear.
The mk2 and 1s just skip the rear along behind and there is not that much tyre grip to generate rear flex worth worrying about. Well that's what I think.
I don't think the mk2s need a front strut either but people put them in.

Its all good stuff tho and makes things stiffer I guess but also adds weight and with the front bars makes it annoying to get at certain things.

I think that one in your car is well worth fitting. 4 wheel drive and big grippy tyres.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Pinkmaggit on September 07, 2011, 10:35:09 AM
That brace looks amazing. If only I wasn't too lazy to take it out each time I needed to fold the seats down I'd definitely get one.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 07, 2011, 10:37:45 AM
Its literaly a 5 minute job to take it out.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 10, 2011, 09:51:56 PM
Started this morning by re-torquing the cylinder head as the raceware stud kit are not stretch bolts so it says to do a re torque after a couple of heat cycles, got a little more out of a few head nuts so in all it was worth doing.
Finished the last of the wiring for the water injection pump which meant the rest of the dash could be put together, the dash has been together a few times only to be pulled apart again for something else so after the 2nd or 3rd time I left it apart  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0163-1.jpg&hash=8ebc538f32594a0b58c5fb946072562cf0a08e27)
Most of the rear interior is in now too, just have to install the B pillar trims but they'll have to wait till the whole window issue is resolved as the fastners for them are behind the B trim.
I did wash it the other day and didn't get any water inside which is a positive sign, both laminate windows are hinged and installed with hinge design #4 which up to now has been good, just gonna see how it holds up with road vibrations etc over the next few months.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0162-1.jpg&hash=09ddc16d74287e1d67632aa3c362d22e0448a5f0)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0164-2.jpg&hash=f206b58fd451a05f000399b65e56139bf0c95c36)
After lunch I did an idle log for Richard with his #2 revision file loaded, essentially left it idling for a while being logged with vagcom.
Have emailed that to him and received file #3 back to carry on with  ;D gotta love his service!
The rear bumper never got buffed out when I painted it as I was kinda over the whole polishing thing so that was another job done this afternoon.

Took it for another drive later in the day and managed to put another 20km on it until the rear susp collapsed on the right side when I called in to see Frank at Euro Auto, looks like those turn buckles are not up to the job after all.
No damage done but just as well it happened only a few 100 metres from work! :-[
Bent it back straight again and drove it home, the next ones I make will be made from scratch and will NOT fail this time!  ;D




Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on September 11, 2011, 11:00:14 AM
bugger.....better now then when you are doing a 100kms hour
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on September 11, 2011, 11:39:42 AM
That's a bit pathetic that they failed

Rear interior looks good, did you have to modify the rear Golf door cards or did they fit straight in?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 11, 2011, 03:02:14 PM
Yeah would have been big trouble had they failed at speed, got some nolathane bushes today to start making complete arms from scratch.
Modified the rear interior cards, not much but had to be changed none the less.

Just a reminder too about the BBQ next saturday, hope the weather plays nice.............
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on September 11, 2011, 03:21:30 PM
looks great John, car is amazing :)  How did u go with the front bumper btw?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 11, 2011, 03:28:47 PM
Hmmm front bumper....................still waiting and thinking about that  ;D
You coming on Sat?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on September 11, 2011, 08:14:47 PM
Had a thought and a quick ms apint ...lol
Mazda 323 SP20 front bumper?

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi888.photobucket.com%2Falbums%2Fac87%2FGolfMini%2Fmk4sp20.jpg&hash=6fed072f485db2e2385e25a34a5ea9e1540ceaaf)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on September 11, 2011, 09:24:51 PM
Noooooooooo
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: hagan on September 11, 2011, 10:26:59 PM
Quote from: Ballin on September 11, 2011, 09:24:51 PM
Noooooooooo
+1
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on September 12, 2011, 07:48:42 AM
Quote from: 80 Vert on September 11, 2011, 03:28:47 PM
Hmmm front bumper....................still waiting and thinking about that  ;D
You coming on Sat?

yeah might pop around 4 abit if I'm not heading back down to Turoa
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 13, 2011, 09:48:44 PM
Adjustable rear bars MK2 are nearly done, been a bit more work then first thought, problem I ran into was that we don't have much in the way of left hand taps and dies so by the time I bought what I needed plus the nolathane bushes I got in the weekend I would have been better off buying two sets of the gruvenparts bars.....................Tooling I did have were an M24x1.5 right hand tap and die, for the left hand threads I just used the thread cutting ability of the lathe................I have NO idea why I didn't think of that before so it just shows how much that gets used  ::)
Its been years and years since I last did any screw cutting on the lathe, farkin awesome once I figured out how it all worked again, takes longer but no need to buy any tooling!
You can pretty much make whatever thread you want, left or right.
Still some threading left to do and weld the components together so hopefully they'll go out for powdercoating this week.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ddr77 on September 14, 2011, 09:13:29 AM
Just read this thread from start to finish very very exciting, well done bet you cant wait to open her up.;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 14, 2011, 02:13:15 PM
Progress from yesterday, just have to make the attachment forks now and weld them together.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0165-1.jpg&hash=a0bdae3b13e039be6a4b8a88148d3a381ebf2585)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on September 14, 2011, 02:28:42 PM
 :o Whoa - who ate all the pies?  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ddr77 on September 14, 2011, 03:28:26 PM
Just read this from scratch aswell as the vento build brilliant stuff. surely deserves to be featured somewhere?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 14, 2011, 05:24:54 PM
Quote from: Filx on September 14, 2011, 02:28:42 PM
:o Whoa - who ate all the pies?  :laugh:

LOL, like I said these will not fail!
Funny thing is that once I have a problem like this then the next time round I tend to over engineer on a big scale  ;D
Loaded file #3 today and ran some more idle logs for Richard, fueling seems a lot closer now with a noticable difference in the way it idles so hopefully he'll ask me to open the taps soon pleeeeeeeeeaaaase Rich?  ;D
But..............this is one of those things that can't be rushed otherwise you'll end up with melted pistons if ya get it wrong  :-X
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on September 14, 2011, 06:51:21 PM
How many times have you had this car to the dyno .

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 14, 2011, 09:26:49 PM
Hasn't been to the dyno yet, just been logging with vagcom to dial in  the fuelling, dyno will happen once we are happy with the way it runs.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 15, 2011, 09:06:02 PM
Did another idle log today with software version #4 which is getting a lot closer to where we need to be according to Rich, he's just sent me version #5 to load which we should see the self adaptation % blocks on vagcom beginning to show readings which means the ECU will then start to self adjust fuelling when needed.
These late model ECU's are awesome with whats built in to them, why on earth would anyone go stand alone  ::)

Up to now the % blocks have not read anything, only lambda voltage meaning the ECU will not self adjust and base fuelling is still a little off.
If the base fuelling is off then everything is off the whole way along, sure am glad to find someone who is taking the time to get this right.
Learning quite a bit at the same time and should be a ripper once going correctly, even at this early stage I'm noticing how it idles better and sounds crisper when revved up Great job Rich!  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 15, 2011, 10:25:40 PM
Almost forgot, just a reminder for the BBQ this sat.
I guess it should have gone in the events but its a bit late for that now.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on September 16, 2011, 07:54:32 AM
I'm there! 11am was it? Maybe post your addy too John?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 16, 2011, 08:13:47 AM
12 onwards Ash, see you then.
Addy is 42 Henderson Valley Road Henderson.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on September 17, 2011, 03:03:28 PM
Good catch up.
Thanks John :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 17, 2011, 03:34:30 PM
Welcome Jem, glad you could make it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Pristle on September 17, 2011, 03:45:26 PM
JK, thank you for hosting a rather good turnout.

Great to see some good work being achieved by several fellow Vaskers. I feel inspired.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Heino on September 17, 2011, 04:28:47 PM
Thanks John for the BBQ was good to meet you all again. John you have some Tremendous skills to have built that r32 jetta, I couldn't get away from it, its just to beautiful :D well done.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 17, 2011, 09:05:12 PM
Cheers everyone for coming over, turned out really well and was good to see some new faces.
Frank brought his awesome MK2 Scirocco over, great job! looks the bizz.
Also thanks to GTIVR6 for the loan of the BBQ and cooking skills! awesome man.
If anyone got any pics feel free to post them up.

Anyhow onwards with the car, finished the rear bars during the week but they were too late to be powdercoated at the same time as some other work stuff so I sandblasted them and painted with POR15, after all they are buried under the car  ::)
Bars assembled this morning ready for fitting
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0166-1.jpg&hash=c45e86f503d8af1bef19862f5c959c020bf855c5)
Ended up coming in a little earlier this morning so that I'd get these in and the car back on the ground for the BBQ, easy as pie to fit and seem pretty solid  >:D another job finished!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0168-1.jpg&hash=e07633455af22c8f65de0e50f7387deb4d960b31)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0167-1.jpg&hash=42d7b6dece8942eaf3e21b0259bde1925acbb165)
After everyone had gone this arvo I got the car out and drove it some more, should really get an alignment done soon too.
Everything seems to be working as it should, getting on top of the tuning so she's almost done.
Only one problem so far, when the fuel pump has primed and you don't start it right away the fuel pressure seems to bleed away out of the fuel rail......... :-\ meaning you have to crank it more to get it going.
Been thinking about this problem and think I've solved that now, when I got my 044 pump it had a one way check valve on it which Greenlane speed shop told me I didn't need (they didn't have the right fittings for me to be able to use it) and I think now that this is the reason it doesn't hold pressure in the rail............ >:(
So last thing today I made the fittings I need, will install check valve next week and see  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GLIDN on September 17, 2011, 10:30:52 PM
Turned up today nut clearly too late. Would have been great to see it in the flesh and catch up with everyone.

The arms look good too
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 17, 2011, 10:33:53 PM
What time was that? Most were still there at 2.30........
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GLIDN on September 17, 2011, 10:38:39 PM
Turned up just after 3pm, about 3:15 to be more exact. It's ok.
Everyone had fun none the less.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on September 18, 2011, 01:12:32 AM
Thanks for having us John, great to see the Jetta in person. A work of art really... Should stay in the showroom... Not >:D

O, and thanks for cooking up a storm on the BBQ Karl!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Omes on September 18, 2011, 04:51:24 PM
Thanks John and Karl  8) good to catch up with everyone who was there.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on September 18, 2011, 05:10:47 PM
A few phone pics, so not the best, but a great showing to check out the Jetta!

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi53.photobucket.com%2Falbums%2Fg75%2FAshvw%2FRandom%2F4e855d6a.jpg&hash=e71829281ddd4024f673439464342fac58d3957e)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi53.photobucket.com%2Falbums%2Fg75%2FAshvw%2FRandom%2F5958e59a.jpg&hash=0afc85cf967e7c3b98dd0cd20682537dfad70bf3)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi53.photobucket.com%2Falbums%2Fg75%2FAshvw%2FRandom%2F4af1795d.jpg&hash=b04229b972df84af9ed746f7e7ad1e5f64ec3333)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi53.photobucket.com%2Falbums%2Fg75%2FAshvw%2FRandom%2F1834de7f.jpg&hash=999338724f99e20d03254b576644831fe4fff141)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi53.photobucket.com%2Falbums%2Fg75%2FAshvw%2FRandom%2F04195896.jpg&hash=b576de75e86d06ca87ef4e05c208460e7c66c318)

As Tristan mentioned, nearly 90% of the cars that were there were reasonably modified! Great to see so many of us really getting into and a lot of it would be due seeing Johns projects and trying to keep up!! ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on September 18, 2011, 06:38:34 PM
And an old Serena van :P
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on September 18, 2011, 07:39:46 PM
Cool day, enjoy that sort of thing. Good caliber of cars to check out too
Cheers John, and Karl for the BBQ skills!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on September 18, 2011, 09:27:58 PM
Great afternoon, Thanks John
Was modified car central
Don't forget the Cultus 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on September 19, 2011, 08:28:52 AM
I liked the quality sausages! I only had one and then John ate the last one ......have to be quicker next time.
Need to build up strenght ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 19, 2011, 09:21:19 AM
Well Jeremy snooze you loose  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 22, 2011, 03:53:45 PM
Its here!, must say its very nooooice  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0143-5.jpg&hash=16edb91d817e8f91fcef170f986c3c56247df87f)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on September 22, 2011, 03:55:35 PM
It's not dissimilar to the one you replaced :)
More bling!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 22, 2011, 04:10:12 PM
Yeah and it cost more LOL!
Is a much better looking wheel / airbag thou
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on September 22, 2011, 04:25:54 PM
Very nice!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ddr77 on September 22, 2011, 05:09:10 PM
Very nice indeed.....But no fast and furious BOOST buttons lol.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on September 22, 2011, 05:32:49 PM
lol  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on September 22, 2011, 06:17:32 PM
500% nicer than the Mk5 wheel IMO 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on September 22, 2011, 06:38:36 PM
Nice wheel. Any front bumper updates?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on September 22, 2011, 09:15:15 PM
Quote from: rambo_005 on September 22, 2011, 06:17:32 PM
500% nicer than the Mk5 wheel IMO 8)

Agree, they look banging in the Mk4 too
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 22, 2011, 10:33:37 PM
Looks like I was right and GSS was wrong, the fuel rail pressure loss was in fact due to the one way valve that was left off the 044 pump.
With the fitting I made last week it was easy to install the Bosch valve in between the pump and outlet fitting and it now starts as I would expect it to so next time I'll ignore advice like oh you don't need that  ::)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on September 23, 2011, 07:53:58 AM
I'm not sure they were wrong :) They said you didn't need it. The car still went so you didn't need it, it just took a few more winds to start. :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 25, 2011, 03:13:37 PM
Steering wheel is in and working, no cutting or soldering wires needed, managed to install the airbag using the MK6 loom and the MK4 slip ring plug only.
The connectors are such a tight fit in the MK4 plug that it all works out good, plugged the loom in and just sat the airbag on the steering wheel to test it, turned the key on and...................light went out and thought cool!................but light came back on again with that sinking feeling to go with it  ;D

Turns out I hadn't plugged the loom in to the airbag itself DOH!  ;D
All good now, colour is a bit lighter but it appears lighter in the pictures than what it really is for some reason.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0146-7.jpg&hash=c755419351a7cd151e375d7224fae47c8db322ce)
Also managed to borrow a wideband reader to double check AFR's as Rich is having some trouble getting the ECU to self adapt fuelling, at least with the wideband we can now see that its running too rich all the way along so this needs to be dialed back some.

Took it for another drive yesterday and seeing we had the wideband in the car and hooked up we could see that its running a little rich so it gave me some confidence in giving it some more right foot  ;D well it can't hurt can it  :P
The EBC is not set up so at only 6.5psi it goes into overboost and that's all you get for now but it feels like its going to go VERY well, even at that low boost its got plenty of punch already for a heavy lardy car.
Downside is that I can't wait now to get on it more  >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 25, 2011, 03:17:22 PM
Quote from: spooln on September 22, 2011, 06:38:36 PM
Nice wheel. Any front bumper updates?

Yep, managed to get an 08 A3 bumper so hopefully that can donate a few sections, had hoped to do some work on that yesterday but didn't quite get there.
This coming week / weekend should see progress in that department as I can't really keep driving around with no front bumper or plates LOL!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on September 25, 2011, 06:20:08 PM
What an awesome day yesterday that turned out to be a feast of boosted dubs. First we went out for a run in the Viper mapped 1.8T Beetle which John has been working on. I've never really been in a new Beetle but it was cool, smooth like butter with great punch and she pulls hard. You can see it would be an awesome fun all-rounder.

Then I was then fortunate enough to be out doing some of the checking with the wideband etc for the Jetta. Faaaaark, people are probably sick of me raving on but the anticipation of how brutal this thing is gonna be is palpable! On just 6 psi it STOMPS and the sound of the VR6 with the turbo/downpipe combo is fantastic. No lag, no effort - just this composed sense of raw urgency as it unleashes itself.

We took the Vento out for a blat afterwards to compare and it's like a stick of dynamite with a long fuse, sure you know the madness is coming but you get a second or two to mentally prepare yourself. Whereas as the VR6T is like standing on a landmine - as soon as you move you foot it's going to go off with big f&%kin bang  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 25, 2011, 06:26:10 PM
You should write magazine articles  ;D Couldn't have summed up better really!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 26, 2011, 04:54:16 PM
This is where I'm goin with the bumper, center section MK5 and end pieces are Audi A3
First idea so far that I'm ok with, difficult to visualise with all the different colours and screws etc but gives a general idea.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0151-2.jpg&hash=d6fec0ae2e2fddea96e20cd42633e5a911062f8f)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0150-2.jpg&hash=f57ca8e04263d00a342e1f4f22704fd16b1eace1)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VeeDub on September 26, 2011, 05:17:56 PM
Looks primo, I like how the centre section lines up with the headlights and continues the line.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on September 26, 2011, 05:25:38 PM
Looking good for shure....I can see the direction your going in,.....keep it in the family......maybe a Skoda lower lip area.... 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on September 26, 2011, 05:48:19 PM
Very oem lines, which it kinda is ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 01, 2011, 06:21:49 PM
Came to a bit of a grinding halt on the engine tuning during the week due to the ECU refusing to self adapt fuelling even though the AFR is bang on what it should be, we do have a bit of a difference between the two lambda sensors so I've ordered 2 new ones to be able to eliminate them from the list.
When fuelling is that close the ECU should self adapt fuelling to maintain a 14.7 AFR at idle but for whatever reason its not doing that  >:(

Not wanting to get down on that problem I've carried on with the bumper, a bunch of plastic welding done its not looking any more pretty but it sure is a lot stronger now!
Made the lower lip today into something I'm fairly happy with so next will be more welding, grinding and smoothing of the plastic  ;D.
Fingers crossed I'll have the bumper ready for primer within the next couple of weeks, still a LOT to do but its really starting to look pretty OEM now.
Hopefully this will be the last custom bumper I ever do, they are not an easy thing to make  :P
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0157-2.jpg&hash=b6c98c1723b3036fdb95b05509e7a2d29d9d2583)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0155-2.jpg&hash=4b9ea8d03b8a12b16e363ec3b97e0cfe513ce870)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0156-3.jpg&hash=031aef49dc7b50b106f29f2922f123ede82b2255)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on October 01, 2011, 08:41:27 PM
oooooooohhh  nice .....are you going to weld the black part and colour code it or blue the rest and black the black?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 01, 2011, 08:44:22 PM
Yep will be one piece bumper, fully painted like I did with the rear one.
The best thing so far is how OEM it fits, gaps are nice and clips on like a stock one  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on October 01, 2011, 08:47:09 PM
Great work buddy!!!.......going to run the Audi spot lights??
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 02, 2011, 09:12:00 AM
I wasn't going to till you mentioned it and been thinking about it since, will probably go have a look at an A3 and see how big they are but yes I'll probably put some form of spotlight there now.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on October 02, 2011, 12:34:56 PM
Ive had a look at one of them and they sit nicely in the curved area
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 02, 2011, 05:36:52 PM
I just bought a couple of sets today, got some MK5 Golf ones and a set of A6 Audi ones so hopefully one of those will be suitable.
Most of the sellers on Ebay that had A3 ones had rediculous shipping prices so we'll see if these others are going to work.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 18, 2011, 09:09:08 PM
Since mapping began a month or so ago we haven't been able to get the adaptive fuelling to work, no matter what we tried with idle fuelling it didn't want to work...... :(
The lambdas were reading a difference between the 2 (bank 1 & 2) which I was told was too far apart and that would affect fuelling so I installed another set of used sensors I had with the same result.
Started to have my doubts by now but could that 2nd set be faulty? so reluctantly I ordered a couple of new ones and installed them again with the same result GRRRRRR F*%#EN CAR!!, it looked like one bank was running leaner than the other........................WTF how can that be?

Then thought I'll put both sensors opposite each other in the downpipe, this time round they both read the same and right around 14.7 AFR at idle so the ECU was getting exactly what it needed but the fuel trims still didn't work.....................I was getting extremely frustrated at this point!
Spoke to Rich on the phone who was also at a loss as to why it refused to work, he suggested that we could continue without it as many manufacturers don't even have that function in their ECU's but that just wasn't going to cut it for me, factory put it there for a reason so keep looking!  >:(

My thought was to put the car back to std, airflow wise and map wise by fitting the std 3" MAF housing and element as well as load a factory map which Richard had emailed.
In the weekend I decided to hold off doing that and searched the TEX for information as to what can stop fuel trims working.
Found a thread on the 1.8T forum where a guy talked about deleting the EVAP system and how that can stop trims working.
He went on to say that tuners normally just remove the fault codes for items removed rather than write it out of the software......which got me thinking about the SAI that I removed from the R's engine...........could this be the problem?

From what I could make out he's saying that even though the fault code is removed it doesn't mean that the ECU isn't looking for that component that has been removed, made sense to me!
Simple test today was just to plug the 4 removed parts back in and whadda ya know FUEL TRIMS WORK!!!
Righto know what to do from here, down to RS components for 330ohm resistors, fitted those in place of the 4 offending parts and trims are working with SAI removed PHEW!!!! ;D ;D ::) ;D
FINALY WE CAN CONTINUE WITH THE MAP, 10PSI BOOST IS NEXT lol!













Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on October 18, 2011, 09:18:20 PM
John, what does SAI stand for?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ddr77 on October 18, 2011, 09:20:20 PM
Good man i was going to suggest the SAI as i knew that the fuel trims were an issue with other mappers on the 1.8ts, well done sherlock good find. Proves that we all do get there in the end.

















Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ddr77 on October 18, 2011, 09:21:53 PM
Quote from: RS ZWEI on October 18, 2011, 09:18:20 PM
John, what does SAI stand for?
Secondary Air Intake ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 18, 2011, 09:22:26 PM
LOL yeah wanted to give up looking more than once let me tell you!  :P
Seem soo simple now looking back................. ::)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on October 18, 2011, 09:23:13 PM
SAI = Secondary Air Injection

Good work John, amazing what the web can turn up. I have actually read on that before when searching on what to use for mapping Corrado but never even crossed my mind for yours.  :(
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 18, 2011, 09:24:20 PM
Quote from: ddr77 on October 18, 2011, 09:21:53 PM
Secondary Air Intake ;D

Secondary air injection  ;)
Basically its a bullcrap way of making the car "appear" cleaner at idle emissions wise by blowing air into the exhaust system, horrible system that I didn't need or in fact have room for!  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ddr77 on October 18, 2011, 09:27:26 PM
Quote from: 80 Vert on October 18, 2011, 09:24:20 PM
Secondary air injection  ;)
Basically its a bulls**t way of making the car "appear" cleaner at idle emissions wise by blowing air into the exhaust system, horrible system that I didn't need or in fact have room for!  ;D
Thats what i meant to write lol was looking at intakes on another web page haha. At least shes all working now.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 18, 2011, 09:28:49 PM
Quote from: M on October 18, 2011, 09:23:13 PM
SAI = Secondary Air Injection

Good work John, amazing what the web can turn up. I have actually read on that before when searching on what to use for mapping Corrado but never even crossed my mind for yours.  :(

Yep plenty of haters on the TEX but it sure serves its purpose very well, did think today that we take the internet for granted these days...............
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on October 19, 2011, 08:39:01 AM
Quote from: 80 Vert on October 18, 2011, 09:24:20 PM
Secondary air injection  ;)
Basically its a bulls**t way of making the car "appear" cleaner at idle emissions wise by blowing air into the exhaust system, horrible system that I didn't need or in fact have room for!  ;D

I was told that the system does make the CATs work quicker or something tho as well and its not quite as much of a con as it first seems?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 22, 2011, 06:57:09 PM
With the adaptive fuelling working as it should Rich sent me another map to run up to 10 psi BOOST  ;D ;D ;D ;D ;D ;D ;D
From here I'll have to log it again and see how its running, once we go over 10 psi in the next stage of tuning I think I may put it on the dyno instead to make things a little simpler.

Loaded the map yesterday so now the race is on to get the bumper done so that things look a bit more legal when tearing around the streets!
Hope to get most of it done this weekend and prime it next week, at least then the certifier can come and check it out so that I can get a wof and reg on to it.
Scored a euro plate today off Ranton-inc, cheers mate!
With 99% of the plastic welding complete I started shaping the bumper with an orbital palm sander & 36 grit, pretty quickly starts to look a whole lot better once the excess plastic is sanded away.
From here its going to get a top coat of a specialised filler for plastic however I doubt that the 1kg pot I bought will be enough to go the distance and of course with everything closed this long weekend it may just screw up my plans................. :P

Also cut the holes for the headlight washers and did a final fit / trim around the IC so its all go from here.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0149-5.jpg&hash=58adee29d63b46de218cc9043cc09048e7651439)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0151-3.jpg&hash=9716d5cc6e85a1088c9dfef1dbba4c866d97a165)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RevHappy on October 22, 2011, 08:56:19 PM
awesome mate. cant wait to see that painted and moulds on
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 24, 2011, 11:27:13 AM
As predicted my flexible filler ran out this morning with only about 85% of the bumper done, pitty really as I could have finished it this weekend.......... :(
Will just have to get some more tomorow and carry on, still not 100% happy with it as the filler I'm using doesn't seem all that flexible so I'd better not hit anything with it  :-\

Always amazes me how much there is to learn about this stuff, would have preffered something a bit more flexible but thats the way the dice rolled.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on October 24, 2011, 11:36:24 AM
maybe use the finished bumper to make a plug from and mould a one-piece bumper for use on the car?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 24, 2011, 12:46:15 PM
Trouble is you'd end up with fiberglass which would be 100 times more prone to damage than what I have now, I think this will work ok just have to avoid hitting stuff.
The other thing being the current bumper bolts on like a stock one with all its guides and mounting holes which you'd never get with any aftermarket type of set up.
This is where I'm at right now.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0152-4.jpg&hash=de5bb33a3ff3b96ae6f004c01b60367299f96a3b)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ddr77 on October 24, 2011, 03:28:56 PM
looks nice job well done.What did you use to plastic weld?Soldering iron?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on October 24, 2011, 05:39:31 PM
That Bumper is looking really good mate! Well done, will be awesome to see it painted and all the grills and spotties sitting in there like there suppose to .......standard/custom work! ..... 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 24, 2011, 05:52:53 PM
I'm using a plastic welding gun, just a glorified heat gun really.
Most welding is done at around 400-420 degC and pretty difficult too boot!

Spotts are out of here Arno, they block the oil cooler so I'm not bothering with them.
Will prime it and 180 block then re prime and put it on the car fully assembled, at least that way the filler and primer can cure / shrink back for a month or so at the same time allowing me to get the car road legal in the meantime.

Probably look at painting / buffing the bumper in the hollidays.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on October 24, 2011, 08:39:58 PM
Fair enough....i looked at the pick with the bumper on the car and was a bit .....ooooh ??? thats close.....
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 25, 2011, 05:58:11 PM
Finaly managed to go a for a drive with the 10 psi map  >:D
Wasn't all good though as it kept hitting the over boost shut down at 12.8 psi  :-\
I double checked the controller was hooked up correctly which was the same as the Vento so a check in that box and the solenoid seemed to be operating...........what else...............???

Decided that the W/G must have a 1 bar spring so I pulled that apart...............wrong.............7 psi as ordered last year..........running out of options now so I thought I'd pressure test the W/G to confirm the 7 psi spring, hmmm doesn't open at all but instead there's air rushing out underneath!!  >:(
Turns out the W/G has 3 possible entry ports, one was used and one plugged but the 3rd was open! DOH!
Plugged that off and tried again, I can say this much that car will attract 5.0 like nothing else  ;D >:D :police:
Only have the boost controller set on about 8.5 psi right now and its already a case of heavy car?? what heavy car???  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on October 25, 2011, 07:52:13 PM
I have no idea about how much boost this car can handle, but with a conservative 15lbs, i suggest this car will be a beast.
Will be very interesting to take it to a dyno to check the power, but more important than power is the torque level that this engine will produce.
Im thinking quite a lot tyre shreading torque.

But post it up John, it will be very impressive.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 25, 2011, 07:56:41 PM
Engine should easily be good for 20 psi and beyond, injectors may max out before then though.
Two things this car will use a lot of I think, tyres and fuel  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on October 25, 2011, 08:47:29 PM
A monster in the making  :-\
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 25, 2011, 09:50:14 PM
Hahahaaaa it makes me laugh reading about 18 psi on a KO3 MK4 GTI, this car on 18psi will be freaken MENTAL! >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on October 26, 2011, 09:31:42 PM
Sounds sporty 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 00quattro00 on October 26, 2011, 10:33:17 PM
Will the driveline handle the power? How much will it take to blow the diff or axles?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on October 27, 2011, 06:57:22 AM
Get at least 2bar through it John. She will love it all day long!!!  ;D

Will be a monster this car, love it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on October 29, 2011, 08:14:06 AM
Awesome. Is there a betting pool on what will cry mummy first as you wind things up...?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 30, 2011, 07:50:03 PM
Getting closer all the time, just about ready for certification.
Primed the bumper last week and with a late night on Friday it was 180 block sanded which surprisingly managed to remove about 95% of the 60 grit scratches in the filler, still work to be done on some of the lines but its looking pretty good already so now was the best time to try and finish everything bumper related.

Made a cardboard template for the oil cooler duct, worked out really well till I made it out of aluminium  ;D Didn't really want to fit at all after that so some gentle beating with a hammer sorted it out.
Don't know how many times this bumper has been on / off but it must be at least 50!  >:D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F413.jpg&hash=834f5eda231b86f3425016e846b2ac525321520c)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F410.jpg&hash=f5de3c37c353d69893f38cf34e21e2a28cf1b844)
Shot up the road for a sheet of mesh and made the grilles for the bumper openings, still have to cut a hole for the towing hook and attach some mounting lugs to the bumper but even as it is they fit really well.
Pretty much assembled the whole bumper and bolted it on to check everything would work out which it did.
The euro plate I got off Ranton just finishes the whole deal so nicely, can't wait to paint it and be done with it!  8)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F419.jpg&hash=05fc9fe834533db6d8c2e21fb486ab5c2dccf4a3)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F416.jpg&hash=9702758fe9c41a716596bd3ec09643bab6f366de)
I could see that after lunch old Phil was chomping at the bit to go do some logging so with laptop in hand we set out on a tiki tour of the wild west, right off the bat the car ran like s**te which forced us to come back to work................... >:( seemed like it was running on 4-5 cylinders so I thought maybe it had fouled a plug but after pulling them all out they all looked fine, changed back an 02 sensor I had swapped and problem solved......................... ;D
Did a bit of driving around on the back roads but that wasn't much chop as the roads are just too damn short and dangerous to do a WOT pull in 3rd or 4th gear.
New motorway perhaps?  Uncharted territory as I hadn't gone that far afield in it yet but heck there's only one way to find out..............
With the boost controller set at 10psi we let it rip in 4th gear, AFR sits steady at 12.2 and it just piles the speed on like you won't believe!
Did a couple more runs back and forth in 4th and 5th mainly checking oil and exhaust temps which are no concern at all, on the motorway the oil cooler duct does a fantastic job with temps sitting at no more than 190F even when hammering it.
The brakes are also bedded in now and they are like nothing else I've ever had, just phenomenal!!!
It seemed the further we drove (did about 85km) the better it ran as the ECU adapted itself, still tuning left to do to make things smoother between changing gears but its well on its way!
Also shot this vid too, great editing Filx!
http://www.youtube.com/watch?v=gmXKLnrDweg
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on October 30, 2011, 08:32:56 PM
I like the beastie fire extinguisher  ;D
Can never be too safe in relatively untested custom car though!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Skilfil on October 30, 2011, 08:37:35 PM
That new motorway is great for testing. I live just down the road so any future projects of mine I'm pretty sorted, its dead empty at night on Sunday nights so you're only putting yourself at risk and its a nice flat open piece.

Can't say much for the idiots that still weave in and out of traffic though.. Wish I'd been around to see your car, I love my filming and have some plans to stand on some of the bridges on that motorway to catch a car screaming past. I bet yours would sound great.  :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 30, 2011, 08:50:25 PM
Quote from: Skilfil on October 30, 2011, 08:37:35 PM
That new motorway is great for testing. I live just down the road so any future projects of mine I'm pretty sorted, its dead empty at night on Sunday nights so you're only putting yourself at risk and its a nice flat open piece.

Can't say much for the idiots that still weave in and out of traffic though.. Wish I'd been around to see your car, I love my filming and have some plans to stand on some of the bridges on that motorway to catch a car screaming past. I bet yours would sound great.  :D

There's on HUGE problem though, there's camera's on poles EVERYWHERE! exept on the stretch going towards Kumeu.  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on October 30, 2011, 09:22:28 PM
It was an awesome day on Sat - there's not much more I can add about what a weapon this thing will be at proper boost levels - the 10psi level just gives you a bit more of an insight into it. It is extremely stout on to put it mildly and the turbo is barely working.

The brakes are something else again though - Vert did a mild push on them for a test stop and my shoulder is still sore from the seat belt and I almost lost hold of the laptop. Feels like a serious stop would see it stand up on it's nose!  :laugh:

Quote from: 80 Vert on October 30, 2011, 07:50:03 PM
Also shot this vid too, great editing Filx!
http://www.youtube.com/watch?v=gmXKLnrDweg

Hehhehee, gettin' a bit flash eh!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Skilfil on October 30, 2011, 09:51:05 PM
Quote from: 80 Vert on October 30, 2011, 08:50:25 PM
There's on HUGE problem though, there's camera's on poles EVERYWHERE! exept on the stretch going towards Kumeu.  ;)

Yeah there is, and a few nice spots for Mr.Plod to hide, just don't make a habit of it and choose your times wisely I'd say. And nothing too crazy of course..
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 31, 2011, 05:19:28 PM
Thinking a Cupra R lip may be required for this, anyone have any idea of cost? and a part#?
Might also help save the bottom of the bumper some and being black should tie in quite well.

Took an hour off work this arvo to take the car for another thrash, all I can say is WOW!
Boost comes on strong from 3000-3500 rpm and you feel like yeeeeaaap here it comes hahahaaaaa!
Seems very willing to rev with 6k rpm quicky achieved at which point I tend to back off as the motor is still quite new and by then its all on should mr plod be watching  :o

Will be interesting to see what Rich thinks of the logs I took, onwards!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: HaNs on October 31, 2011, 05:58:24 PM
Should be about $70 + gst for the cupra lip
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Pinkmaggit on November 01, 2011, 08:21:23 AM
Part # is 1ML805903
http://www.ecstuning.com/Search/Cupra/ES7754/
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ranton-inc on November 01, 2011, 08:31:18 AM
Easy to order from Giltraps.. they have the part number on file there im pretty sure..

I have ordered at least 3 of them..
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on November 01, 2011, 08:50:43 AM
You boys and your over powered toy >:D
When will you ever grow up and get a nice sedate older BMW :angel:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on November 01, 2011, 10:03:38 AM
Quote from: Pinkmaggit on November 01, 2011, 08:21:23 AM
Part # is 1ML805903
http://www.ecstuning.com/Search/Cupra/ES7754/

I went to order a leather key ring ($14 US) from ECS a few days ago, fright was $40US . . .

Id try and get the lip locally first.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 01, 2011, 10:29:23 AM
Quote from: RS ZWEI on November 01, 2011, 10:03:38 AM
I went to order a leather key ring ($14 US) from ECS a few days ago, fright was $40US . . .

Id try and get the lip locally first.

Yeah a kind vasker is going to lend me one to see if it will look any good, if if does I'll order one here.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on November 01, 2011, 07:15:52 PM
Im loving that bumper and a subtle lip like a cupra one or something similar whould finish that off perfectly! .....cant wait to see this thing up close!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 03, 2011, 04:45:56 PM
Certification is done, passed no probs with nothing extra needing doing.
Just have to wait for the plate to come before rego and wof, very close to being legal now.

Got a good insight today as to why we have the cert process, while a pain in the bum for me its TOTALLY required as the pictures I got shown today of other cars being built blew me away...........shocking welding, bolts left half undone, one of the best was a big vise grip on an exhaust manifold because one of the studs had broken! I KID YOU NOT!  he was serious about certing it this way! ;D
Saucepan (with handle) being used as a spill ring on a fuel cell  >:D or the Lincoln Continental on airbags with the mounts coming away from the chassis due to the crap welding and too light gauge metal.............then there's the range rover with such severe rust the steeringbox was about to fall off!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on November 03, 2011, 06:09:59 PM
crikey, by the sounds of things I could probably build my own car, planning and learning along the way and still come out ok. :o
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: le mans on November 03, 2011, 06:11:42 PM
Congratulations - another milestone!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 03, 2011, 08:54:31 PM
Quote from: le mans on November 03, 2011, 06:11:42 PM
Congratulations - another milestone!

Thanks Jon, without you getting your Viper map I may have never come across Richard.
Looks like his cables may just possibly be staying here so that I can offer his maps here.
Even he's now sticking an R32 engine in his car!  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ritmo on November 03, 2011, 10:46:05 PM
Nice work as per usual. :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on November 04, 2011, 08:54:00 AM
Get a Corolla!
Drop it and tint it, mint.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on November 04, 2011, 03:54:55 PM
Congrats John :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on November 04, 2011, 06:01:12 PM
a nice big tick for that! ....congrats guys!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on November 04, 2011, 07:53:12 PM
Boys at work loving this project, right back to the rear license plate fab!!!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M M on November 04, 2011, 08:05:09 PM
Awesome, congratulations  :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 04, 2011, 10:01:20 PM
Thanks guys, was certed as a coupe too which I thought was pretty cool.
If anyone is certing a car try Clint Field of MS vehicle certification, have dealt with him many years now and is a top guy to deal with.
Always turns up when he says and is VERY respectfull of your car.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on November 04, 2011, 10:13:17 PM
So this is officially a vw Jetta/bora coupe??
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 04, 2011, 10:17:42 PM
Yep it sure is!  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on November 04, 2011, 10:37:25 PM
Woo fuking hooo if I can say so ! ...go you good thing!!!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on November 05, 2011, 12:48:32 AM
Could you pm me Clint's no? Need to get cert sorted for mk3
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VeeDub on November 05, 2011, 03:46:41 PM
I was privileged today to be able to help Vert do some logging in his R32T Jetta.

WOW.

After spotting Poonmobile in town and Rylan on Lincoln Rd, I got to John's at around 12 today just as ddr77 was leaving. John fired her up and backed her out of the workshop. The sound of this thing sitting at idle is enough to crack a woody, I could only imagine what it would sound like at high RPM on boost! I was quite excited for the afternoon ahead..  >:D

We covered around 90kms over a couple of hours, doing various 4th gear pulls, and an incredibly impressive 3rd, 4th, 5th pull on a nice straight road. The power delivery in this car is mind blowing. John could be sitting at 2k rpm in a high gear and just feather lightly on the accelerator and it'd light right up and load power on and on and on. Before I knew it we'd be doing some very big speeds and he hadn't even given her much! It just wants to go, and it wants to go faster and harder than you could ever dream of taking it. For NZ roads, this car is crazy, there's just no way you could ever have it at it's limit. All the time I'm trying to remember that it's still only on 10psi!!! I don't know if my skeletal system would be able to handle the force of more boost in that car!!  :o

I was truely blown away at how rapid, yet comfortable it is. This thing had me laughing and giggling like a little school boy every time Vert put his foot down. And the brakes? Wow. Pulling into some tight corners at high speeds i'm thinking "25 corner.... 25 corner..... 25 CORNER!!!!!" Not far from the upcoming bend, the Jetta would drastically cut her speed right back in a distance you wouldn't believe possible. We'd pull smoothly through the corner, the Jetta feeling incredibly firm, flat and tight, and then effortlessly pull straight out the other end and instantly be doing some crazy numbers again. It's just phenomenal how well every aspect of this build has come together and created this end product that's nothing short of amazing.

You can't forget the interior either - it's all so factory and feels like it has come straight from the factory - you won't find any horey trim bits, cables hanging out or a mis fitting dash in this car.

All in all this is probably the most crazy build I may ever have the chance to experience first hand. My hat is off to John and what he's created. You may be impressed when you see it, but the old "photos don't do it justice" type thing applies here too, even seeing it in the flesh isn't enough to appreciate what it really is. I can't wait for the finishing touches to come together, the mapping to be done and to feel this thing with a even more boost!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 05, 2011, 08:04:24 PM
Cheers for helping T, 2 people make it much easier.
Was kinda funny when you noticed the speedo needle climbing faster than the rpm  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VeeDub on November 05, 2011, 08:09:08 PM
Quote from: 80 Vert on November 05, 2011, 08:04:24 PM
Cheers for helping T, 2 people make it much easier.
Was kinda funny when you noticed the speedo needle climbing faster than the rpm  ;D

Oh yes! I forgot about that! I've never seen a speedo needle moving so fast  :o :o :o
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ritmo on November 05, 2011, 08:47:28 PM
Thats a great write up T..... must be so satisfying John.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ddr77 on November 05, 2011, 09:54:01 PM
Agreed T, what a great guy John is and the car in the flesh deserves to be appreciated by many others for such a fantastic build. Blood and sweat well pulled off, if i was the head guys at VW and spotted this i would be defo giving John the Chief designing engineers Roll to create something as good or better for rolling off the production line, as this Bora is certainly a perfectionists finish of product. Would of loved a passenger ride maybe in the future.

Well done John thanks again for the starter.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on November 06, 2011, 09:24:38 AM
Awesome write up T, guys overseas will be creaming themselves! Truly a world class build...
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on November 06, 2011, 12:42:05 PM
Perhaps a challenge to the VW rally team when they pass through in 2013?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on November 06, 2011, 07:03:05 PM
Can I put my name down for a ride?  :P :-*

Congratulations on it though, good to see you pulled through when you had a few tough times with it
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 06, 2011, 07:53:10 PM
Cheers, yeah it was touch and go there a few times.
Also realised very quickly that if I didn't persist and instead parked it for a while that would be the end of it!
Been a very complicated / challenging build but learnt lots and its been a lot of fun, will be nice to get the last few things done before the hollidays and then just drive the snot out of it.  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: nacnud on November 06, 2011, 09:11:21 PM
Quote from: coons on November 06, 2011, 07:03:05 PM
Can I put my name down for a ride?  :P :-*

Congratulations on it though, good to see you pulled through when you had a few tough times with it

x2! Super keen for a ride and to check it out some time.

Well done John!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on November 08, 2011, 06:10:29 PM
yeah you should try your hand at a bit of auto-journalism Tbag!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 10, 2011, 05:35:58 PM
Finally got round to doing a wheel alignment today, front was pretty close so not a bad job done with the old measuring tape!  Rear however was a different story, over 13mm toe in! (weird thing is it drove pretty good  ;D)
Lowered the car some more in the weekend and since I'm doing quite a bit of driving to take logs I thought I'd better sort it out.

The guys at the tyre shop I use set up the measuring system and kinda just left me to it so I did my own alignment, rear bars I made work perfect and I was able to easily get back to factory specs with adjustment left to go.
Only bummer now is that by pulling the wheels in to correct the rear toe my wheel adaptors could have been wider  >:(
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on November 10, 2011, 07:40:40 PM
Quote from: 80 Vert on November 10, 2011, 05:35:58 PM
Only bummer now is that by pulling the wheels in to correct the rear toe my wheel adaptors could have been wider  >:(

Ahh that's like a ten minute jobfor you ...with your eyes shut and and beer in one hand!  ;D
I love that you got to do your own alignment .......awesome!......hows that bumper coming along by the way?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 10, 2011, 09:46:12 PM
Haha yeah already conjuring up a way to "fix" that problem...................
Bumper is still in primer, will take it off this weekend and take it home to 180 block it again.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 5-pot on November 16, 2011, 01:53:03 PM
Why have there been no updates for six days?  SIX. DAYS.  Do you know how long SIX DAYS feels like when you're watching an epic build like this?! >:( ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 16, 2011, 02:37:51 PM
Nearly bought some 18" LM's but the offset just wasn't going to work.............
Other than that not much been happening, just waiting for the cert plate to come.
Will take the bumper off this week and do some more on that but motivation to "work" on it has been lacking since its driveable......... ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on November 16, 2011, 08:02:25 PM
Saw her today. Sooooo close to beng everything done. Possibly subject to Verts massive attention to detail.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 19, 2011, 06:08:10 PM
Geez these last left over bits to do are like pulling teeth!
Thought the bumper was pretty close for paint but after sanding it again I quickly realised its nowhere near ready  :(
So instead of being out on the road having fun doing logs with the car today I ended up working on the bumper again.................Still, I did manage to finish a few more interior pieces and ordered a new tie rod as the one on the car is bent from the rollover the R32 suffered.
Did get the cert plate last week so the list is getting very much shorter and I can't wait for it all to be done!  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ddr77 on November 19, 2011, 06:59:26 PM
Well done john can't wait to see a blue bumper on her.Grit your teeth and dig deep it will be worth it in the end when you see YOUR completed handy work.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 26, 2011, 07:36:06 PM
Bumper is finally at a point where I'm happy............everything fits good which is always a bonus too, now to let it cure till Xmas holidays then I'll paint it.
Spent most of the day finishing a bunch of little things and got the last of the interior in place, cleaned all of the interior and conditioned the seats- man did they soak up the conditioner!!  ;D

Rich also emailed another updated map last week which I didn't even have time to run some logs on so hopefully I'll do that tomorrow but from driving it home tonight I can already tell that the current map is the best by a big margin so the tuning is very very close now and time to turn up the boost!  >:D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FIMG_0048.jpg&hash=68b7e41df4488ddfd049f88af9ad1f354e02528f)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FIMG_0046.jpg&hash=87a8ee08e69fef0bd04dbd042d6a194a5f6f269c)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: CBRT on November 26, 2011, 08:04:15 PM
Looks so smooth and OEM+

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on November 26, 2011, 10:32:50 PM
..................awesome........................
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on November 30, 2011, 06:29:39 PM
Bit of an update,
Been driving the Jetta daily since last Saturday, impressions soo far are that its by far the best VW I've ever owned!
Usually take the long way to work and go for a decent drive after work as well >:D Tonight I headed up scenic drive and most corners you can take in 5th gear easily pulling away from 1300-1400 rpm  :o
The availablility of power at just about any rpm is awesome, lug it around at 1300 rpm no problem, thrash it at 6500rpm no problem.........

Played around with the boost controller and lowered the gate pressure so it now has a much more linear boost curve which is a lot nicer than before as it would just give you a 8-10psi hit in one go.
Its hard to describe just how effortless it disposes of hills or passes other cars, sure doesn't feel like a heavy car anymore.
The torque delivery is something a weedy 1800 just can't compete with, the old saying there's no substitute for displacement is very very true  ;D
I've still got an annoying noise from the fuel lines which I need to sort out, have a feeling that the return line isn't big enough compared to the monsterous supply line and thus fuel can't return back to the tank well enough.

Still some more mapping to do but it can only get better from here,

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on December 02, 2011, 02:01:58 PM
Isn't that no replacement for displacement ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on December 02, 2011, 02:53:32 PM
Press + boost x fuel = smile
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 03, 2011, 07:23:59 PM
Ear to ear grin Neil  ;D
Made some changes today, had a really annoying noise from the fuel lines when the engine was running and I thought it would be the fact that my return line was stock where as the supply line is now 10mm  :o
The goal was to replace the entire return line with the hope the noise would go away, took all morning to replace it with a combination of fuel hose and hard lines and annoyingly the noise remained  >:(
With the car up in the air and running you could now tell that the noise was actually vibration in the supply line, why I didn't do this in the first place is beyond me but anyway.

In the end it was the one way valve on the pump which made the vibration caused mainly by being terribly restricted, drilled out the holes to a bigger size and replaced the ball bearing with a larger one its 90% better but still not totally gone  ::)

From driving it this past week the other item of annoyance was you'd get a whiff of engine vapour now and then due to the catch can being vented to atmosphere, fumes would get in through the fresh air fan.
Its a smell one can do without so I plumbed the can back into the airbox so the fumes are re burnt, seems good so far.
Just an exhaust rattle to sort out but that can wait for a while.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0173.jpg&hash=0715305db5504e826c370da911b6e35f4f8e433c)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0174.jpg&hash=b8d952eb63fab531d278ffb39c9a98b741f266c1)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on December 03, 2011, 07:27:00 PM
Ha, ha, ha - I'm still trying to figure out how to remove the rubbers out of a quarter light!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 04, 2011, 10:45:16 AM
Couple of shots I took yesterday while out and about,
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FIMG_0073.jpg&hash=7b2a8047a76643b02b26ce13ef0ef2300a317996)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FIMG_0069.jpg&hash=0e1d1027f9379a7f20c0dba27374f865df8fa613)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ranton-inc on December 04, 2011, 01:21:42 PM
nice number plates  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on December 08, 2011, 06:00:47 PM
Its a good lookin car.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on December 10, 2011, 05:11:53 PM
I went for a spin in this beast today, rapid!!
Very jealous!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 10, 2011, 05:28:54 PM
I noticed on my way home it was only set at 8psi too  :( how disapointing........
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on December 10, 2011, 05:34:57 PM
I want to see full throttle  >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Period_Correct_ on December 10, 2011, 08:52:59 PM
this is an awesome car, John, i too want to go for a joyride in it...

Jetta > Golf.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 23, 2011, 06:25:38 PM
Managed to fab up a strut brace over the last couple of days, not much room to play with so I made it such that it hugs the rain tray to not stick out into the engine bay too much.
Took it to get powdercoated yesterday but they had already shut down for the year but then the guy spotted the car so we got talking about that and his Camaro he just bought and as luck would have it they were running satin black last thing at lunchtime so he slipped my job in, how good is that!  Gotta love car guys!  ;D

Quite surpised how much its stiffened up the front end, wasn't sure that I liked it at first but turn in is much sharper now and hugely noticable.
Best stop f*cking about with it now before I make it so rigid it becomes undriveable on our roads LOL!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0175.jpg&hash=304000710be244603923b59ba7b70b5a92e00af9)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0176.jpg&hash=11972feb754497c904e87a0e52a30b9812b64327)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on December 23, 2011, 06:47:54 PM
Ooh, me LIKE!  8)

Musta been hard drilling holes in the nice shiny paint on the strut towers though  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on December 23, 2011, 07:08:54 PM
Nice work on the powdercoaters. It's so custom in there it needed a custom brace. Looks awesome.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Toro on December 23, 2011, 11:04:05 PM
Vert, did you measure weight?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on December 24, 2011, 08:57:09 AM
Its good to hear feed back like that it made so much difference!
I often wonder if those braces really do so much but I think on some cars they really do.

I know im smoking and don't like Vags and stuff and you all hate me :laugh: :laugh: But I wanna go for a ride too Vert! Please!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on December 24, 2011, 09:55:03 AM
If only to have the work shop you have to be able to fab up random bits and pieces like this

Looking good!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 07, 2012, 05:36:03 PM
What to do with a rainly weekend...................??
Stand outside wet sanding the bumper  ;D Not much fun but it has to be done, I'm about 2/3's done so hopefully finish it tomorow and hire a booth somewhere next week to finish it.

Slowly but surely the last remaining things are getting done meaning I can make a start on the Karmann Ghia!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 10, 2012, 08:42:37 PM
Managed to use Mike's booth late this afternoon to play around with the bumper...............pics speak louder than words..................... :P

Going to pick it up in the morning and hopefully bolt that sucka on!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0170.jpg&hash=ed957cda91a96f60a6169e75c699875cab514c3c)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0171.jpg&hash=fecf65ceac12f956efc3a6cb3b822ff9eccd5c82)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on January 10, 2012, 10:56:48 PM
Ace!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M M on January 11, 2012, 09:06:46 AM
Looking forward to see that on!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 11, 2012, 05:02:19 PM
Down to Mike's at the crack of dawn this morning, actually the earliest I've gotten up in all of the hollidays..............sad but true!  ::)
Anyways took it home with me and put it together here which was quite nice for a change.
Its changed the look loads now that its all painted, have to say I like it a lot but am leaning towards the Cupra lip to finish it off.
Will take some better shots in the weekend but here's a few teasers.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0175-1.jpg&hash=0a0108012e9fb15baa9c88b9f8d330129a829e31)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0174-1.jpg&hash=d627e93498e55b2d755cf0236ffb9dd8448bec89)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0176-1.jpg&hash=6a44406f2d4ab59b956188bec095b5aaf7db93a1)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: OOOO on January 11, 2012, 05:46:52 PM
I think you are right with the lip to finish it off.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ranton-inc on January 11, 2012, 06:49:52 PM
Cupra Lip will look good John...!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: nacnud on January 11, 2012, 07:19:54 PM
wow, that looks good!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on January 11, 2012, 10:23:20 PM
Standing ovation!!!!11  ;D ;D ;D well done! ......x1 for the lip too!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on January 11, 2012, 10:46:27 PM
Perfect, x3 for lip

And I know you aren't a fan but moah low!  ;) >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on January 11, 2012, 11:23:53 PM
Car looks great John! Well done!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M M on January 12, 2012, 04:41:36 PM
Looking good!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on January 12, 2012, 04:56:30 PM
Looking awesome!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on January 12, 2012, 07:50:04 PM
I think it needs the spots to make sense of the outer dips in the vents - just an opinion
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 12, 2012, 08:05:04 PM
Quote from: the phantom on January 12, 2012, 07:50:04 PM
I think it needs the spots to make sense of the outer dips in the vents - just an opinion

Agree, but would completely block air to the oil cooler so decided not to fit them.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ddr77 on January 13, 2012, 07:44:57 AM
John looks fantastic, I agree with the cupra lip,however use your handy skills to make a different one everyone does the cupra. :).
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on January 23, 2012, 02:09:38 PM
What's better than work on a Monday morning?  >:D

Sneak preview --> http://www.youtube.com/watch?v=GmMf0mRdqG0&feature=youtu.be (http://www.youtube.com/watch?v=GmMf0mRdqG0&feature=youtu.be)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 24, 2012, 05:32:24 PM
Yeap the day finally came, I had booked it in prior to the hollidays for a data gathering session so thats what we did yesterday.
I have to say each time I go to Torque those guys impress me with their utter proffesionalism and the respect they have for your car, sure keeps me going back to the same people.
Anyway with the car strapped down we ran 10psi first to see how things were looking, he felt that the AFR was dropping a little late but nothing really to worry about so with my ok he pressed on with 14psi which made 245kw (about 335hp) @ all 4 wheels.
We kept the revs managable cutting it off at 6.5K rpm so there's probably more power to be had there but seeing as I don't really rev it past that on the street I didn't see much point.

Not really sure how I feel about those numbers, in some ways I expected more but in other ways it doesn't seem that bad so maybe there's just soo much hype on the net from other people who have built simmilar cars.
Certainly driving it on the street @ 14psi makes it come alive to whole new level, we did take some video too so once I get my act sorted I'll post it up.

Dyno graph:


Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RevHappy on January 24, 2012, 07:51:53 PM
woow. thats awesome vert, you should be proud cause thats some awesome power for a drivable street car. we have a 450hp skyline gtr at work and thats really not drivable.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on January 24, 2012, 07:56:45 PM
Such a great project, I'm undecided wether it's a good thing that this is pretty much complete .....what's next vert?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on January 24, 2012, 09:29:42 PM
I thought the result was good considering the tune is still a work in progress - it is likely a bit more fuel and timing will bump the kw figure up a bit at the same boost level. I'm looking forward to a 20psi run - my money is on 300+ atw easy.  >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 26, 2012, 08:27:48 PM
Quote from: spooln on January 24, 2012, 07:56:45 PM
Such a great project, I'm undecided wether it's a good thing that this is pretty much complete .....what's next vert?

Tackling the Ghia next Neil, started pulling it apart last weekend......................shoulda been called a Fiat with all the rust I've found already  :'( gonna need a whole lot of love!
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FType%252034%2FDSCF0177.jpg&hash=f13e44590b4626dfe9f18e2d5d56c989701c6c75)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 26, 2012, 08:44:30 PM
Took the long way home via scenic drive tonight, drove it a little different to normal by mainly using 3rd through the twisties  ;D
Its sooo funny to drive a car that has power to spare, jab on the gas in 3rd gives unparalelled forward momentum, quick jab on the brakes and flick it round the corner back on the gas again.
With the revs above 3k rpm its pretty much on boost all the time but the lift off through the corners makes the rear end a little unsettling so I'll probably look at a Haldex controller next.

Got to say without question this is the most fun car I've had and it isn't even fully sorted yet!
Have always loved bigger engines and this thing just reinforces that, no replacement for displacement  ;D

Got the Cupra lip also so I'll have a look at fitting that this weekend, fun never ends.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on January 27, 2012, 12:05:03 AM
Quote from: 80 Vert on January 26, 2012, 08:44:30 PM

Got to say without question this is the most fun car I've had and it isn't even fully sorted yet!
Have always loved bigger engines and this thing just reinforces that, no replacement for displacement  ;D

^This!! Can't wait for a ride!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Pristle on January 27, 2012, 08:29:18 AM
Quote from: 80 Vert on January 26, 2012, 08:27:48 PM
......................shoulda been called a Fiat with all the rust I've found already  :'( gonna need a whole lot of love!



You did find on the coast didn't you?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on January 27, 2012, 10:09:21 AM
Quote from: Poonmobile on January 27, 2012, 12:05:03 AM
^This!! Can't wait for a ride!!

Yea I want a ride too.
  I promise not to go on about any airbags or anything annoying :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on January 27, 2012, 10:42:32 AM
new thread time, methinks  :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 27, 2012, 04:48:06 PM
Quote from: the phantom on January 27, 2012, 10:42:32 AM
new thread time, methinks  :D

New thread for?........
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on January 27, 2012, 05:05:47 PM
Quote from: 80 Vert on January 27, 2012, 04:48:06 PM
New thread for?........

the Ghia  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 27, 2012, 05:07:40 PM
Nah not gonna bother, hardly anyone here cares about aircooled.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on January 27, 2012, 05:48:17 PM
I'd follow any of your projects. And definitely a Ghia, they're cool.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ritmo on January 27, 2012, 05:50:25 PM
Quote from: 80 Vert on January 27, 2012, 05:07:40 PM
Nah not gonna bother, hardly anyone here cares about aircooled.

I will let the fiat comment slide if you do a thread ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: nacnud on January 27, 2012, 06:41:35 PM
Start a damn thread John!!

I love old aircooleds!

My mates old left hook type 3 Variant

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi209.photobucket.com%2Falbums%2Fbb244%2Fduncanandkim%2Fn602982463_2239051_9129.jpg&hash=65ccf5be77634caaddeabe5220e4ec2fc291af9c)

Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on January 27, 2012, 08:05:39 PM
Yep +1 for a thread

You could be building a lawn mower and I'd still follow your thread!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on January 27, 2012, 08:11:24 PM
Quote from: 80 Vert on January 27, 2012, 05:07:40 PM
Nah not gonna bother, hardly anyone here cares about aircooled.

I care  :-*
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on January 27, 2012, 08:58:53 PM
there's enough petrol headism on this site to support a Ghia build   ;D  do it!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 27, 2012, 09:14:32 PM
Doubt it will be that interesting to follow though, lots of panel making and rust repairs..........we'll see how I feel after tomorow.....may test the waters  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on January 27, 2012, 09:20:02 PM
..............do it.............. ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on January 28, 2012, 09:40:29 AM
Build a cool lawn mower! 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: blackbetty on January 28, 2012, 12:52:13 PM
Quote from: BB on January 28, 2012, 09:40:29 AM
Build a cool lawn mower! 8)

If vert built one I'd follow the thread.

Be keen to follow a thread on the Ghia. ;D
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on January 30, 2012, 09:32:54 AM
So about that dyno video :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 30, 2012, 08:52:04 PM
Quote from: coons on January 30, 2012, 09:32:54 AM
So about that dyno video :D

Yeah Filx..........about that dyno video  ;D :P
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on January 30, 2012, 09:08:20 PM
Yeah that dyno video............ hold that thought for a few days.  :laugh:

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FJan2012006.jpg&hash=50353a33727dfbe4ba96d6df23b99e8a327e095a)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FJan2012007.jpg&hash=329059ad8b347cc85e3c6b48abda638ee60a0c65)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: le mans on January 30, 2012, 10:02:18 PM
Spill the beans then!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on February 02, 2012, 05:30:51 PM
And here it is  8) Please don't laugh at my video editing skillz  >:D

http://www.youtube.com/watch?v=Rbq2fxnCc-I (http://www.youtube.com/watch?v=Rbq2fxnCc-I)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on February 02, 2012, 09:18:43 PM
NASA.... eat your heart out cause this car is gonna take offffffff!!!!!!!!!!!!!!!!!!!!!!!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: The Truth on February 02, 2012, 10:07:29 PM
That sound.......

:o

Is what I've been waiting to hear!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on February 02, 2012, 10:09:14 PM
Quote from: The Truth on February 02, 2012, 10:07:29 PM
That sound.......

:o

Is what I've been waiting to hear!

X1 ^^
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: le mans on February 02, 2012, 10:32:32 PM
That's mental on 14psi isn't it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on February 03, 2012, 08:58:19 AM
She pushed out 200kw atw at 10psi so approx 10kw per psi of boost given 245kw at 14psi. Extrapolated out that means at 20psi it should be around 300 kw atw. But the story is really the torque mountain this thing produces  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: BB on February 03, 2012, 09:15:22 AM
I used to work with Young Dave as we called him at Coyle park where he did his apprenticeship.
He is such a good and hard working fellow. But is also a bit of a party boy and has a laugh.
You do not want to to be near him when he drops his guts tho, That's one thing I can never forget :-X
Its great too see him at work on all these fun cars its his dream job.

And Vert the car sounds like a 747 taking off.

Look forward to a grudge match between you and Nigel in that rocket ship TT he has at the drags >:D >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 03, 2012, 04:30:50 PM
I'm surprised how little the engine moves around, quite impressed with those Black Forrest ind mounts.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on February 03, 2012, 07:47:21 PM
where did you get the BFI mounts? I have been trying to get stuff directly thru them but they wont?? ??? :-\ :'(
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 03, 2012, 07:54:08 PM
Direct from BFI   ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 12, 2012, 12:01:38 PM
So anyways the Cupra lip turned up a while ago and I had a go at fitting it at home, took the bumper off and started cutting the lip to shape but things didn't go so well..........
Just seemed like it was never going to fit and after thinking about it some more I gave up and just put the bumper back on, driving to work on the Monday I thought well the lip is pretty much trash now because I've already cut it so I might as well have another go at it  >:D

This time doing it at work where I have my tools handy I pretty much carried on shaping the front of it to match the lines of the bumper but in the end cutting the lip in half and fitting one side at a time was the only way, still pretty difficult even though I heated and re shaped the sides as much as possible.
Bit nerve wracking drilling holes in the bumper because if it didn't pan out then the holes would have ruined that!  ::)
Still............fortunately things worked out and has added another dimension to the front  8)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F11Feb2012021.jpg&hash=29080b259963d2d29eddb9f1e74c380b4cde3370)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F11Feb2012016.jpg&hash=404dbf60887191a7529e2c9551bca161c41d123d)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F11Feb2012014.jpg&hash=d41215fd8b704f88a91696b1d1d48b3c6def93d3)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on February 12, 2012, 12:03:32 PM
Quote from: 80 Vert on February 03, 2012, 07:54:08 PM
Direct from BFI   ;D

really? Any chance i can go thru you to get a few bits?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on February 12, 2012, 12:06:15 PM
Yes! Looks fantastic!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on February 12, 2012, 12:35:47 PM
PERFECTION Rite there! Works so well..........well done!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on February 12, 2012, 03:44:09 PM
looks spot on John, good stuff :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M M on February 12, 2012, 04:59:19 PM
Very nice.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on February 12, 2012, 06:24:03 PM
I think it has been said lots before, but congratulations on a job done so well and so professionally.
You should feel good with the effort.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 12, 2012, 06:43:36 PM
Thanks Noel, I love the car and how its turned out.
Biggest reward is it makes me smile when I drive it, just does most things soo well.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on February 12, 2012, 07:56:47 PM
maaaate! that Cupra lip is the magic finishing touch!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: choppy16v on February 12, 2012, 10:23:28 PM
IMO that lip balances out the whole car and makes it look grumpy and purposefull 8) 8) 8) glad you had another crack at it!
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on February 12, 2012, 11:36:51 PM
^+1
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Pinkmaggit on February 13, 2012, 07:15:27 PM
The lip really does finish it off. Wonder what it'd look like painted in the blue also?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on February 13, 2012, 07:25:11 PM
I must have a look tomorrow. Looks good!
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ranton-inc on February 13, 2012, 07:42:13 PM
Cupra lip is one of the ultimate aesthetic mods for any mkiv strangely enough ive fitted them to alsorts of cars and they look good on all... Even on a 106 pug


Sent from my iPhone using my fingers
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 20, 2012, 05:07:23 PM
New adaptors made and on...............more wide = better  ;D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0219.jpg&hash=2065411d8f671d74ee8ff2e2cf27d9f466e4d1e5)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on February 20, 2012, 10:21:25 PM
What ? is that dirty car ?............looking great!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on February 21, 2012, 09:22:22 AM
Quote from: DubMan on February 20, 2012, 10:21:25 PM
What ? is that dirty car ?............looking great!

haha, its called a daily driver  :P
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ranton-inc on February 21, 2012, 09:28:15 AM
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fassets.sbnation.com%2Fimported_assets%2F29277%2Fborat_nice-1.jpg&hash=02860f76379e84efdb4caa0bae6da65eea122db1)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DubMan on February 21, 2012, 10:03:22 PM
haha awesome!........NICE ...x1
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 01wolfy on March 01, 2012, 11:56:07 AM
I have spent the last two days reading this build whenever i have a free moment during work... I am blown away, had to register just so I could say how inspiring this is, I was only looking for info on a 4mo swap when I found this >:D!  You have done great work here sir, thanks for sharing your work in so much detail.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 31, 2012, 08:36:22 PM
KA-CHING 18psi run today............ ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on March 31, 2012, 08:41:18 PM
And how did that go?  >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on March 31, 2012, 08:44:43 PM
Quote from: 80 Vert on March 31, 2012, 08:36:22 PM
KA-CHING 18psi run today............ ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D ;D

Nice!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Toro on March 31, 2012, 08:57:05 PM
18psi, that must be sick to drive.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on March 31, 2012, 09:07:02 PM
Quote from: coons on March 31, 2012, 08:41:18 PM
And how did that go?  >:D

Whaaaaaa, psh, waaaaaaaaaaaahhhhh, psh, WAAAAAAAAAAAHHHHHHHHHHHHHH, psh.  >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 00quattro00 on March 31, 2012, 09:08:37 PM
Quote from: Filx on March 31, 2012, 09:07:02 PM
Whaaaaaa, psh, waaaaaaaaaaaahhhhh, psh, WAAAAAAAAAAAHHHHHHHHHHHHHH, psh.  >:D

Only into 3rd?
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: polo_GTI on March 31, 2012, 09:10:29 PM
This is epic... Can you please more videos up vert? I really really love this machine!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on March 31, 2012, 09:15:21 PM
Quote from: 00quattro00 on March 31, 2012, 09:08:37 PM
Only into 3rd?

Started from 2000rpm in 3rd  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 31, 2012, 09:32:22 PM
Quote from: Filx on March 31, 2012, 09:15:21 PM
Started from 2000rpm in 3rd  ;)

5.5K pull from 2krpm in 4th  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on April 01, 2012, 02:29:18 PM
Did some data logging with vert yesterday - AFRs on 18psi seemed rock solid and the car is errrrm, shall we say very "rapid".  ;D
As a passenger you notice the nose noticeably lifts now under WOT and the shove into the seat is pronounced. Quite incredible how civil it is though - no spinning tyres and other crazyness, she just gets up and goes.

Grabbed this short vid after stopping to pack away the laptop etc - doesn't really do it justice but I love the sound!
http://www.youtube.com/watch?v=6MVqMx_P5_s&feature=youtu.be (http://www.youtube.com/watch?v=6MVqMx_P5_s&feature=youtu.be)

Next step is run some more boost but I think that will need to be back on the dyno possibly.

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 01, 2012, 09:35:40 AM
Looks like the tuning is just about done, Rich @ Viper is happy so I'm happy  ;D
Next on the to do list is more boost, he wants to see how it reacts with some more boost, 20-22 psi  ;D ;D ;D ;D ;D ;D ;D
More boost = bigger grin!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on May 01, 2012, 11:37:04 AM
Holy F%#k balls! that's gonna be AWESOME! can i come for a ride?!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 01, 2012, 12:20:35 PM
Quote from: Poonmobile on May 01, 2012, 11:37:04 AM
Holy F%#k balls! that's gonna be AWESOME! can i come for a ride?!

LOL, took you for a ride already  ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on May 01, 2012, 02:26:26 PM
yeah, but i wanna see what 22psi is like!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: the phantom on May 01, 2012, 03:06:27 PM
Ash wants a 10-trip ticket!   ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on August 13, 2012, 09:56:45 PM
Really feel kinda bad for not finishing the last few things on this car, just been driving the pants off it instead.
Must make a plan to head back to the dyno for the final time hopefully to just double check it all so that I can take the wideband out (which is still going in through the pass window  :-\)
Couple of other minor things to complete, hard to believe its been on the road for nearly a year now........... :o
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on August 14, 2012, 09:30:46 AM
Those kids over at VW Votex are gagging for updates too  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ranton-inc on August 14, 2012, 10:46:31 AM
Quote from: coons on August 14, 2012, 09:30:46 AM
Those kids over at VW Votex are gagging for updates too  ;)

they gag for anything over there..
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: JPK on August 14, 2012, 08:18:14 PM
Wow. Spent a good chunk of the day reading all 78 pages. Very impressive build and cant get over how OEM everything looks!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: slowmo on August 14, 2012, 08:22:55 PM
Niiiiiceee!

Has this been featured in any magazine yet? It needs to be!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: tyz-fly on September 07, 2012, 08:01:37 PM
can we get a video of this thing boosting around please John? >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 25, 2012, 09:48:15 AM
Oh dear.................... >:(
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0011.jpg&hash=6eceacae0110f4164fc9b4d850bf2e7dc9cb7410)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on September 25, 2012, 09:53:10 AM
Hmmmm

A) Bigger turbo
B) Repairing and cleaning the grill after sucking in a  small dog
C) Installing pedestrian melting spotlights
or
D)Some small gasket or hose cried mummy and failed
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ritmo on September 25, 2012, 10:03:11 AM
Knowing cars..... I choose D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ranton-inc on September 25, 2012, 10:26:12 AM
Im picking W8 turbo swap  ::)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ERRRNO on September 25, 2012, 05:33:07 PM
explain....someone!!!!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 25, 2012, 05:47:24 PM
I'm wrecking it...........
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 00quattro00 on September 25, 2012, 05:50:41 PM
Quote from: 80 Vert on September 25, 2012, 05:47:24 PM
I'm wrecking it...........

ill give you $50 for it then ;D
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ritmo on September 25, 2012, 06:01:40 PM
Quote from: 80 Vert on September 25, 2012, 05:47:24 PM
I'm wrecking it...........

Haha like anyone is going to believe you.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: virus-zn on September 25, 2012, 07:12:26 PM
r36 bi turbo time  >:D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: qta4 on September 25, 2012, 07:57:04 PM
Quote from: 80 Vert on September 25, 2012, 09:48:15 AM
Oh dear.................... >:(
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FDSCF0011.jpg&hash=6eceacae0110f4164fc9b4d850bf2e7dc9cb7410)

How much excessive heat is evident around the turbo John?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on September 25, 2012, 08:47:00 PM
None that I can see Noel, its buried behind the engine  ;D
The reason the front was off is due to the radiator, I thought I was doing the right thing by buying a 30% larger aluminium radiator for better cooling but last week after only 3000km it decided to start leaking from the core so out it came to be replaced with a factory plastic tank one  >:(

They have a lifetime warranty so we'll see if they cough up with a new one, you hear lifetime warranty all the time well now I'll put it to the test I guess.

Will be interesting to see if it runs any hotter, oil temps, exhaust temps and water temps have never even remotely been a concern before.
Looking at the ali rad compared to the factory one its piss all different, core is a few mm wider and tanks are bigger holding another 0.5L coolant overall.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on September 25, 2012, 08:57:20 PM
The whole aluminium rad thing is crap in my experience. 2003-on Range Rovers for instance have a HUGE alu rad and I replaced mine at 90,000, brother in law done his around same time and countless other Range Rovers I have worked on have had them, very common failure.

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 20, 2012, 10:44:17 AM
Pulled the car off the road over summer to finish the last things I never got round to doing and also fit a bigger dry cell battery.
Stumbled upon a set of 18" BBS LM's, well actually credit for that should go to BBS whore Veedub  ;D Had to buy an entire car to get them but the car is long gone now so that worked out pretty nicely.
Took the barrels in to Arrow Wheels a couple of weeks back and got them back today, superb job done as always.........just can't speak highly enough of the guys at Arrow.
Will get them polished next and paint the centers, cleaning all the bolts won't be fun but it has to be done.

Over the next few months it should see all those little jobs get done and a new set of shoes fitted  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on December 20, 2012, 11:56:50 AM
What colours are you planning on painting the LM's John?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 20, 2012, 12:28:36 PM
Will be a polished lip with the centers done in the same colour as what the Superleggeras are now.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M M on December 20, 2012, 12:43:58 PM
That is going to look great with the LM's.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ranton-inc on December 20, 2012, 12:50:29 PM
Jeez two boras with LMs in auckland! hahaha
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 20, 2012, 01:53:33 PM
Quote from: ranton on December 20, 2012, 12:50:29 PM
Jeez two boras with LMs in auckland! hahaha
[/quote

Yeah haha Elliot the copy cat  ;) ;D
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on December 22, 2012, 05:38:24 PM
Chrome dip the bolts? Or paint them?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 22, 2012, 10:42:03 PM
Surprisingly all the bolts are in great condition so they just need a soak in some nasty chemical and a clean, will be doing that Christmas day along with polishing the barrel lips  ;D
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on December 23, 2012, 09:16:03 AM
I don't know how you're still married, like   7 cars and polishing bolts and wheel lips on Christmas! :P
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 23, 2012, 10:32:18 AM
Haha its all good, will be doing that at home though lol  ;D
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on December 23, 2012, 06:00:40 PM
If you have black bolts John, they are easy as to spruce up. Looking forward to seeing them on!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 23, 2012, 06:49:24 PM
Bolts are chrome Ash, they just have a thick layer of baked on brake dust on them but none look rusty so hopefully just a good clean will suffice
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ranton-inc on December 23, 2012, 08:06:34 PM
Quote from: 80 Vert on December 23, 2012, 06:49:24 PM
Bolts are chrome Ash, they just have a thick layer of baked on brake dust on them but none look rusty so hopefully just a good clean will suffice

Tergophos is great for cleaning off brake dust!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 25, 2012, 01:59:05 PM
Ideal quiet day for LM refurb!
Just cleaned the barrels of all the brake grime etc, can now paint strip the clear coat off the lips and polish them.
Hopefully get on to cleaning the bolts later, bit over scrubbing crap off for now  >:D
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FP1010061.jpg&hash=9226f75a5d643e7c8e2ff2e940483c9ab162b059)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on December 25, 2012, 05:13:46 PM
4 barrels of metal never looked so good! hahahaa
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on December 25, 2012, 06:53:03 PM
Wait till those lips get polished!! You painting barrels John?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 25, 2012, 08:13:51 PM
Don't think so, probably get the lips polished as I'm just too lazy to do it then clear powdercoat the entire thing so that I never have to polish them again.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on December 27, 2012, 02:46:26 PM
Cleaned all 80 bolts yesterday by hand, not really a fun job as they were all pretty filthy and no matter what chemical I tried nothing came up as good as cleaning by hand with a scotch pad.
Hopefully I'll get to stripping off the clear coat tonight and then its off to the polisher.
Centers are pretty good, they just need a scuff and a fresh color.
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FP1010062.jpg&hash=3023391d40d1bebaf16d19c4b718ee89354f23c6)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: dubstar on December 27, 2012, 05:39:26 PM
I did the bolts on my RS's by hand.  It took the entire Bathurst 1000 race.

I like the Eagle 1 metal wool.  It comes in a tin and is a metal/cotton candy floss impregnated with metal polish.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: SOFTLAD on December 27, 2012, 08:57:28 PM
I used a bottle of Cokacola when I did my bolts.
Glad i have never drunk the stuff because of diabetes because if it does that to precious and normal metals whats it doing to your insides
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Brett on December 29, 2012, 12:42:31 PM
Cant wait to see these LM's on. Make sure you lower it too  ;)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 22, 2013, 08:36:49 PM
LM refurb continues, paint stripped the clear off the lips which I can now polish before I get them clear powdercoated.
Wasn't quite sure what to do with the centers but after looking at them carefully there's some corrosion under the original paint and since I'm kinda over the whole process decided to just get them paint stripped so that all I need to do is prime and paint them  ;D
Should have the centers back by Friday so I'll try and at least prime them this weekend, decided to paint them the same colour as the Superleggeras are now.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Pinkmaggit on January 22, 2013, 10:52:46 PM
The colour the Superleggeras really suits the blue (and the red pings off them too). Good choice :)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 27, 2013, 09:25:21 AM
Centers are back and ready for primer / paint, Tbag has kindly offered to organise getting the lips polished so they should be done soon as well.
All coming together nicely............
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2FP1010094.jpg&hash=c0fa286f93953cfb50f476c34fd7d05043e10f0f)
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on January 27, 2013, 10:37:32 AM
The one thing that annoys me about the polished lips is they go 'milky' over time, and the only thing that delays that is to not drive it :/ hahaha can't wait to see the colour combo against the Jetta!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 27, 2013, 03:19:16 PM
Thats why I'll clear powdercoat them Ash, won't be as shiny but it means I'll never have to polish them which suits me better hahahaaa
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on January 27, 2013, 03:32:30 PM
Ill be interested so see the finish of them John, might clear mine too
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: nacnud on January 27, 2013, 04:09:31 PM
oh x2 on that! I kinda preffer that look too. A lot more OEM
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on January 27, 2013, 05:52:10 PM
Quote from: 80 Vert on January 27, 2013, 03:19:16 PM
Thats why I'll clear powdercoat them Ash, won't be as shiny but it means I'll never have to polish them which suits me better hahahaaa

Will be interesting to see what the finish is like, if yours looks good i may split mine again and do the same!
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ritmo on January 27, 2013, 05:54:47 PM
Powder coat clear can be done in three sorts of clear. Your biggest drama is making sure the face that bolts to wheel centre is free of powder in order to free flat surface.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 27, 2013, 06:14:26 PM
Quote from: ritmo on January 27, 2013, 05:54:47 PM
Powder coat clear can be done in three sorts of clear. Your biggest drama is making sure the face that bolts to wheel centre is free of powder in order to free flat surface.

Please elaborate on the clears............ ;)
Face where center bolts on is easy to mask off.
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ritmo on January 27, 2013, 06:31:36 PM
Quote from: 80 Vert on January 27, 2013, 06:14:26 PM
Please elaborate on the clears............ ;)
Face where center bolts on is easy to mask off.

Haha gloss, semi gloss and matt. Which I sure you already knew. Most places only carry gloss and matt tho. Yip masking easy. Get the powder cost tape  which leaves no residual when removed after baking.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 27, 2013, 06:39:12 PM
Of course Duh  ;D
Will be gloss on mine, just way easier than polishing.
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ritmo on January 27, 2013, 07:42:29 PM
Quote from: 80 Vert on January 27, 2013, 06:39:12 PM
Of course Duh  ;D
Will be gloss on mine, just way easier than polishing.

Yeah I figured you knew as much but others might not so any knowledge shared is a good thing. Gloss certainly the nicest if done well. Looks like glass. Just need a good place who doesn't overspray it ..... Easy to do.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: MK3SOME on January 28, 2013, 01:29:19 PM
if you have a clean environment id use a high solid ceramic scratch resistant 2k clear and paint yourself.sikkens do a good one.you just have to make sure you clean them well with prepsol
then another good clean with deionised water to get rid of the solvent residue.then you will get good depth and high gloss with a mirror finish..
lm's will ice the cake on that car
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on April 10, 2013, 01:27:29 PM
Time to get my A into G.................
(https://lh3.googleusercontent.com/-KzSnQirICEg/UWS1nq4YERI/AAAAAAAAAKE/czAuEUsjddI/s640/P1010228.JPG)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on April 10, 2013, 03:27:17 PM
nice one John!  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on April 10, 2013, 10:12:47 PM
Oh man, I'm jealous of little bolts those have
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on April 10, 2013, 10:37:19 PM
It's business time!!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ranton-inc on April 10, 2013, 10:52:23 PM
Quote from: coons on April 10, 2013, 10:12:47 PM
Oh man, I'm jealous of little bolts those have

and the lack of a need for sealant?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on May 31, 2013, 09:04:25 PM
After 5 months of procrastinating the Jetta has finally got a new battery, after all of that it wasn't even that difficult to fit a bigger Optima dry cell in the boot.
Just meant making new mounting points to hold the side of the battery and a strap in the middle to hold it down.
This is one of the problems associated with having too much crap and cars sitting around........ :(
New shoes are also just about done at long last, clear powder coat is done and if I get a dry day this weekend I'll paint the centers.
Just the exhaust to modify a bit as well as a couple of little finishing bits to do, then set up the water injection and run more boost  ;D
(https://lh3.googleusercontent.com/-_15DTh5x0kY/UahmOPLWOsI/AAAAAAAAASc/ZyX6yWtDRv4/s640/P1010361.JPG)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Filx on May 31, 2013, 09:53:31 PM
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Ftctechcrunch2011.files.wordpress.com%2F2010%2F10%2Fawesome.jpg&hash=d817de271bc1f3a6a67c3fbf7ae5ec0cdd80ac77)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: V6DUB24V on June 01, 2013, 05:23:41 AM
Looks good. Well done. The car must be a monster if you are getting more boost out of it. I guess that turbo slams you right back in the seat.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 01, 2013, 12:49:51 PM
Couldn't believe my luck this morning, calm dry day!!!
Ideal for painting wheels outside  ;D Out of desperation nearly took them to Arrow last week to have them do the paint but just couldn't justify the $600 cost for something I can easily do myself......
First off a coat of 440 epoxy over the bare aluminium, let that flash off and hit them with colour........wet on wet works well on wheels..............best of all no sanding!!  >:D
(https://lh4.googleusercontent.com/-TuChWqrtkuE/UalDYUuxSnI/AAAAAAAAATc/eUlwdxICacs/s640/wheels%2520001.jpg)
(https://lh3.googleusercontent.com/-Cuu5Eowj7cg/UalDZSacvaI/AAAAAAAAATc/0C_5Yd_D27E/s640/wheels%2520002.jpg)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: nacnud on June 02, 2013, 10:10:12 AM
How did the clear powder coat come out John? Really keen to see that!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on June 02, 2013, 02:34:38 PM
Faces look smart John.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 04, 2013, 02:24:12 PM
Quote from: nacnud on June 02, 2013, 10:10:12 AM
How did the clear powder coat come out John? Really keen to see that!

Came out great, lost just about none of its polished shine which I didn't expect.
Perfect for a lazy person like me, never have to polish them up.
Just gotta put em together now.
(https://lh4.googleusercontent.com/-u82fG7a_KAU/Ua1O8cNpRvI/AAAAAAAAAUg/5HtkRfVCJsE/s640/P1010365.JPG)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Pinkmaggit on June 04, 2013, 03:23:11 PM
They're gonna look so good!
Still prefer the OZ though
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 04, 2013, 05:30:15 PM
Magic! one down 3 to go........... ;D
(https://lh3.googleusercontent.com/-Ebob6FVnYdM/Ua16znJjjtI/AAAAAAAAAU8/6oYRjBKbwjk/s640/P1010367.JPG)
Good detective work on Tbag's part finding these, should look pretty groovy!
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: nacnud on June 04, 2013, 06:11:56 PM
Hubba hubb! Clear coat looks good, wish I did that now.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on June 05, 2013, 12:18:48 PM
Yea man clear coat is the way to do, did mine too. Polishing is a pain in the ass!
Looking good John
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ERRRNO on June 05, 2013, 12:21:54 PM
Did you powdercoat the lips and the centres?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 05, 2013, 12:29:20 PM
Quote from: LetsTalk-VAG on June 05, 2013, 12:21:54 PM
Did you powdercoat the lips and the centres?

You didn't look at the previous page did you... ;) ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Omes on June 05, 2013, 12:48:21 PM
ooooh Nice John!  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on June 05, 2013, 01:22:24 PM
very nice John  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 05, 2013, 09:08:02 PM
Cheers fellas, torqued them all up tonight ready for tyres to be mounted.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on June 05, 2013, 09:09:49 PM
Quote from: 80 Vert on June 05, 2013, 09:08:02 PM
Cheers fellas, torqued them all up tonight ready for tyres to be mounted.

What torque setting did u use on the bolts?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 07, 2013, 01:41:47 PM
22-25 foot pounds.
But...............................................LM's don't fit  :( :'(
My monster calipers are too big................will loose wheels before my brakes........
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ranton-inc on June 07, 2013, 01:53:07 PM
Quote from: 80 Vert on June 07, 2013, 01:41:47 PM
22-25 foot pounds.
But...............................................LM's don't fit  :( :'(
My monster calipers are too big................will loose wheels before my brakes........

heh?

how so?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on June 07, 2013, 02:37:42 PM
is it the rubbing on the barrels John?  :(
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 07, 2013, 02:39:51 PM
To clear calipers will need bigger spacer which then means they stick out way too far, comparing them the Superleggeras have awesome clearance for large brakes.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Omes on June 07, 2013, 02:40:03 PM
oh dear  :-\

Always trial fit first, I would have thought you did that no?

Quote from: 80 Vert on June 07, 2013, 01:41:47 PM
But...............................................LM's don't fit  :( :'(
My monster calipers are too big................will loose wheels before my brakes........
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 07, 2013, 02:42:02 PM
Quote from: Omes on June 07, 2013, 02:40:03 PM
oh dear  :-\

Always trial fit first, I would have thought you did that no?

Yes I did..................on the back hahaha  ::)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Omes on June 07, 2013, 02:51:02 PM
ah.  :laugh:
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RobClubley on June 07, 2013, 02:59:05 PM
They'd look good on a Skoda.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 00quattro00 on June 07, 2013, 03:09:39 PM
Are you going to sell them? What size, offset and pcd are they?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on June 07, 2013, 03:35:36 PM
How much more clearance do you need?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on June 07, 2013, 03:39:41 PM
Oh no! that sux  :'(
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on June 07, 2013, 04:03:00 PM
You could mount the face as per norm and reduce et?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 07, 2013, 04:05:47 PM
Quote from: Poonmobile on June 07, 2013, 04:03:00 PM
You could mount the face as per norm and reduce et?

Yep that's what I'm doing, not the look I wanted but you can't have everything!  ;)
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on June 07, 2013, 05:12:22 PM
Keep the rears reverse? No one even notices on mine...

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fimg.tapatalk.com%2Fd%2F13%2F06%2F07%2F8y3y4aze.jpg&hash=cdc9e3f34e082ef55ee2e7a529a9a60a6cd4fc94)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Angle on June 07, 2013, 05:13:47 PM
Quote from: 80 Vert on June 07, 2013, 02:39:51 PM
To clear calipers will need bigger spacer which then means they stick out way too far, comparing them the Superleggeras have awesome clearance for large brakes.

The guy who bought those Superleggeras must have know his s***!! :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on June 07, 2013, 07:10:18 PM
Very subtle. Certainly doesn't  detract from the looks.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 07, 2013, 08:01:12 PM
Quote from: Poonmobile on June 07, 2013, 05:12:22 PM
Keep the rears reverse? No one even notices on mine...

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fimg.tapatalk.com%2Fd%2F13%2F06%2F07%2F8y3y4aze.jpg&hash=cdc9e3f34e082ef55ee2e7a529a9a60a6cd4fc94)

That's what i'm thinking too, I will however consider machining the paint off the lip where the bolts go and polishing that to match the rear.
Will just be the offset which is different then.
Have seriously looked at ways to make the fronts fit as reverse mount but without stretched tyres it won't work at all.
Just something about the Superleggeras which like a lot so don't think I'll be selling them just yet.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 07, 2013, 09:18:13 PM
Car care is hard work! Felt pretty bad for neglecting the paint work for so long so the past couple of nights has been clay bar / polish time  :-\
Quite shocked how much grime was on the paint, still...not washing it for over a year probably didn't help my cause.
Did a test fit on one side as well  ;D Bingo!
(https://lh6.googleusercontent.com/-1OeJMuD9jFE/UbGi4rWGz5I/AAAAAAAAAWA/MopjtjHA678/s512/P1010383.JPG)
(https://lh5.googleusercontent.com/-u_ZVdBQuccw/UbGjj1YI9wI/AAAAAAAAAWQ/6SFfGxkEdR8/s512/P1010381.JPG)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on June 07, 2013, 09:38:39 PM
That looks awesome John, classy  8)
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on June 07, 2013, 09:42:51 PM
John. That looks great! 8)
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: coons on June 07, 2013, 10:12:23 PM
Boom
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M on June 08, 2013, 08:35:22 AM
I like them, but I can't say I am 100% on them.......

Quote from: 80 Vert on February 12, 2012, 12:01:38 PM

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F11Feb2012016.jpg&hash=404dbf60887191a7529e2c9551bca161c41d123d)
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fi290.photobucket.com%2Falbums%2Fll272%2Fvert111%2FMK2%2520Jetta%2520R32%2F11Feb2012014.jpg&hash=d41215fd8b704f88a91696b1d1d48b3c6def93d3)

Or

Quote from: 80 Vert on June 07, 2013, 09:18:13 PM
(https://lh6.googleusercontent.com/-1OeJMuD9jFE/UbGi4rWGz5I/AAAAAAAAAWA/MopjtjHA678/s512/P1010383.JPG)
(https://lh5.googleusercontent.com/-u_ZVdBQuccw/UbGjj1YI9wI/AAAAAAAAAWQ/6SFfGxkEdR8/s512/P1010381.JPG)

I think both are as good as each other, and just me personally but I wouldn't want to run the centres the wrong way, unless both were wrong  ;D Although your idea with polishing is a decent one. Hmmmmmm just un-decided.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 08, 2013, 08:55:37 AM
I feel exactly the same way Barry, in some ways I prefer the other wheels.......... :-X
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 00quattro00 on June 08, 2013, 10:09:53 AM
I think the original wheels look better than the lm's
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: zyeffur on June 08, 2013, 10:17:43 AM
OZs for me too. LMs just doesn't look right on Jettas..
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: ritmo on June 08, 2013, 10:47:00 AM
OZs by a country mile I reckon.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 08, 2013, 02:05:38 PM
Still undecided, I like the LM's but the painted bolting lip on the front wheels bugs the sh*t out of me.
It makes them look different diameter front to back, especially with a dark colour like mine so I thought I'd take them apart again and chuck the center in the lathe this morning and machine the paint off that area  :-X
Went remarkably well and even managed to use the lathe to sand through the various grits smoothing the metal out making polishing a lot easier.
Its a huge improvement IMHO but we'll see what they look like mounted.
I'll roll with this for a while and see how they go, can always go back to what I had.......
(https://lh6.googleusercontent.com/-eV3jNlExLiA/UbKQQznEQyI/AAAAAAAAAXA/3b_0yDpes8Q/s640/P1010384.JPG)
(https://lh3.googleusercontent.com/-M8FRsnN3qdE/UbKQP-JhPdI/AAAAAAAAAXA/ibYkWQAzYrw/s640/P1010385.JPG)
(https://lh5.googleusercontent.com/-2JYwT1Q2wUM/UbKQPcUJGUI/AAAAAAAAAXA/EQBwYI0yl8w/s640/P1010386.JPG)
Title: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on June 08, 2013, 03:19:02 PM
That's a good idea!! That looks pretty good to me. Time to see what they look like on, I think a better photo would do it justice.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: deedub on June 08, 2013, 03:31:36 PM
Both are nice sets of wheels but I really think the Ozs suit the car so well. It is such a smooth clean car that it doesn't need the more fussy wheel design of the LMs  with bolts and chrome, and also the Ozs show off the brakes better. Plus the design of the LMs make them look like much smaller wheels than the Ozs, especially when run with the centers behind the lip.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 08, 2013, 05:39:18 PM
Quote from: Poonmobile on June 08, 2013, 03:19:02 PM
That's a good idea!! That looks pretty good to me. Time to see what they look like on, I think a better photo would do it justice.

Yep both are polished and clear coated now so once dry I'll put them together for the 3rd time and hopefully the last  ;D
Agree, a better shot outside will do it more justice.
Have to say I like them a lot more now that the edge is polished but changing things around is what its all about, fu*king around with cars and wheels hahahahaaaa!

I did some measuring too between the 2, there's a 13mm offset difference (reverse mount LM) and then need an additional 7mm to clear caliper with the LM so 20mm overall just aint gonna work.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on June 08, 2013, 06:41:26 PM
Outside mounted as well, Worthersee
(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fwww.vwvortex.com%2Fwp-content%2Fuploads%2F2013%2F05%2Fworthersee-2013-gallery-si-gray-092-e1367593627355.jpg&hash=4717e5b8da70e4545b866b77c3e0d4573a91b65c)

(https://www.vask.org.nz/proxy.php?request=http%3A%2F%2Fwww.vwvortex.com%2Fwp-content%2Fuploads%2F2013%2F05%2Fworthersee-2013-gallery-si-gray-048.jpg&hash=94e6520ac655129d8a675ef40dca4e4358e73234)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Fizz on June 08, 2013, 06:52:07 PM
That was fast work John! Looks great!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Omes on June 09, 2013, 08:52:30 AM
Reverse mount! Comes to the rescue!

Stick with them John, by far more classy.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 10, 2013, 04:47:54 PM
Got the other tyres fitted today and chucked them on, not too shabby after all  ;D >:D
I'll roll these for a while and see..........
(https://lh4.googleusercontent.com/-y3ybSuzgHVU/UbVYrjW4kxI/AAAAAAAAAX4/q4hgkB56SV8/s640/P1010389.JPG)
(https://lh6.googleusercontent.com/-ZxOFmhpdBPY/UbVYsU6v3vI/AAAAAAAAAX4/AgShBcj-IOg/s640/P1010388.JPG)
(https://lh3.googleusercontent.com/-Knn9vc7oGnM/UbVY6qDrJUI/AAAAAAAAAX4/jsdK0lUleSw/s640/P1010390.JPG)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Poonmobile on June 10, 2013, 11:05:49 PM
 8) 8) 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: M M on June 11, 2013, 11:05:56 AM
I like the LMs better, I think the polished lip goes so well with that blue.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: DAPPR on June 16, 2013, 03:49:19 PM
Truly stunning.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: gti vr6 on June 17, 2013, 09:56:53 AM
OZ Wheels look the business.
This car is about the GO not the SHOW.

Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: hagan on June 17, 2013, 10:01:33 AM
The LM's are awesome but the OZ wheels i reckon!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: Skilfil on June 25, 2013, 10:53:49 AM
I'm a BBS LM fan-boy, but I reckon the O.Z's suit the car perfectly. Still, car looks damn good either way.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: catilre on January 14, 2014, 10:02:54 AM
John!!! First off, WOW, this is the most incredible Jetta I have ever seen. I have always wished VW would make one of these. A 2-Door AWD R32 Jetta... An you went and Turbo'd it... Im from South Africa, we never got the big displacement V6 models here. The biggest we got was a 2.3L V5. We did get the Golf in a R32, not sure if it came in a 3 door and/or AWD here. So well done, your work is amazing.

The only thing i can't agree with is the LM wheels. I love BBS wheels but those OZ Supers are a perfect fit for the car. I could not have put it better than gti vr6 if i tried:
Quote from: gti vr6 on June 17, 2013, 09:56:53 AM
OZ Wheels look the business.
This car is about the GO not the SHOW.

The attention to detail is astonishing. The pivot badge boot catch is very much a "nice-to-have" but you put the same effort and passion in to it as every other inch of the car. This (http://forums.vwvortex.com/showthread.php?4492614) used to be my favourite of all Jetta front bumpers, not any more... And I'm so glad you didn't ruin that beautiful front by removing the badge. Its been said so many times, the best part about this car is that it all looks OEM.

I do have some questions though, things i don't remember reading... Are those headlights some aftermarket set or is a regional thing? They look different to the ones on my 2005 MK4 Jetta TDI. I say regional because US spec cars have amber lense side indicators where we have clear lenses. Also did you change the gear ratios at all? Is it a 5 or 6 speed? Sorry if you have already answered all this(things i don't remember reading).

Did you ever say how much tyre trashing, earth moving, time warping torque was measured on the dyno? I saw 245KW, but never a torque figure... Also what was the most you boosted to and what sort of figures did you manage to safely get? Did you ever make it to the 300KW mark?

Well done again. Just finished admiring you work on the Jetta, now off to read all about the Ghia.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on January 14, 2014, 09:42:30 PM
The headlights are just stock OEM xenons as fitted to the v6 4 motion models, I actually haven't been back on the dyno since that initial test session which was 245kw at 12psi which is mostly what I run on the street.
We left the tuning at 18psi but need to dyno again at 21-22 psi which the tuner thinks will be the limit of this map but to be honest 18psi on the street gets you in to enough trouble very easily.
The gearbox is the 6 speed Bora box as its reportedly stronger than the R32 one.

I agree about the LM's hence I have them for sale right now so the Superleggeras are going back on, just love them! ;D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 08, 2015, 03:24:47 PM
Some changes are in the works for the old girl, the 02M is coming out and DSG going in.
After doing a track day in a MK5 R32 I'm sold on DSG and combined with a turbo it should be pretty sweet.

I had planned DSG anyway for the R36 motor but rather than wait till that swap happens I'll do the DSG conversion first and iron out any problems it has.
Just researching can bus connectivity issues now before I tear the thing apart so if anyone has info feel free to share, I'll want to do the swap including paddles on the wheel.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on March 08, 2015, 05:33:59 PM
To clarify, is the r36 going the get turboed and end up in this?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 08, 2015, 05:53:28 PM
Yep, R36TT
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: VW'n on March 08, 2015, 06:31:48 PM
Quote from: 80 Vert on March 08, 2015, 05:53:28 PM
Yep, R36TT

You the MAN!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: virus-zn on March 08, 2015, 09:10:32 PM
Quote from: 80 Vert on March 08, 2015, 05:53:28 PM
Yep, R36TT


hahahaa thats what i said ages ago....

glad you finally doing it

going to be a beast
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 08, 2015, 09:17:22 PM
Not doing the motor yet.........just DSG on existing R32
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on March 08, 2015, 10:25:20 PM
Awesome John.
But how can you pull yourself away from the 964?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GLIDN on March 09, 2015, 12:17:54 PM
Quote from: 80 Vert on March 08, 2015, 03:24:47 PM
Some changes are in the works for the old girl, the 02M is coming out and DSG going in.
After doing a track day in a MK5 R32 I'm sold on DSG and combined with a turbo it should be pretty sweet.

I had planned DSG anyway for the R36 motor but rather than wait till that swap happens I'll do the DSG conversion first and iron out any problems it has.
Just researching can bus connectivity issues now before I tear the thing apart so if anyone has info feel free to share, I'll want to do the swap including paddles on the wheel.

You will require the MK5/6 (CH) steering wheel control module, Slip ring, As far as I know, the canbus on all MK4's were via the cluster. In the MK5 it of course has the external Canbus.
Therefore if you go to this change over, you will also need the CECM (Comfort Electronic Control Module). These, I do not know how they are going to handle the MK4 platform parts. Mainly as I have not played enough with them. Well the interchangeability that is.

To Be honest if you get a Audi TT (Gen 1 Facelift) DSG controller etc then it will be a much of a plug and play affair.
As you know however, the MK5/6 engine require the Fuel pump and controllers, which will only work on the CECM unit not the CCM units.

I guess your almost at the point of work involved you could save some time and go straight to the R36 conversion and run NA? Till all issue's are resolved then perhaps build the motor and have the R36TT?

Not sure how that fit's with how you wanted to progress with this build however.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on March 09, 2015, 02:10:44 PM
Quote from: GLIDN on March 09, 2015, 12:17:54 PM
You will require the MK5/6 (CH) steering wheel control module, Slip ring, As far as I know, the canbus on all MK4's were via the cluster. In the MK5 it of course has the external Canbus.
Therefore if you go to this change over, you will also need the CECM (Comfort Electronic Control Module). These, I do not know how they are going to handle the MK4 platform parts. Mainly as I have not played enough with them. Well the interchangeability that is.

To Be honest if you get a Audi TT (Gen 1 Facelift) DSG controller etc then it will be a much of a plug and play affair.
As you know however, the MK5/6 engine require the Fuel pump and controllers, which will only work on the CECM unit not the CCM units.

I guess your almost at the point of work involved you could save some time and go straight to the R36 conversion and run NA? Till all issue's are resolved then perhaps build the motor and have the R36TT?

Not sure how that fit's with how you wanted to progress with this build however.

Lets not forget that Mk4 R32's were avaliable with DSG.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 09, 2015, 10:39:35 PM
Pretty rare though and gen 1 TT will use the same parts, I'd guess the Audi being a more expensive car new would have seen the technology first.
As far as the R36 goes i'll be getting rid of the FSI and running 630cc injectors in the manifold like I have now so I think using gen 1 TT parts would be the way to go to keep things as simple as possible.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GLIDN on March 10, 2015, 06:09:03 PM
Quote from: RS ZWEI on March 09, 2015, 02:10:44 PM
Lets not forget that Mk4 R32's were avaliable with DSG.


They did indeed, However, where are you going to find them other than the USA or perhaps Europe?
Not that many made. Hence I recommended the Gen 1 TT instead

Quote from: 80 Vert on March 09, 2015, 10:39:35 PM
Pretty rare though and gen 1 TT will use the same parts, I'd guess the Audi being a more expensive car new would have seen the technology first.
As far as the R36 goes i'll be getting rid of the FSI and running 630cc injectors in the manifold like I have now so I think using gen 1 TT parts would be the way to go to keep things as simple as possible.

Well if you are going to end up with a GEN 1 TT intake/head. Or are you going to block of the TFSI injectors in the R36 head?
The fact you can effectively have your cake and eat it too. Well so to speak, using the MK1 TT platform. As I'm sure you can land them for next to nothing in the grand scheme of things?

Here is some info and links that  could help.

http://www.clubgti.com/showthread.php?256582-VW-R36-Engines-Hardware-differences
http://unitedmotorsport.co.uk/2010/12/27/r36-t-running-motronic-med9-world-first/
http://www.golfmkv.com/forums/showthread.php?t=149093&page=2
http://www.dutchbuild.com/index.php/en/shop/db-customs/custom-engine-wiring/custom-engine-wiring-r36-fsi-detail

This guy maybe worthwhile getting in conact with and getting some info.
http://www.r32oc.com/topic/44323-my-mk4-r32r36-36-fsi/




Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on March 10, 2015, 07:27:23 PM
I'll make plugs to block the FSI injectors off, cheers will have a browse through.
Most likely import a complete TT from Japan.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: GLIDN on March 11, 2015, 08:40:21 AM
Quote from: 80 Vert on March 10, 2015, 07:27:23 PM
I'll make plugs to block the FSI injectors off, cheers will have a browse through.
Most likely import a complete TT from Japan.

Pretty much what I thought you would do.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: spooln on March 12, 2015, 03:14:32 PM
Just thinking....as this has an upgrade coming, this engine would go great in the supercharged jetta, which I see is for sale again.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 14, 2015, 10:04:20 PM
Tomorrow..............D day.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: RS ZWEI on October 15, 2015, 03:05:34 PM
Quote from: 80 Vert on October 14, 2015, 10:04:20 PM
Tomorrow..............D day.

For?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on October 15, 2015, 09:33:04 PM
Motor / box out and sold
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: rambo_005 on October 16, 2015, 06:54:23 AM
Going in DHN353?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R32 Turbo
Post by: 80 Vert on June 23, 2016, 09:10:34 PM
Some new hardware arrived today in the form of a pair of HGP turbo's and manifolds and an HGP/HPA 3.6 turbo inlet manifold with injectors and fuel rail. Next month will see the new gearbox and transfer case arrive, a DQ500 7 speed dsg.
Thought it a waste of time to try and make the DQ250 from the Passat try to cope with what the engine will be capable of delivering so hence gearbox change as well.
Poor car has no idea whats in store  >:D
(https://lh3.googleusercontent.com/-AyJ7mKIhiWw/V2umCYcSqvI/AAAAAAAACC0/iGdwBd_epvEhckRiOHLVPaV-1rfs3bBPwCCo/s800/20160623_161207.jpg)
(https://lh3.googleusercontent.com/-Pu0VIJuzNHU/V2umBAEYVZI/AAAAAAAACC0/2loWCks1r3Ew8mm2vMkmF31F9BzHv4JPwCCo/s800/20160623_161235.jpg)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: rambo_005 on June 23, 2016, 09:16:37 PM
Exciting 8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: spooln on June 23, 2016, 09:33:39 PM
Is the dq500 a factory box or a custom mod?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: 80 Vert on June 23, 2016, 09:37:00 PM
Factory in RS3, TTRS and a few others. Handles double the torque of the DQ250.
My current train of thought is to swap in full MK5 electronics to make integration easier but that's still a little ways down the track.
Decided best option is to keep stock FSI and run piggy back ecu to run 6 extra injectors and separate fuel supply when on boost.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: RS ZWEI on June 24, 2016, 02:55:14 PM
Thats going to be mad John. Any idea how how much power it will be putting out?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: 80 Vert on June 24, 2016, 04:13:00 PM
Aiming for 650-700 although it should be able to do a lot more
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: spooln on June 24, 2016, 04:31:13 PM
Std bottem end ok or shiny new  bits in there as well?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: 80 Vert on June 24, 2016, 05:21:02 PM
Forged rods / pistons
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: GLIDN on June 24, 2016, 05:58:36 PM
Quote from: 80 Vert on June 23, 2016, 09:37:00 PM
Factory in RS3, TTRS and a few others. Handles double the torque of the DQ250.
My current train of thought is to swap in full MK5 electronics to make integration easier but that's still a little ways down the track.
Decided best option is to keep stock FSI and run piggy back ecu to run 6 extra injectors and separate fuel supply when on boost.

Why not tune OEM ECU?
It's more than up to the task to handle your request.
Look at AP's R36TT mk5 R32. He is running north of 700hp and still on OEM management running 10.4 or 10.6 in full street trim last time I checked.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: 80 Vert on June 24, 2016, 06:53:42 PM
I will be running oem ecu, MK5 R32 harness with the Passat ECU
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: 80 Vert on October 16, 2020, 01:08:56 PM
Engine strip downs completed, R36 engine with broken block is completely stripped and my donor crispy fire damaged 3.6 engine also stripped.
Going forward I intend to use the forged BWS crank from the R36 along with the head and cams and put that in to the donor 3.6 block.
Have both side by side to compare but so far they both look identical.
One cylinder on the crispy engine has had water in it but scaping the remains away it doesn't look like the bore is damaged, a light hone will reveal if its ok to use.

Ordered head studs and main studs, have IE rods already so that just leaves pistons to sort.
Current thinking is to use the R36 ECU to run FSI as per standard and some sort of piggy back system to control the 6 other injectors in the manifold under boost.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: 80 Vert on October 18, 2020, 09:45:04 PM
The damaged R36.......Block and pan are toast. Hopefully the crank isn't bent. Spins free but dial gauge will tell the story once I place it in the good block.
(https://i.imgur.com/5rkYxDI.jpg)
Stripping engine #2, crispy the fire damaged motor.
Upon a light hone in the cylinder that has had water sitting it turns out the bores are quite worn.
Not huge mileage on this but perhaps wrong oil used who knows. Block will need boring.
On the plus side check out the port sizes!! No wonder these things make epic power.
(https://i.imgur.com/goHm7QV.jpg)
(https://i.imgur.com/t1KOxH6.jpg)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: le mans on October 19, 2020, 09:46:38 AM
Hi John, is this an old project you had parked or have you suffered a recent engine failure? Always interesting to see what you?re up to!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: 80 Vert on October 19, 2020, 10:26:46 AM
I've had this engine for many years Jon, the R32T I had in this car was sold 5 years ago and had always planned to put the R36 in but just never really got there till now.
The broken engine I harvested out of a R36 Passat I wrecked many years ago and has sat ever since.
I'll build this up with forged internals as I've got twin turbos to go on it.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: superfueler on October 19, 2020, 02:10:12 PM
This car will be something to behold when its done. I'll be watching with interest.  :D
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: le mans on October 19, 2020, 02:41:55 PM
I concur!
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: 80 Vert on November 05, 2020, 08:38:41 PM
The clutch for this project came in today, all I can say is wow!!
I had not heard of this company until I saw them mentioned in a really interesting youtube video and decided to contact them.
Right from the get go their communication and professionalism was outstanding, anyway I placed an order for their twin plate clutch set up and got their input shaft support kit as well.
Unboxing the clutch today it is very very high end, the quality just looks absolutely superb and a shame to hide away in the bell housing.
This particular set is a 2 plate rated at 1200NM torque which should be good on my twin turbo set up.
If anyone is looking for a serious single or double plate clutch contact TTV Racing UK.
(https://i.imgur.com/k4rwzZC.jpg)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: rambo_005 on November 05, 2020, 11:30:17 PM
Does this mean you're no longer going with the DSG?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: 80 Vert on November 06, 2020, 06:38:51 AM
Absolutely yes, no more DSG. Don't know what I was thinking considering DSG  8)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: le mans on November 06, 2020, 07:28:37 AM
Looks very shiny John. Quality.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: 80 Vert on May 31, 2021, 07:46:49 AM
Things are creeping along very slowly with this project but since stripping the R36 cylinder head I ran in to some issues, namely my turbos didn't fit?
Bit of a head scratcher as they were sold to me as R36 but definitely don't fit over the exhaust studs on the head, not R32 either as that pattern is completely wrong.
So, a couple weeks back I bought some 3.6 VR6 exhaust gaskets from FCP thinking I'd use those to mark and re drill the exhaust housings on the turbos however
upon placing the gaskets on the turbo they line up perfectly!! Which means my turbos are 3.6 VR instead of R36.

Thankfully "crispy" the fire damaged motor is a 3.6 VR so yesterday I decided to do some investigating and sure enough the R36 exhaust ports are 10-15% larger
than a regular 3.6, both turbos bolt straight on.
The new plan therefore is use "crispy's" head with R36 cams and valve train. Bit of a shame not to use the R36 head with bigger ports but with boost I doubt this will
have much of an effect.
Test fitted the intake and turbos yesterday confirming fit so this can now go ahead and be stripped / rebuilt.
(https://i.imgur.com/RUsGydG.jpg)
(https://i.imgur.com/ZzzAoTK.jpg)
(https://i.imgur.com/SLOTIbV.jpg)
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: mark2 golf on May 31, 2021, 09:00:34 AM
Hi John what the plan of the injection. I see port injectors. Both?
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: 80 Vert on May 31, 2021, 09:09:14 AM
Hey Mark, yes I'll be running the R36 ECU and FSI set up plus a separate ECU to run additional 630cc port injection under boost.
Probably some sort of MAP injector controller.
Title: Re: PROJECT CAR: Mk4 Jetta Coupe 4 Motion R36 twin turbo
Post by: mark2 golf on May 31, 2021, 09:33:39 AM
Ok. There doesn't seem to be many options to run fsi with a standalone ecu.