PROJECT CAR: Mk4 Bora/Jetta 4 Motion

Started by 80 Vert, April 11, 2007, 09:15:40 PM

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Fizz

Awesom Vert1 Looking 4ward 2 the pics :)

Turbo

man, impressive undertaking.

i feel like a mechanic just checkin the oil.
2000 S4, MTM stage 1, Oettinger RE's, Bilstein Sports, Vogtland springs, H&R Swaybars, DBA 4000 rotors, EBC Yellow stuff pads, 710N DV's, F1 tints, RS4 clutch

80 Vert

2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

More fun, wiring headache!
2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

robh

wow, now that's what I call a shell!
Daily Driver - VW Touareg V8 TDI 2012 "towing beast"
Too Many Cars - Lotus Elise S 2013 "tangerine dream"
Project Car - Golf VR6 Turbo "built not bought"
Wifes - Audi S4 Avant 2012 "I want a white car that sounds nice"

80 Vert

Believe it or not there was less of it when I started!
Things are progressing very nicely, the sound deadening is going back in tonight along with the pedals, steering colomn etc
2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

robh

seeing all these cool projects being done makes me want to redo so many areas of my car, but I just don't have the workshop space to embark on it right now, talk about frustrated  :(
Daily Driver - VW Touareg V8 TDI 2012 "towing beast"
Too Many Cars - Lotus Elise S 2013 "tangerine dream"
Project Car - Golf VR6 Turbo "built not bought"
Wifes - Audi S4 Avant 2012 "I want a white car that sounds nice"

Filx

Quote from: vert1 on July 25, 2007, 08:28:07 AM
Believe it or not there was less of it when I started!

I can second that - literally not a nut, bolt or washer left in there when I saw it in its birthday suit a few weeks ago! Awesome work John!!!
FAIL - First Attempt In Learning

80 Vert

Got on with modifying the pedal assy today, Its not a good idea to use a LHD car as a donor for pedals! Funny enough there seems to be more footwell room in Phils MK3 (LHD pedals went right in) than in a MK4. The other thing I have since found out is that the RHD bulkhead I fitted is for a cable throttle and not a FBW and thus vastly different. But with lots of cutting and fabricating new mountings they are in! I actualy used a combination of automatic and manual brackets and made the rest, doing this at home is no easy task as all my tools, welder etc are at the shop but luckily I'm only 5 min away.
Going to start lengthening some of the engine bay wiring next week to get it to a stage where the motor/box can go back in and then the front susp/subframe will go back in.
2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

After plenty of cutting, trips to the shop and a lot of swearing the pedals are where I want them. In the end it all worked out great with no need to buy more parts. I'll have to hang the doors now before the dash sub structure can go back in for good as you can't get to the hinge bolts once this is in place.
The engine bay is nearly ready for the engine, I've run all the hard lines for the brakes and clutch with some wiring to lengthen before the engine goes back in.
2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

Done a bit more on the interior too, got the sunroof back in along with the curtain airbags.
Have since fitted the headliner and all the roof related stuff since this pic.
I'll have a look at fitting the rear doors tonight with the fronts maybe tomorow.
2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

More parts today, Oettinger rear window extension, Caractere rear lip spoiler. Getting the new Michelin pilot sports fitted tomorow so the wheels can be thrown back on, getting a bit tired of looking at the old steelies.
2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

OMFG, wiring!
Been doing the engine bay wiring the last few nights and has been completed tonight. Stripped the supercharger off the engine today so that the new pulley can go on when it turns up, MORE POWER!
I have to say that the VF stuff is super nice quality and nicely installed.
I'm going to be using the engine from the 4M car so we removed the sump today to drill and tap for the SC oil return line and changed some hoses and fittings between the two engines.
I've borrowed and engine hoist today so I'm gonna try to install the engine and box over the next couple of nights and then get the whole front end of the car finished before doing the wiring inside (not looking forward to that)
Converting from LHD to RHD sounds simple in theory but even having all the parts it still is a huge task.
2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

gti vr6

Good stuff John, I thought the wiring would take longer than that!
1986 Mk2 Scirocco
2021 T6.1 4M LWB Transporter Trendline

80 Vert

Bit late but some more updates
2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

And another, Motor and box back in. Have since done the steering rack, subframe, susp, brakes etc.
Had to trial fit the subframe a few times as the rack had some clearance issues with the downpipe to the cats. Just ended up taking an oxy aceteylene set home and heated the exhaust pipe to clearance it.
All the power steering lines seem to fit now, the rack is still close to the exhaust but we'll see if it hits when I drive it.
2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

BB

Ive got an engine crane and a block and tackle if you ever need to borrow it Vert1, plus one of those across the bonnet engine supports.
The end is nigh, but the end of what is the question?

Angle

I don't know whether to cry or congratulate you. Looks great. I didn't realise you had gotten so far. Now I just need to find my Mk I. Can't believe I slept through the last three!

80 Vert

Good to see you back on here Dennis! Yeah it was looking pretty sad there for a while. But hey things are looking up now as its all going back together. Will bring it around for you in its "new" form, and it will even have the steering on the CORRECT side too!
2019 Jetta GLI (USA)
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

HandsomeDan

I can't quite put my finger on it, but there's just something missing....;D
1998 Mk III Golf,
1992 B4 Audi 80
2007 Toyota RAV4
2000 Mazda SP20 AWD (JDM Mazdaspeed Edition)
1996 Toyota Starlet - daily hack
2003 Opel Zafira GSi 2.2
2007 Volvo XC70