VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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Wow, has read this epic tread from start to finish! Took me some hours;) Great work, and keep updating, cant wait to see pics/vids of the jetta ripping it out there on the track again! A real trackday hero! Just the way I like it:) Cheers bud, can't wait to get back out there and have fun again. Found several issues whilst i've been pulling it apart which will have been playing havoc with the handling etc, so it should be soo much better when its back on the road again. After more work, this is where i'm currently up to: Bit more crud to remove off the floor etc and the rear wheel arches to strip, then its onto cutting out some rusty bits and making repair panels to go in.
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Last Edit: Apr 3, 2010 21:46:37 GMT by VWDan
If only everything in life was as cool as a retro VW racer.
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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Round hole, square plug: Won't be fitted like that. Wheel arch sealant removed courtesy of BBQ lighter fluid and a match: Remainder of black crud gone from the front end thanks to Gunk and LOTS of scrubbing: And rolled onto the other side: Last wheel arch to do and few bits of crud to remove whilst i work out how to fit the cell and flat-floor the boot.
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If only everything in life was as cool as a retro VW racer.
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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If only everything in life was as cool as a retro VW racer.
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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If only everything in life was as cool as a retro VW racer.
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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Jul 10, 2010 22:10:03 GMT
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Not much done over the past few weeks due to other things, but got some done over the last day or so. Was up to here: Both sides done: Put in a strengthener for the rear valance: Lower rear quarters needed some work: Ends of the sills that were repaired a couple of years ago leave a bit to be desired, so need to be re-done: Rear crossmember finished: Friday evening, made some repair patches up: Bit of a fold: Bit of a trim: Welded them up today: Decided to replace the whole sill rather then patch it up, to make access to the inner sill easier and should look neater too, so no use for this: Another one of those on order....tomorrow i'll get the grinder out and tidy it all up a little.
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If only everything in life was as cool as a retro VW racer.
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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Jul 11, 2010 21:12:33 GMT
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If only everything in life was as cool as a retro VW racer.
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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Nov 22, 2010 22:55:47 GMT
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If only everything in life was as cool as a retro VW racer.
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Sammo
Club Retro Rides Member
Posts: 1,461
Club RR Member Number: 103
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Nov 27, 2010 15:01:07 GMT
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I have just sat and read this from start to finish! Epic thread Is the G60 turbo engine going in the blue Jetta then???
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Follow Me On Instagram - @parttimecartinkerer
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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Nov 29, 2010 21:46:27 GMT
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Cheers bud, nice to get a reply for a change Yep - the G60T will be going in although might be changed slightly as got hold of a bigger turbo for it and not sure if the G60 rods will be up to the extra poke, so things might be changed a bit. Also plan on sorting a different tubular manifold as the Turbo Technics one will be a bit restrictive and hope to run an external wastegate too. Sold the 020 box and the Quaife 02A will be going in as its been sat there ready for a while now Got the garage walls and roof boarded this weekend and its nearly ready for paint then electrics. Really excited at the prospect of having a proper garage to work in for the first time in 17 years of driving I'll put pics up of the finished article as it should look ok Just itching to get cracking with the car again as lots to do and soo many plans - thread should get more interesting then Think Berg Cup and you'll get an idea where the project is heading Had a year off this year and only went to the odd show and trackday and despite having fun mountainbiking and doing other things, REALLY miss having the car to drive, so going to push the boat out to get it done for 2012.
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If only everything in life was as cool as a retro VW racer.
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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Dec 12, 2010 21:54:43 GMT
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Getting close to finishing the garage, just one strip light to finish and the ring main for the sockets to do. Probably going to leave painting the floor till next year due to the weather, so i can make a start on the car again.
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If only everything in life was as cool as a retro VW racer.
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Dec 12, 2010 22:01:04 GMT
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whay ya mean its not finished top stuff - wish i had skillz room etc gerrorf moi laaaaaaaaaand lol
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2001 HONDA CT110 (NOT RCV)
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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Dec 12, 2010 23:37:10 GMT
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Lol Couldn't have built it without mucho help from Dad, he's been great. Next year theres also a small workshop bit to built on the side, hence the (door) hole in the side - might as well make use of the space in the side garden Got a day off tomorrow so hope to finish the electrics and a few other bits and bobs.
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If only everything in life was as cool as a retro VW racer.
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Dec 14, 2010 16:24:40 GMT
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praaaaper jaaaaaaab ;D
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2001 HONDA CT110 (NOT RCV)
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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Dec 14, 2010 23:02:01 GMT
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If only everything in life was as cool as a retro VW racer.
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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Dec 22, 2010 20:25:15 GMT
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If only everything in life was as cool as a retro VW racer.
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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Dec 30, 2010 20:31:39 GMT
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PROGRESS!!! No, i'm not joking either ;D Firstly, end of an era: And start of a new one: At last, a free drive to use when needed Then spent the rest of the day with an angle grinder like old times ;D: First, made a template from the repair panel: Then cut the outer panel back, trimmed the inner arch, fettled and bent the repair panel and slotted it in place: Looking at it again, it needs to stick out a bit more at the bottom and taper in less, so will weld it in slightly different to the pics, but it gives the general idea. Trying to keep a decent arch line on the rear quarter and keep the need for too much filler down to a minimum. Once its in place properly, i'll decide where to trim the outer edge to give a nice shape to cover the wheel. Might use one of the accessory arches i've got to get the shape right and also need to suss out how to get a decent lip on it, but will cross that hurdle when i come to it. Next step is to trim the sill and get that ready to fit, then see how it'll all fit together.
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If only everything in life was as cool as a retro VW racer.
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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Bit more done on the rear arch today. Started off by stripping the paint back on the rear quarter and arch to make the lines easier to see: Also trimmed back the inner arch some more after this pic to give about a 10mm lip. Bit of bashing and trimming of the new arch: That got trimmed back some more after this pic and a smaller lip put on to sit behind the outer panel. Then put a few slits in the inner erch: And then welded the arch on: Excuse the welding, not done any for a few months and was desperately trying not to blow holes in the panels! Then i spun it over and seam welded the inside lip: And ended the night by bending the inner arch back into shape and tack welding it onto the new arch, ready for seam welding: Quite happy with the way its turned out so far, arch line is pretty good and it sits even at the front and back with the same width. It should only need more than a skim of filler at the top to keep the arch line flowing - will be easier to see once its been ground back and sanded and given a lick of paint.
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If only everything in life was as cool as a retro VW racer.
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kee
Posted a lot
Posts: 4,988
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nice idea using the inner arch, something i've thought about briefly before. will you be using the same inner for all 4 arches?
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VWDan
Part of things
VW Jetta MK1, VW Caravelle 1.9TD, Audi A6 Tdi Avant
Posts: 841
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Yep, going to order three more when i get chance. I'll do the front wings later as need to get the rest of the welding done first - both sills to do, lower rear quarter on the other side, turret tops to extend and some bits to add to the cage to tie it into the shell some more. Also some work to the front chassis legs to give more clearance for the steering arms and drive shafts, going to sink the battery into where the rear seat used to be and the exhaust will pop out of the opposite side, which will need the sill notching. Also want to add another bar to tie both rear axle mounts underneath together and a couple of bars to tie the turrets to the front chassis legs. Plus some other bits to do......... The shape of the inner arch is pretty much the same all the way round bar the bottom corners, which will be cut off anyway. Hard part will be getting both sides the same, but so long as i cut the outer on the other side the same it should be fine - the template i made will help with that. Other side should be easier now i know what i'm doing! Can't use a drivers side inner for the other side due to it being a different shape due to the filler neck, which will be deleted. I did try some Berg Cup arches on it, but due to the Jetta front wings being different at the bottom where it meets the valance and the fact its a 4 door it would have been too much work for me to make them fit, so had the idea to make them out of metal instead ;D Lots to do, but keen to to keep going and its soo much easier and comfortable to work on it now with the garage and chassis spinner Well worth spending three months building the garage! I'll update as things progress.
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If only everything in life was as cool as a retro VW racer.
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Sammo
Club Retro Rides Member
Posts: 1,461
Club RR Member Number: 103
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This is going to be a mental car when your finished with it
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Follow Me On Instagram - @parttimecartinkerer
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