"Old Guy" It may take a decade 16v build thread

[All VW All the time]

This build thread will be rebuilt from the beginning. Have patience with me. I have uploaded all my pics to my new Photobucket account.

Screw Hostdub.

This weekend begins year four of my build.

I thought I would start a thread that I could make regular posts to...

So I'll fill in the intervals from my lack of consistent forward progress by including some of the mini projects that I have completed so far.

This was a fun weekend, as I finally got my Porsche 914 mirrors mounted that my wifey got me for Christmas. I like 'em. I think they fit the squared off lines of the body.

To mount them I had to make new rubber seals to make up the 17 degree difference between the mirror base and the slanted door. Contact cemeted the rubber to a piece of wood and ran it through the table saw at work. Worked like a charm.

I have enough of the cut rubber to make two extra seals if anyone else would like to mount these mirrors.

The stock mirrors have a wider mounting hole spacing and the cable access hole that all need filled in by weldng.

I used a piece of 1/4" x 5/8" bar stock to fill in the cable hole, because the rear 914 mirror mounting hole will need to be drilled and tapped through it. The front mounting hole is drilled and tapped at the origional front hole location.

All filled in.

And drilled and tapped using a 6mm. x 1.0 tap. Use the same screws that are used on the 914. They will be long enough, and they have a nice chromed oval phillips head.

My project will hopefully show some of my detail ideas that have not been done before, stay tuned... Like or don't like, don't hesitate to chime in.



Modified by All VW All the time at 9:35 PM 12-13-2007

[addictheadvw]

I think it looks great! What are you welding with, o/a?

[So Euro]

not to shabby at all

[caddy 2 dope]

very cool

[coolerow]

wtf, no 16V? false advertising.

[jonny_breakz]

Those do look good. I thought about picking up a set a few years ago for my cabby. nice work , but couldnt you have possibley switched bases on those mirrors to perhaps a set of flag mirrors? that was my idea if the holes didnt match up.

[All VW All the time]

Quote, originally posted by addictheadvw »

I think it looks great! What are you welding with, o/a?

My Hobart is now my newest best friend. I keep learning but I have a long way to go.

But now, lets to go back in time three years...

One of the first things I did once the car was all stripped down and cleaned (you don't want to see those pics, way too boring, and you've seen them before in most every other build thread) was to install a custom hitch that will be hidden when I am not towing. I will make a removable fiberglass rear valance panel that will attach using Dzus fasteners. Haven't started the valance project yet. I have to make the mold first from the metal panel I got from Far Out Parts, then I will make a couple of new valances pieces off the mold.

The hitch bar looks way off center, but the bar only extends out so the relocated hitch endplates can bolt through the off center spare wheel well on both sides and also through the floor. I welded backup plates on both sides of the floor to spread the load out. There will be seven bolts total. Its not going anywhere!

You can just see the 2.0 16v short block on the stand. Bottom end is done. Long way to go to finish it. Lots of head and manifold porting. Finishing the engine will be this winters project.

Far Out Parts came through for me on the rear valance. No problems, and it only took two weeks to arrive Now, they are no longer in bidness! Or so I've read. Bummer because they had a nice selection of the kinds of things we all need to rebuild these cars.

I won't be running a spare so I needed to make a recess pocket to provide clearance for the hitch behind the wheel well.

I also made a battery tray in the wheel well to hold the Optima at a low enough height that will still allow a nice flat floor. There will still be room for a 12v portable compressor and a can of fix-a-flat along with the obligatory complete tool kit.

Back to the present: Engine Bay

Making hole plugs. Slow and boring. Cleaning up and shaving all the crap I won't be needing. Keeping the rain tray and heat though. (Cleveland can get cold)

Shaving the rail lip. The first step in the long process.

Thats one side.

All for now. Way more to come.

Modified by All VW All the time at 7:22 PM 12-13-2007

[evil_brother1]

Very nice job. Better to do an awesome job in 4 years that a crappy one in 4 months.

[Road Boss]

Quote, originally posted by All VW All the time »

Far Out Parts came through for me on the rear valance. No problems, and it only took two weeks to arrive

You got something from Far Out Parts?

[All VW All the time]

My custom bumps...

I want them tucked up nice and tight and tapered to match the fender lines. I have always hated the rubber endcaps.
I will paint them body color and make a polished aluminum center strip with hidden mounting bolts. The removable valence hiding the hitch is not done yet, but the bumper will hide the top seam.

The front was more challenging because it needs to work with the GTI spoiler shape, the fender lines, and the side of the grill. I have always liked the Westy/GTI front end and intend to keep it. No rounds for me!

SAVE THE WESTY!

The original bump with about 1 1/4" shaved off the top surface to get it tucked in tight.

Trimed the ends to match the tapered fender line

Made 1/2" end plates and Weld 'em on. Chop, cut, weld, grind, fit, file, sand, file, sand, file, sand and repeat.

Notched the back edge of the bumper bottom so the air spilling off the spoiler can still get in through the lower radiator opening below the grill.

I used the original brackets that were then sectioned 3" and rewelded for both the front and rear. I cut almost 10lbs. off the original bumpers and brackets in the process.



Modified by All VW All the time at 7:46 PM 12-13-2007

[richardbachman]

Looks like quality work. I'll bet you can't wait to finish it and then drive it.

[killerrabbittruck]

i see no pics

[2manyprojects]

The custom bumpers are killer

[2mAn]

Quote, originally posted by 2manyprojects »

The custom bumpers are killer

x2

[avw4me]

Good work on those bumpers

[MattySull]

Those mirrors are nice, good work

[crittah911]

love how you're keeping the westy, and the work looks like good quality

[pappas64]

I was considering getting euro plastics, but maybe working with the stock bumpers on my 83 is a better idea. They look great so far.

[opusdestructo]

are you welding the bumpers with the hobart as well? that's a mig correct?

[All VW All the time]

Quote, originally posted by opusdestructo »

are you welding the bumpers with the hobart as well? that's a mig correct?

No, I tapp into a friend on all things aluminum. He has a welding shop and is very good.

My next welding step is to get a TIG. Any real welding fabrication should be TIG.


Modified by All VW All the time at 12:13 AM 7-11-2007

[killerrabbittruck]

i see pics now, nice work, definitely keep us posted, and show the bumpers when they are done, i'm trying to figure mine out right now too

[All VW All the time]

Whopee!!!! Hostdub is back and working!!!!

Lots of work in the engine bay since May. I'll get the pics hosted and update tomorrow.

Guess where the wires are going.


Modified by All VW All the time at 7:51 PM 12-13-2007

[the_mad_rabbit]

Quote, originally posted by All VW All the time »

Thats exactly how I shaved my engine bay

[Chronicsinners]

build looks great thus far, i love what you have done with the bumpers

When welding them, they are just steel correct?

[All VW All the time]

Quote, originally posted by Chronicsinners »

build looks great thus far, i love what you have done with the bumpers When welding them, they are just steel correct?

Bumpers are Aluminum, brackets are steel.

[automk2slowness]

beautiful work on the engine bay! is it safe to shave off the rail lip like that tho?? sweet build so far.

[All VW All the time]

Quote, originally posted by automk2slowness »

beautiful work on the engine bay! is it safe to shave off the rail lip like that tho?? sweet build so far.

I hope so!

Tried to make sure to keep a good bead of weld down the seam. As long as the two halves are welded together solidly, I would think its as strong as with the spot welded lip seam.

I like having the sides open to the ground instead of filling in big flat plates between the rails and inner fenders.

[odj]

looking great so far

[woodrowstar]

i bet the neighbors had some serious head scratching the day you rotored the car. Looks sweet.

[All VW All the time]

Gonna hide the wiring harness' inside the two frame rails. Routing through the fender well just doesn't seam to me to be safe, or durable. Routing them up the rails will for sure be a major pain, but I think it will be worth the hassle.

Ever notice that most of the newly shaved bay pics you see on the tex never have the wiring installed Just an observation from my endless search for "How did THEY do it" examples.

So I will bring them out from the fuse box through the firewall straight into the rails. So I made a template....

Cut out the holes...

Making the fillers took way more time than I could have imagined. If you grind off too much, you start over. So you have to take little bits at a time I took two tries on the drivers side, one on the passenger side. I learned to go slow.

I've seen this done on a couple of other cars and I thought they were too square to the bulkhead. Made them look unnatural. So I made mine tapered back a little bit to wrap around the tower a bit. I think they look better.

Finally, got to weld

And grind

And then, do it all over again on the other side.

but its a different and harder shape to make

Keeping the tray, cause well, I live in Cl-cl-cl-Cleveland so I will want heat without stink!

I'm on drill motor number three from all the wire brushing I've done.

Core support mods next.



Modified by All VW All the time at 8:09 PM 12-13-2007

[tobiwonkonobi]

Progress is looking great for whats done
Im the guy that has the similiar bumpers..we talked about them at H20 last year..good job thusfar

[Beau]

Very nice indeed.

Lots of work though.

[All VW All the time]

The work you did this year is very nice.

Love the black / white contrast and you kept the rain tray too.

Slick, very slick! 1st. is on me

See you at Jolly Rogers


Modified by All VW All the time at 8:18 PM 12-13-2007

[ON3GO]

great job on the welding! my type of guy!
great job so far!

[rok801]

stoked to see more progress!