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    Thread: Cabrio project for the wifey... build thread

    1. Member
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      Apr 2nd, 2004
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      near Rochester NY
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      05 Allroad 2.7T,13 GTI, 93 Cabriolet, 2009 Silverado
      03-22-2017 10:42 AM #351
      Quote Originally Posted by drkreign View Post
      Love the work and attention to detail but I have to ask, why run the brake lines inside the car and not underneath it? I would think after passengers or the first time the top leaks and moisture gets trapped near the lines you could have a rather large mess. Not knocking at all, just curious on your choice


      Sent from my iPhone using Tapatalk

      I dont forsee any issues with corrosion, Ive used all ss fittings and the nicopp line is VERY corrosion resistant.

      Ive done this purely for aesthetics.

      The top can only leak if you take it out in the rain.

      Dan

    2. Member
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      05 Allroad 2.7T,13 GTI, 93 Cabriolet, 2009 Silverado
      03-22-2017 10:44 AM #352
      Finished trimming and flaring the 3 output lines last night. I also played around with some zip ties, which hold them together surprisingly well. I still need to come up with at least one mount for the firewall.





      Then it was time to tackle the input lines. Im not really happy with how these turned out. 1. the bulkheads are just so damn tall and 2. id like a little more clearance to the steering shaft (yes, I could bend them away more). So I ordered some electroless nickel plated 90 deg bulkheads this am. Ill need to have the engine bay side flange redone to accommodate the nuts and then hope like hell one out of the 6 choices allows the 90 to be keyed correctly inside (I can also shim them some if necessary).

      Note: yes, one of the bulkhead fittings i had to substitute with a bolt as I left one at work.









      Dan

    3. Member oopseyesharted's Avatar
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      07' Rabbit & 86' Cabby
      03-23-2017 06:38 AM #353
      Those lines look great. Does that line running behind the accelerator pedal come in contact with the pedal?
      Nothing interesting here.

    4. Member
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      05 Allroad 2.7T,13 GTI, 93 Cabriolet, 2009 Silverado
      03-23-2017 10:12 PM #354
      Quote Originally Posted by oopseyesharted View Post
      Those lines look great. Does that line running behind the accelerator pedal come in contact with the pedal?
      Nah. It cant hit even without the plastic stop in the carpet.

      Dan

    5. Member
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      05 Allroad 2.7T,13 GTI, 93 Cabriolet, 2009 Silverado
      03-27-2017 01:23 PM #355
      Wasnt digging the dumb bends on the input lines at the firewall so I picked up some nickel plated bulkhead 90s. It turned out SO much better.







      With that done, I whipped up the rear crossover line and bracket. Im still deciding on what to use for clamps, hence its just floating right now.
      There will be no hard line on the drivers side, the braided line from the caliper will just extend right to the tee.







      And hose routing on the pass side around the surge tank and thru the axle beam





      Finally, I was able to work out routing of the ebrake cables without getting crazy and completely re-routing them. I just need the next size longer, 1800mm vs 1730mm. They are on order. I had to do a small notch in the fuel filter bracket (still needs a tiny bit more clearance) and massaged the corner of the gas tank a bit to add a small channel.









      Dan

    6. Member
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      05 Allroad 2.7T,13 GTI, 93 Cabriolet, 2009 Silverado
      03-29-2017 10:27 AM #356
      Test fit a wheel last night to both verify my axle spacer measurements were right and also to see how much wheel clearance I had for the axle beam brace "towers".

      Perfect fit, and no rubbing. I know very un-vw.





      With that I welded up these little towers. I happened to have the rod ends and bar "in stock", leftovers from cavy projects I guess.



      Trying to decide where to mount them. I really like them over the shock mount, but then they could get filled up with water and whatever. Im thinking a drain hole might be good enough to keep water from washes drained. Also unsure if the swaybar mount "lollipop" bolt is long enough to go through the extra metal.

      I dont know how I took this to be powder coated years ago with the condition of the pass side shock mount area. Its pretty hammerd (literally). At least I can address that now as well since its going to need to be re-coated.







      Dan

    7. Member
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      05 Allroad 2.7T,13 GTI, 93 Cabriolet, 2009 Silverado
      04-03-2017 10:27 AM #357
      Was never a huge fan of the rear bumper cover or the huge tow hooks. The bumper flap in had a big crack right in the middle, so I decided to do a little trimming. At some point I may come up with a simple diffuser but for now just having that middle flap cut out and the tow hooks gone is a huge improvement.









      So long ugly ass tow hooks



      I think it will be pretty business looking once the bracing is in.






      Next was time to fix the pass side shock mount area on the beam. How I ever took this to powder 6 years ago Ill never know. It was very bent up and beat to hell. Must be someone couldnt get the shock out at one time. A little beating with a BFH, welding, grinding, and redrilling and its pretty close to normal.










      Also got the second brace tower welded up. Decided not to mount them over the shock hole. To keep them from filling up with water I welded up the oe hole in the beam, then tacked the towers on





      Autotech swaybar and longer tie rods will be here by thursday so I can finish up this beam and get everything back to powder sat am.

      Dan

    8. 04-07-2017 05:01 PM #358
      nice build man, cant wait to see more progress

    9. Junior Member Mr.Pink1942's Avatar
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      04-12-2017 08:47 PM #359
      Awesome work.

    10. Member
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      05 Allroad 2.7T,13 GTI, 93 Cabriolet, 2009 Silverado
      04-17-2017 10:26 AM #360
      Fabbed up the inner axle beam bracing mounts last night. Still need to be welded but Im currently out of sheild gas for the TIG. Also dont mind the random wheel studs, it was the only 5/8" bolts I had that were long enough. The fin at the bottom double serves as a jack point should I not be near the lift.









      Dan

    11. Member matty kirk's Avatar
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      1990 VW Cabriolet 1.8L 2H 5Spd Digi2 - 1981 Ford E-150, 300 6, 4 on the floor
      04-18-2017 09:36 AM #361
      Extreme!!
      Even a blind squirrel finds a nut in the dark, sometimes.

    12. Member
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      05 Allroad 2.7T,13 GTI, 93 Cabriolet, 2009 Silverado
      04-21-2017 10:49 AM #362
      Finished up the beam bracing last night. Welds arent my best, but itll work









      Also had to modify the inner swaybar mounts. The OE mounts are supposed to fit the Autotech big swaybar, well mine didnt. They were about 1/4" too short. Its really weird, all of the MK1 VW cars have the same OE part number for this bracket, just different revisions dep on year. Given these are NLA and if I found a used set who knows if theyd fit, I decided just to mod them

      First welded a shim to the mounting hole side.


      Then cut off the bent end.


      Bent / cut up a new peice


      Positioned, tacked, and bent around the orig bracket


      Ugly welded in place


      Ground and sanded to sort of match the OE look


      Perfect fit




      And the whole smash on the car


      Up next I need to get the motor back in then start on the exhaust.

      Dan

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