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    Thread: Project CAR (Coupe on Air Ride) is under way!!! MK1 air ride build inside!

    1. Banned WCHLVR's Avatar
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      12-18-2009 06:36 AM #1
      Thought some of the stalkers in here might enjoy my shenanigans.



      Click here



      Modified by WCHLVR at 4:04 AM 12-19-2009


    2. Member vwnthusiast's Avatar
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      12-18-2009 08:20 AM #2

    3. 12-18-2009 12:12 PM #3
      already watching it terry. hoping to learn another thing or three.
      epitome - Like McCormicks, we're seasoned
      "Car shows are more fun if you keep your doors and hood closed. It's about the people, not a dinky glass trophy." - dabble
      "i should not use mark as an example though, as he is a god amongst mortals on this tiny planet we call home.." - Us2bA4dr

    4. Member
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      12-18-2009 12:44 PM #4
      dope

    5. 12-18-2009 08:18 PM #5
      Props Holmes.

    6. Member jimothy cricket's Avatar
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      12-18-2009 09:00 PM #6
      this is gunna be shwweeet.
      “Good design is as little design possible.”

    7. Senior Member Shawn W.'s Avatar
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      12-19-2009 12:22 AM #7
      where did the surf green hot rod go?
      L.L.S

    8. Banned WCHLVR's Avatar
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      12-19-2009 05:05 AM #8
      Quote, originally posted by Shawn W. »
      where did the surf green hot rod go?

      Short story- Its gone!


    9. Member rotorwerks's Avatar
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      12-19-2009 09:49 AM #9
      this is gonna be fantastic

    10. Member Phunkshon's Avatar
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      12-19-2009 03:19 PM #10

    11. Senior Member Shawn W.'s Avatar
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      12-19-2009 03:47 PM #11
      You are going to have to tell me the long story some day
      L.L.S

    12. Banned WCHLVR's Avatar
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      Project Doppelganger
      01-20-2010 05:05 AM #12
      Update bump!

      Dug back into the Jetta today.

      Cliff Notes Version- Front mounting arrangements are now complete. Planning for another mock up on the Jetta tomorrow.

      Now I bring you my latest art work!

      Everything measured up and come out to: "42". Here is the airbag upper mount tacked together.

      As it sits in relation to the MK4 Strut bearing mount/bushing. When assembled there will be a provided "gap" for the bushing.

      Here is the upper strut cap tacked and resting in place.

      Completely mocked together one more time before final weld.

      Here they are! They look like little chrome stove pipe hats!

      Upper Bag Mount in place!

      All resting in place.

      Looks like I should have everything complete dialed. At "Lock" and under hard camber the strut pitches 5 degrees. This equates to just under 3/8" of spacing need to clear the bag mount and the upper mount... all factored into the mount. It is also designed to allow for adjustablity should it need a little more or less!

      Enjoy!


    13. Banned WCHLVR's Avatar
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      01-23-2010 12:57 AM #13
      So I have some good news and some bad news.

      The Good News-

      Everything bolted up perfectly and works great!


      The Bad News-

      The UA bags are only able to compress to 4". There simply isn't not enough room for a 165/45 (20.8" diameter) tire (on a wheel with an ET35) to layout without raising the towers. The closest it will come is 3/4" (with the pinch weld cut off). Any tire with a smaller diameter or even a lower offset will make a huge difference in laying out.

      Here is where we sit currently.



      Did get the pinch welds in the strut tower pounded flat to help clear the bag. Do note- This setup will require a C-Notch and a Hood Notch.

      Feeling a little disappointed that I couldn't get it closer. I'm certain I can get more out of it by trimming the fenders and slapping on some wheel spacers!

      Enjoy!


    14. 01-23-2010 01:17 AM #14
      yay on the good news and bbbooo on the bad news. still great engineering terry.

      the hassles you are going through are one of the reasons I sold the UVAirs I had and went to the bagyards. Yeah, it was a lot more money, but I don't have the time and patience that you have. (and yes, i still need to get my front lower. )

      epitome - Like McCormicks, we're seasoned
      "Car shows are more fun if you keep your doors and hood closed. It's about the people, not a dinky glass trophy." - dabble
      "i should not use mark as an example though, as he is a god amongst mortals on this tiny planet we call home.." - Us2bA4dr

    15. Banned WCHLVR's Avatar
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      01-23-2010 04:52 AM #15
      Quote, originally posted by SKIDMRK »
      yay on the good news and bbbooo on the bad news. still great engineering terry.

      the hassles you are going through are one of the reasons I sold the UVAirs I had and went to the bagyards. Yeah, it was a lot more money, but I don't have the time and patience that you have. (and yes, i still need to get my front lower. )

      Thanks brotha. Just do my best to bring a little something new to the stale MK1 scene.


    16. Member Plain's Avatar
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      01-23-2010 06:17 PM #16
      Subscribed.
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    17. Member ryanmiller's Avatar
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      01-24-2010 11:45 AM #17
      cool idea with the external strut bushing!

      why was it not able to go as low as the first time you mocked it up? is the sleeve hitting the inside of the top mounts that you made?

      Dub Cult ESAD

    18. Banned WCHLVR's Avatar
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      01-24-2010 03:25 PM #18
      Quote, originally posted by ryanmiller »
      ..why was it not able to go as low as the first time you mocked it up? is the sleeve hitting the inside of the top mounts that you made?

      The reason is during the first mock ups the strut cap and the upper bag mount were sitting on each other. Once I added the needed "space" for the strut bearing to operate correctly I lost a little ground. The setup still allows for the car to lay out, its the bag that's limiting me now. Going to try some wheel spacers today and see if I can lower the bag down a little more!


    19. Member vwovw's Avatar
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      01-24-2010 05:02 PM #19
      looking good. i've been planning on doing this to my caddy this spring. now i'll watch and see where you go

    20. 01-24-2010 08:38 PM #20
      nice progress

    21. Banned WCHLVR's Avatar
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      01-26-2010 11:08 PM #21
      Got the coilovers clearanced for the air fitting. My local supplier also hook me up with Parker DOT fittings. Super high quality.

      Here is my test Schrader setup!

      Added a 5mm spacer. Worked great. Think we are going to ultimately do 10mm. Clearance looks great from all angles!

      So how does it look?

      Aired up

      Aired out

      How does it sit?

      The oil pan is sitting on the ground. Once the ass is low, this will pull the oil pan up a little. Might be able to get a little more low.

      And here is a GIF for your visual stimulation!

      Enjoy!


    22. Geriatric Member ValveCoverGasket's Avatar
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      01-27-2010 10:03 AM #22
      right on

      keeping an eye on this one


    23. Member crippled4life's Avatar
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      03-11-2010 02:05 AM #23
      nice

    24. 03-11-2010 07:56 PM #24
      MK1 coupe... secks
      Unbagged B5 Wagon

    25. Member President Lincoln's Avatar
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      03-11-2010 10:46 PM #25

      kinda reminds me of my 4 door in my sig

      1966 Beetle - 83 Jetta Deluxe - 87 VR GTi - No. 0242 - 2012 Tiguan (hers)


    26. Member MkIII Jetta's Avatar
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      03-16-2010 10:10 PM #26
      this is nice custom work

    27. 03-17-2010 06:25 PM #27
      This is looking great so far! Great work on the mounts.

    28. Member mikegilbert's Avatar
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      03-17-2010 06:55 PM #28
      Car is lookin' good!
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    29. Member President Lincoln's Avatar
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      03-17-2010 07:03 PM #29
      I was wonderin when someone would bump this again. I hate to be the last to post.


      Car is looking good though. Subscribed.

      1966 Beetle - 83 Jetta Deluxe - 87 VR GTi - No. 0242 - 2012 Tiguan (hers)


    30. Banned WCHLVR's Avatar
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      03-17-2010 07:21 PM #30
      Rear struts are on the work bench. Looking to have them mounted in the next week of so.

      Fingers Crossed


    31. Member Mylch's Avatar
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      03-18-2010 09:52 PM #31

    32. Banned WCHLVR's Avatar
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      04-21-2010 11:38 PM #32
      Forgot I had this thread going too. Here's some updates for ya'll...

      So we are getting close to having the rear ready to layout.

      Chapmans have arrived

      Finally found a poly rod end solution I am pleased with that will fit the strut mount pocket on the MK1 beam. The intent here is to have thread-in rod end that is a direct fit for the Chapman and VW's. I plan to lop the head off a M24 bolt (threads right into the Chapman), fish mouth it and weld it to the bushing assy. Should have the bushings early next week.

      Last- We have toying around with slapping on some drop plates just to help keep the wheels as centered as possible in the fenderwells. While I was at it I went ahead and whipped out a few variations-


      Looking to have them cut on the waterjet out of 1/2 stock. All the curves and lines are meant to match the OE pieces and they will also clear disc brake mountings if we decide to upgrade later.

      Yes- You read that correctly... I made a CAD for lift plates too. Could a ton of fun pair up with my front strut spacers!

      Thats all for now... Enjoy!


      Modified by WCHLVR at 8:40 PM 4-21-2010


    33. Banned WCHLVR's Avatar
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      04-28-2010 04:05 PM #33
      Looks like the "man in the brown shorts" should be dropping off the rod ends tomorrow. We picked up the needed fittings for a test run. Need to grab some jam nuts. Looking to have the rear on air by Friday.

      Drop/Lift Plate update- After tossing around ideas with a few of my friends (I get to call them that cuz I pay them) I went back to the drawing board in the hopes of coming up with something more innovative. What I ended up with is this-

      Select-A-Drop and Select-A-Lift Plates

      What I did was combine a 2" and a 3" Drop/Lift plate into one plate. In order to pull this off I needed to notch the plate for the brake lines and bleeder. For the lift plates it does require that one swap the left and right backing plates as well as spin them 180 degrees (Thanks for that one J). This allows for clear access for the brake lines and bleeder. Nuf talking... here is a CAD pic. Should have the first set cut very shortly. Shoot me your thoughts!


    34. Banned WCHLVR's Avatar
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      04-30-2010 02:48 AM #34
      The time has come that everyone has been waiting for- The Coupe is sitting on air!!!

      Rod ends are done (still waiting for the jam nuts)

      Got them mounted up late tonight. I will have to snap some "dancing" pics tomorrow. She tucks the 165/45's. I think she still has more to offer. Need to do some clearancing and fender rolling.

      All up

      Gangster Lean



      Enough for now... Enjoy!


    35. Member vwgliin05's Avatar
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      04-30-2010 04:37 AM #35
      Looks awesome i wanna see it all laid out....

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