Build Thread: Victoria, my 1990 Jetta GLI

[Volkswageneer1990]

I just got the same exact radio lol, but I think I put mine behind the little dashboard cage thing, It's all wobbly back there, I gotta fix it and take pics . This weekend I plan to tackle my fog lights

I love the radio! I used to use one of those crappy cassette adapters and now I use the AUX cable. SOOOOO much better quality!

Let me know if you need any help with the fog lights!

That;s normal, why would you want to be blinded by an unnecessarily bright light?

It looks crappy and dim. I like Christmas tree dashboards where everything is illuminated. But since it's supposed to be like that I can't complain.


Ok, well sad update today

I was planning on installing my 50mm Manifold today but then I found out that I need even MORE parts than I originally planned

It seems that now I need rubber O-Rings because you are supposed to replace them every time you take out the injectors. How freakin nice....

[jimothy cricket]

get those O-rings!

[jaxgti95]

Did you get the torque wrench? It is a MUST have! I just bought this one. http://www.amazon.com/gp/product/B00...00_i00_details

[Devinadidas15]

one tip is not to buy ****ty tools spend your money on a 70 dollar torque wrench from lowes , it wont have problems like chesp ones may have,you dont want to mess around with ****ty tools if parts have specific specs.

[jaxgti95]

one tip is not to buy ****ty tools spend your money on a 70 dollar torque wrench from lowes , it wont have problems like chesp ones may have,you dont want to mess around with ****ty tools if parts have specific specs.

A torque wrench is a torque wrench is a torque wrench. It serves the same purpose, and I've used it many times in the 2 weeks I have had it, and it works like a charm every time. I clean it after every use, set it to the lowest torque specification on the little dial, so this way the special lubricants inside spread apart when ever you adjust the torque, and I then put it back in its little plastic baggy inside the hard plastic box it came in. There, you don't need to spend 70 bucks at Lowe's for something that is the same exact tool, has the same functions, and costs way less, on line!

[Chim]

Nice build! Great attention to detail

[Devinadidas15]

A torque wrench is a torque wrench is a torque wrench. It serves the same purpose, and I've used it many times in the 2 weeks I have had it, and it works like a charm every time. I clean it after every use, set it to the lowest torque specification on the little dial, so this way the special lubricants inside spread apart when ever you adjust the torque, and I then put it back in its little plastic baggy inside the hard plastic box it came in. There, you don't need to spend 70 bucks at Lowe's for something that is the same exact tool, has the same functions, and costs way less, on line!

better safe thn sorry

[jaxgti95]

better safe thn sorry

I guess, but its the same exact tool I saw at lowe's, and I mean like literally, exactly alike. Coincidence? lol

[jaxgti95]

Updates?

[Volkswageneer1990]

Nice build! Great attention to detail

Thank you!!

Updates?

Well here it is, school has been a real bitch and I haven't had anytime to get on and update this thing but I have time right now

Ok, well I started with the 50mm conversion, but 1 out of the 5 bolts securing the lower manifold to the head is stripped. It seems that the previous owner did some stuff with the engine and wasn't careful enough NOT to strip the head bolts

So before I continue here is a question: How do I remedy the stripped head bolt and get the lower manifold out?

Here are some pictures of the beginning of the conversion when we took out the injectors.





Well since that was a dud, the car kinda took a break for a couple weeks. Then this past weekend I put on the drivers side CE2 Underdash tray which is pretty rare here in the U.S.
It was like Christmas morning when I opened the box with it in, I was so excited!!

But then the going got tough with the kneebar brackets. We were able to remove 3 out of the 4 bolts that secure the kneebar brackets using PB blaster and a breaker bar. But then the forth decided not to cooperate and it ultimately got stripped.

So then at that point we went down the list with our options. 1) Make it a Hex head using a dremel sander. 2) Make it a deep flat head screw with the dremel sander again. 3) Drill into the bolt and remove it using a backwards thread bit that when you tighten the bit, you actually loosen the bolt.

We tried 1 & 2 with no luck so 3 was our last bet. It took us about 2 hours to take out the damn thing, but here is what's left of it.

The one on the top is the one that got stripped and was drilled:






And finally, some traditional Before and After pictures of the CE2 Underdash tray installation.








Then over the week I recieved the missing drivers floormat from my Mk3 set that I put under the Mk2 set to further protect both the carpet and the Mk2 mats.

It might be worn, but it does its job since it's not really seen and since it has the spiked rubber underside.





And then today I recieved a Westy Grille complete with emblem and lower metal strip that I plan to trade for something very special...

This picture is mainly for the Westy enthusiats out there. The order of effects are Normal, Vintage, and then Vintage Warm. All taken using an HTC Inspire. Enjoy






That's all for now, carry on.

[Hater GTI]

[20th#726]

So before I continue here is a question: How do I remedy the stripped head bolt and get the lower manifold out?

I had the exact same issue on my 16V with those allens stripping easy. I went to sears and bought the 5 piece bolt out set similar to these. This is the 14 piece kit, they should have a 5 piece kit. http://www.craftsman.com/shc/s/p_101...1&blockType=L1

Do NOT get the low profile ones. The heads of them don't fit in tight spaces when you have a bolt that is set down.

[cdiddydo]

those things are such a bitch, find just letting it soak in pb blaster is always a good bet, maybe a bit of heat if you can get in there, also try tightning it a tiny bit so the pb gets into the threads then it should come losose

[steveo27]

ive always liked the CE2 trays

[Devinadidas15]

the things i do to take a striped bolt out
1) use the allen and tap into the bolt to get some power on it
2) use a vise grip
3) get my dads revise drill bit set ( works everytime)

when bolts get stripped or wont turn its seems to me that its always the head of the bolt that is stuck not the thread it self . oh and before putting new bolts in or the same ones buy some anti seeze and spread it on the threads, youll be able to find it in any auto parts store.good luck

[Volkswageneer1990]

I will be tackling the stripped head bolt tomorrow, so stay tuned for that.

In the meanwhile, I made some huge progress yesterday and today.

I installed the passenger side tray (the one I had was for European A/C cars, so it didn't fit mine)




Then I went to work on installing a Hanging Center Console. I love it!!




Now because I have cruise control, I had to relocate the brains and the relay that goes with it. I found a way to sort of get a screw and put it to where it holds up the brain. It is not screwed into anything (the less holes the better) it is just blocking the brain from falling.

However, I do have a question: Is it detrimental that the brain partially covers half of the lower air vent?








In addition to working on the inside of the car, I got to work on putting the fog lights back on the car after about a month without them.

I put together the assembly, using dielectric grease to ensure a good seal, and I also used some JB weld on the broken tab holder. Hopefully now the lights don't leak... That JB Weld is strong!!






I am also on the lookout for a Westy Grille Badge to complete the trade for a very special item...

If you have one, please let me know, I really need it!!

Here is a picture for comparison:




Cheers!

[VDub2625]

Heat will probably be bad for it, yeah. Stuff it somewhere above the VAG Service pocket, there's room.

What do you mean "for European AC cars"? There's no difference.

[Volkswageneer1990]

Heat will probably be bad for it, yeah. Stuff it somewhere above the VAG Service pocket, there's room.

What do you mean "for European AC cars"? There's no difference.

Ok, I will be looking into that. Sounds good.

And by that I mean that the passenger underdash tray that I got with the pair did not fit my car. My guess is that it is for Non-A/C cars even though the guy I bought it from said it wasn't....

Here's a pic of the passenger side that I got:




Anyway, I got two things in the mail that completely MADE MY DAY!

The first, an already cut power window center console that (as you see below) I plan on mating on the bottom of the hanging console.

So here's a little DIY (unfinished though) on retrofitting the Hanging Console to a power window car.

Start with the cut center console. You can cut it up as much as you want, just leave about 6.7cm worth of space between the top (which will be come the bottom) of the console, to the bottom of the switches.



Next, cut up just to the very top line of the ashtray.



Now test fit and see how it looks





I want the switches to be tilted up toward me instead of pointing toward the back of the car, so I will need to cut a bit more, and plastic weld some pieces on to make it flush with the Hanging Console.

TO BE CONTINUED.....


And the second thing that made my day, I got a future project in the mail from Germany!! Passat B2 Headlights that I plan on retrofitting onto the car







And a pic for all the westy lovers out there, I am officially a parts whore...




More progess to come tomorrow.....

Enjoy!

[$westmoreland$]

Love the last pic, possible to choose one set up???

[VDub2625]

And by that I mean that the passenger underdash tray that I got with the pair did not fit my car. My guess is that it is for Non-A/C cars even though the guy I bought it from said it wasn't....

That is a non-AC tray, the smaller version. There's also a larger version. Both came on both sides of the pond.

Console seems interesting... just don't cut /attach anything to the hanging console

[Volkswageneer1990]

Love the last pic, possible to choose one set up???

Haha, well the one closest to the chair may be coming to you soon

That is a non-AC tray, the smaller version. There's also a larger version. Both came on both sides of the pond.

Console seems interesting... just don't cut /attach anything to the hanging console

Ahh, gotcha now, thanks!

And yep here are some updated pictures, I got a lot more sanding done and it sits a lot better.

And the only thing that I will be doing to keep it in place is some double sided tape on the bottom to attach it. I would never dream of cutting up one of these things!


Here are pictures of more progress:

Continuation!:

Sand down the new top to make it level



Then start sanding inward towards the bottom to how ever you feel you want it at. A lot of test fitting is required to get it how you want it. This is how much I needed to sand to have the switches pointing upward at me.



Then, as previously stated, test fit! This is my finished test fitting:



Then look at the mess you made
Btw, the tools I used are what you see, the Dremel cutter, and a coarse/fine cast iron sander (particularily the curved/flat one [the one without a blue handle])



TO BE CONTINUED....


Then yesterday, I got to work on boxing up a Westy front to ship to France for a special trade....

It is so hard custom making boxes for these things, but I think I managed to keep it sturdy and safe

[jaxgti95]

LOL loving the french caution

The only thing I don't really like is the cutting up you're doing. Doesn't that defeat the purpose of the hanging console? But I guess you had no other choice because you have power windows, I have manual windows Can't wait to see the special trade!!!

[Volkswageneer1990]

LOL loving the french caution

The only thing I don't really like is the cutting up you're doing. Doesn't that defeat the purpose of the hanging console? But I guess you had no other choice because you have power windows, I have manual windows Can't wait to see the special trade!!!

Haha yeah I want to make sure that wherever this is going, they understand that it is very fragile!!

And I am not cutting up the Hanging Center Console at all, I would never dream of that. All I am doing is just adding a lower power window plate from a normal console and putting at the bottom. Maybe attach it with some double sided tape or velcro.

And I can't wait either!!!

[Mean 'n Green86]

a lot of nice progress since i last checked. i like what your doing with the console

[Heidelberg2az]

Great progress so far. I still need to find a westy setup for my jetta

[Volkswageneer1990]

a lot of nice progress since i last checked. i like what your doing with the console

Thanks! Now all that's left is making it look flush with the Hanging console

Great progress so far. I still need to find a westy setup for my jetta

Thanks! And yeah, I got pretty lucky to find three at great prices

[Volkswageneer1990]

Ok, it's been a while since I've checked in, but I have gotten A LOT of stuff done!

Here is a continuation of the hanging console power window install.

Last Continuation!

Take a piece of paper, and kind of sketch the parts that you need to make it look flush. I put a flashlight on the other side of the console that I was working on so that the shadow would help me draw the lines.




Now I went to the junkyard last weekend and got some pieces of a side of regular console. Using those pieces I cut out the pieces I needed according to the paper.




Here's a picture of all four.



Now take a soldering iron and start plastic welding the pieces on to the cut power window console. Warning: These fumes WILL give you a headache for a good part of the day!!






And here's where you're at



Now it's time to test fit and see how it looks. I warn you now, there will be countless times of going to where you are soldering and back to the car for this project. Test Fitting is KEY!





Now since I have OCD when it comes to this car, I HATE the gap between the side pieces and the console.

So I went and plastic welded more pieces on to make it flush. Also note that I took off the tab looking things on the drivers side. Turns out I didn't need them.





I also wanted it to look level with the general line of the car, so using the side mat (idk how else to call it?) I made it look level according to that.

And after all the plastic welding, test fitting, and headaches, here is the final product. I'm going to look into how to make it look like it wasn't plastic welded so much... Any Suggestions to making the sides look better?







And with the switches, I have a wierd cool thing going on. Haha, its not a problem, infact I like it but the two outer switches come on when you turn the key to the 2nd position. Then the inner three switches come on when you turn on the lights. And the two outer have a greenish light to it, and the two inner (power window) have a tealish light to it. So it's a half and half ratio. I like

So that's one project down.


Now in other news, here is what I traded 2 Westy Setups for.... DRUM ROLL PLEASE!!






It's a COMPLETE DIGIFIZ 8k setup with uncut CE2 Wiring!!

I was just jumping all over the place when I got it.

And now added to the bottom of my list below, you can see another project that will take place.


Here's my list so far:

Paint Rims
Reblacken Exterior Plastics
Fix Spoiler
Fix Washer Jets
Install 50mm Manifold
Paint Alternator
Fix Foglight Switch Light
Fix HVAC Faceplate Light
Fix Shorted Wires
Fix Lights Buzzer
Fix Seat Motor
Fix Seat Bolster
Fix Glove Box Light
Shifter Rebuild
Liquids Reflush
New Brakes
Sound Deaden
Replace Carpet
Undercoat Wheel Wells
Undercoat Underbody
Clean Trunk Carpet
Install Subwoofer
Install Trunk Net
Replace Exterior B-Pillar Decals
Install Duostyle Gauges
Backlight Gauge Cluster
Re-upholster Door Cards
Re-upholster Seats
Re-do Headliner
Re-do Sunvisors
Twist Drivers Seatbelt
Fix Flickering BRAKE Light
Fix Seatbelt Warning Light
Relay Headlights
Explore Idea of LED Tailights
Replace Plate Lights
Organize Fusebox Wires
Engine Rebuild
Transmission Rebuild
Polish Rims
New Tires
Install and Modify Hanging Center Console for Power Windows
Repair P/S Map Pocket
Fix Rear Drivers Window Regulator
Align Drivers Window
Replace Door Seals
Replace Vapor Barriers
Install DIGIFIZ Setup


That's all for now, I'm going to be installing the 50mm Manifold next weekend (3 day weekend for good friday) so stay tuned!

Enjoy!!

[audi80Quattro]

Doesn't this defeat the whole purpose of the hanging console though?

[VDub2625]

Sand, filler, paint in texture.

[Volkswageneer1990]

Doesn't this defeat the whole purpose of the hanging console though?

Well I didn't want to cut into the actual console for fear of it being a sacrilege so this is all I had left. It's still the same console, just with switches at the bottom.

Sand, filler, paint in texture.

[audi80Quattro]

Well I didn't want to cut into the actual console for fear of it being a sacrilege so this is all I had left. It's still the same console, just with switches at the bottom.

But you lose the whole allure of the hangy-ness of the console. I applaud your inventiveness, and I don't want you to misconstrue my comment as dislike, I think it looks cool. I'm just saying you no longer technically have the look of the hanging console. But what else could you do with the switches? I can't thing of anything.

[Volkswageneer1990]

But you lose the whole allure of the hangy-ness of the console. I applaud your inventiveness, and I don't want you to misconstrue my comment as dislike, I think it looks cool. I'm just saying you no longer technically have the look of the hanging console. But what else could you do with the switches? I can't thing of anything.

No no I gotcha, thanks for the comment, I didn't take it as a negative one. And yeah I thought about that too, how the "Hanging" part of the console has been essentially lost but this is what I thought about doing.

I could have put the switches in the VAG Service pocket on the Underdash tray but I like having my manual and insurance stuff there.

Cheers!

[jaxgti95]

Wow man, that is such an AWESOME trade! How are you gonna wire it up and stuff? It's also in KM/H, how you gonna watch your speed?

[der hauptmann]

I just read this whole thread. I wish I'd gotten started at 16. Solid work.

[Volkswageneer1990]

Wow man, that is such an AWESOME trade! How are you gonna wire it up and stuff? It's also in KM/H, how you gonna watch your speed?

Yeah it is! The wiring is CE2 so its just plug and play.

As for the speed, I will just remember that 64km/h = 40mph, 72km/h = 45mph, 80km/h = 50mph, 112km/h = 70mph, 120km/h = 75mph, 128km/h = 80mph

I just read this whole thread. I wish I'd gotten started at 16. Solid work.

Thanks a bunch!


Ok, so I got some work done on my Passat B2 Headlight install.

I cut the posts, or whatever you call them, and bent it down, then hammered it out to make it flat. Now the headlight brackets for the Passaat headlights fit.