Build Thread: Victoria, my 1990 Jetta GLI

[Volkswageneer1990]

dam i wish i could trade my black lower grill eyebrow thing for your montana green one!

Haha, well as you will see lower down in pictures, I switched the Montana Green one for a Tornado Red Spare I had. The Monty is now on a Westy front for sale on eBay UK

Can't wait to see how the lights turn out, so far so good. to get it smooth, start with the JB Weld and get it down. rough it up and use a skim coat of lightweight bondo to finish smoothing it out. The bondo will be much easier to sand. Just use the JB Weld for reinforcement.

Thanks, I should have used something like that, but I went ahead and just sanded down the JB Weld, and well I think it came out pretty darn good. But I'll let you be the judge of that

Everytime i see an update from you i get my hopes up that the grill is on haha

Well now it is!

oh those pressure regulators suck when they go out. I just had my friend do mine yesterday. Made a world of difference on my brakes though.

I will most likely be doing mine soon. Can you please ask your friend for any tips on how to take it out? I have no idea how to...


Okayyyyy, as promised here is an update with the Passat Headlight Setup!

I sanded down the JB Weld/Some of the grille to a smooth even surface and then painted with Rustoleum Paint For Plastic Black Satin. I think it came out pretty damn good for a project on a budget.

I also switched out the Montanta Green lower metal strip for a correct Tornado Red one.






I will be test fitting the setup this coming weekend and making any further adjustments then.

Comments? Suggestions? Questions? Shoot! I love to hear 'em all!

That's all for now, enjoy

[jaxgti95]

Well done my friend, looks fantastically clean!

[NTUNED]

Looks great buddy!!

[Mean 'n Green86]

dude your great. bravo

[Devinadidas15]

any pics of the back of the lights, nice job with everything definitely going to have a nice front end and different as well

[Volkswageneer1990]

Well done my friend, looks fantastically clean!

Looks great buddy!!

dude your great. bravo

any pics of the back of the lights, nice job with everything definitely going to have a nice front end and different as well

Thanks to all of you guys, the support is what keeps my motivation high to continue on

And I wil snap a pic of the rear of the lights for you later on as well, don't let me forget!


Okay, so today, I test fitted and saw that the road to making this perfect is not yet over!

Here are some pictures, and then I'll explain what is next.







That last picture dictates what needs to be done. As you can see, the headlights point too much downward, so I will be adjusting them and most likely putting new adjustment screws on to make it point correctly. Same goes with the fog lights.


So that's that, meanwhile, I started with my Interior Refinish first before everything else. Mainly because I can have the interior off and it won't affect the ability to drive.

I started with the back seat bottom first.




And here are the fabrics I'm going to be using. It's going to be a combo.



Here are all the pieces that I cut out.



Here they are on the actual seat:



And here is the foam backing that will be placed on the fabric.




All the fabric and supplies so far have cost me $168 at Hancock Fabrics. If I reach more than $300 then I'm just going to send it to a Reupolstery shop and have it done.

That's the updates I have so far, nothing too special, just progress.

Enjoy!

[ejijah]

i was thinking about re doing my seats with leather would you recommend it? is it worth the work?

[VDub2625]

Why are you recovering the seat?

Remember, if you aim the headlights way back, the beam pattern will be awful, so it'll have to be a show-only front end...

[Volkswageneer1990]

i was thinking about re doing my seats with leather would you recommend it? is it worth the work?

Depending on the quality of the leather and your work (no offense) then it can either come out show quality and beautiful, or okay. I'm using Vinyl instead of leather. They don't sell Genuine Leather at Hancock Fabrics...

Why are you recovering the seat?

Remember, if you aim the headlights way back, the beam pattern will be awful, so it'll have to be a show-only front end...

Because the fabric of the OEM Recaros looked terrible and trashy. And if I'm going to rebuild a car, it's going to get a 100% rebuild.

Regarding the lights, what would you suggest to make them fall back (for lack of a better word) and still have funcitonality?

[VDub2625]

You can't do anything. The glass has to stay at that angle for the beam pattern to project correctly. Either recess the lights a bit more, or leave the top protruding. I don't think it'll look that odd if the grille is made to match. Maybe some body work to the fenders and hood. The Passat front end has a vertical/slightly foraward lean to it (like a Mk1), so it'll be near impossible to fit on a Mk2 directly.

[steveo27]

Neat, but shoot that grille in some trim paint

[Volkswageneer1990]

You can't do anything. The glass has to stay at that angle for the beam pattern to project correctly. Either recess the lights a bit more, or leave the top protruding. I don't think it'll look that odd if the grille is made to match. Maybe some body work to the fenders and hood. The Passat front end has a vertical/slightly foraward lean to it (like a Mk1), so it'll be near impossible to fit on a Mk2 directly.

What if I cut the metal that has the holes for the buckets, moved them back and skew them upward and then added rivets to hold them in place? Would that work? My concern is the air intake box and possibly the battery.

Neat, but shoot that grille in some trim paint

That would give it more of a Satin look correct?


Okay, update (just minus pictures right now)

I decided to scratch the idea of reupholstering my own seats. When I finished stitching the fabrics together I didn't like how it came out. So now I'm saving up to take them here:

http://tinlizzieaffair.com/

If you look on their website, they do crazy work. Ferraris, Lamborginis, Alfa Romeos and more. Its crazy. I know that when I take my seats there, I'm going to get some quality work.

I'll post pics of the cover reassembled. It isn't exactly like it was but I can live with it. I like to think of it as if I just restitched the seats.

Cheers!

[VDub2625]

What if I cut the metal that has the holes for the buckets, moved them back and skew them upward and then added rivets to hold them in place? Would that work? My concern is the air intake box and possibly the battery.

You do not understand. Think of holding a flashlight. if you hold it horizontal, the beam comes out horizontal. if you tilt it up, the beam tilts up. if you somehow modded the reflector to tilt up, but left the body horizontal, the beam will still tilt up.

Your only option is to say "**** it", or mod the front end to match the angle of the lights.

[Volkswageneer1990]

You do not understand. Think of holding a flashlight. if you hold it horizontal, the beam comes out horizontal. if you tilt it up, the beam tilts up. if you somehow modded the reflector to tilt up, but left the body horizontal, the beam will still tilt up.

Your only option is to say "**** it", or mod the front end to match the angle of the lights.

Yeah I got you, I need to adjust the headlights, but them back on, then see how they sit after I do horizontal and vertical adjustments. I'm most likely going to say f**k it, because when I put it on for real, it's going to stay on and be my headlights for however long of time.

[Volkswageneer1990]

Okay well updates!!

I got the cover of the back seat back on like I said before, but here is a picture reassembled.



In other news, I bought a 16v Cluster that had a short for an amazing price and got the functioning speedo from it. Now my GLI has the correct speedometer!!

Because I got the extra cluster, I decided to do my little project of putting in a CEL light in the blank warning light spaces. The little metal symbol display plate is OEM too! I think it came out pretty good!!

Here are pics!








I also decided to fix the short on the extra cluster I got. BTW it only had 11K miles on it so the speedo, flexible circuit, and everything else is MINT! After I fixed the short, I put in a Helios or CE1 140mph Speedo (call it what you want) that I had into it. I had to cut the top to be able to put a piece from a CE2 speedo so that the voltage regulator could mount correctly.

Here are some pictures of that!






Now I have two functioning 16v Clusters, and one with a rare CEL Cluster light

I feel like today was a good day for the car

Here is my list so far:

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
Chrome Plate BBS RA's
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
Install Passat B2 Headlight Setup
Reinstall 140mph Speedometer
Install OEM CEL Cluster Light
Install CE2 Underdash Trays
Install B-Pillar Seatbelt Outer Pillar Covers
Install Heated Washer Jets


Enjoy!

[NTUNED]

Cluster looks great buddy

if it wasn't for the oem cel plate, I would of put the light on the center lol but turned out really good

[Volkswageneer1990]

Cluster looks great buddy

if it wasn't for the oem cel plate, I would of put the light on the center lol but turned out really good

Thanks a bunch man!

Well you know me, OEM freak x15318548!


Well did a little work in the mornning, before it got ungodly hot...

I installed the last piece needed in a complete B-Pillar setup. The outer B-Pillar covers.

I only got to one side though because of the heat...

Pics!

Before:


After:


And the glue I used. It's crazy good! Got it from the Home Depot for $10!


Now I have to do the passenger side. It got too hot today.

Enjoy!

[NTUNED]

tell me about the heat,


half my work is outside and with the rain has been nice but today has sucked so far

[black gti]

any pics of the hood closed with the new lights?

it's lookin good!

[VR6 GLX Man]

Damn this is some good work. Glad this has been kept all stock, makes the car even more special when everything is kept stock and for its age aslo.

[Volkswageneer1990]

tell me about the heat,


half my work is outside and with the rain has been nice but today has sucked so far

Today was pretty nice though. I went outside around 5 to clean out my garage and put everything including the car inside and away from the elements.

any pics of the hood closed with the new lights?

it's lookin good!

Thanks!
No finished pictures yet, I'm still working out kinks and ironing out wrinkles

Damn this is some good work. Glad this has been kept all stock, makes the car even more special when everything is kept stock and for its age aslo.

Thanks so much! Yeah I am an OEM period correct freak if you can't already tell

As stated above all I did was clean up my garage to put the car inside and away from the horrible Texas sun.

I also glued on the other B-Pillar cover which finishes up that project

Here's a pic & the list.



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
Chrome Plate BBS RA's
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
Install Passat B2 Headlight Setup
Reinstall 140mph Speedometer
Install OEM CEL Cluster Light
Install CE2 Underdash Trays
Install B-Pillar Seatbelt Outer Pillar Covers
Install Heated Washer Jets

[Volkswageneer1990]

Small update:

The Passat B2 Headlight setup is still in progress. Today I took tab holders from an Aero bucket and JB Welded them onto the B2 buckets. Now the bottom corner tabs are no longer hanging freely.

Pics!

[steveo27]

[mellbergVWfan]

I wish I had my **** together like you when I was in high school. Good work so far. The Scirocco light setup looks pretty cool and unique.

[Volkswageneer1990]

I wish I had my **** together like you when I was in high school. Good work so far. The Scirocco light setup looks pretty cool and unique.

Thanks so much man, I really appreciate the comment

And thanks on the compliments on the headlights, they are actually Euro Passat B2 Headlights, but they look very similar to Scirocco

Cheers!

[killacam1111]

car looks good keep it up!!!

[Volkswageneer1990]

car looks good keep it up!!!

Thanks!

Well I did some much needed work on the brakes last night.

I blew out my Rear Brake Pressure Regulator quite some time ago and the brakes were not preforming well. However now that I replaced the Regulator and bled the brakes again, the brakes feel AMAZING!!! I can actually slam on the brakes and get some decent stopping power!

Here are some pics of the procedure




BTW: Is it okay to place the jack stand where I did?





There was brake fluid just pouring out of this thing when I got all the brake lines loose...

However I am glad that this maintence is done and has given the brake system of the car a refresher.

That's all for now, enjoy!

[VDub2625]

There was brake fluid just pouring out of this thing when I got all the brake lines loose...

Yeah, cause they were loose

That's odd that you already had the aluminum one. Must have been changed in the past. That arm looks like hell.

The jackstand on the axle is fine, for what you did (since the axle wasn't fully swung down, the arm was easy to remove). If you did any suspension work, I'd place it on the flat spot of the body, so the axle can hang down.

[killacam1111]

You can't do anything. The glass has to stay at that angle for the beam pattern to project correctly. Either recess the lights a bit more, or leave the top protruding. I don't think it'll look that odd if the grille is made to match. Maybe some body work to the fenders and hood. The Passat front end has a vertical/slightly foraward lean to it (like a Mk1), so it'll be near impossible to fit on a Mk2 directly.

You do not understand. Think of holding a flashlight. if you hold it horizontal, the beam comes out horizontal. if you tilt it up, the beam tilts up. if you somehow modded the reflector to tilt up, but left the body horizontal, the beam will still tilt up.

Your only option is to say "**** it", or mod the front end to match the angle of the lights.

just so you know i have already done this setup and you can make them fit perfectly with the grill and the body and to get the beam pattern lower after tilting the housing backwards is tilt the bulb up and it will shine the beam lower. i did it on mine and havent had a problem at all...not blinding anyone and i am able to see at night.

pics for reference


Untitled by Cam Savela (killacam1111), on Flickr

Untitled by Cam Savela (killacam1111), on Flickr

Untitled by Cam Savela (killacam1111), on Flickr

[revolution_Jd3]

snap

[VDub2625]

Angling the bulb is not something I'd suggest, but if it works...

Sent from my PC36100 using Tapatalk

[killacam1111]

Angling the bulb is not something I'd suggest, but if it works...

Sent from my PC36100 using Tapatalk

i understand it isnt 100% proper but it works and it isnt a huge difference.

[Volkswageneer1990]

Well I started on the floors yesterday. And this stuff is TIRING work!! I have to do it in my cramped garage because it's freaking 104*F outside...

But I stripped 1 of 4 floors of the car. I'm going to take out the drivers seat and work on the rear drivers floor next.

I had to take a bunch of breaks so that's how I'm naming the pictures.

Starting...


Break #1....


Break #2....


Break #3 and the floor is now completely stripped to bare metal.



That's all for now! Enjoy!

[TAG TIMER]

This build thread is awesome... I am absolutely loving the front lights

[revolution_Jd3]

remeber to re seal around the two drain plugs...good work