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    Thread: Budget Blown Boosted 8v Build

    1. Member .T.o.n.y.'s Avatar
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      96' Jetta aba-t, 00' Audi A4, 01' Passat 30v
      05-31-2011 01:17 PM #1
      Well, back in September of 2010 i picked this cherry up as a flip car for some quick cash. Well after getting it home and really getting into it i decided to keep it for myself for a daily as my Hemi 2500 isnt so good on gas. Onto the pics.

      Car was in good machanical condition only had a leaking oil cooler seal. picked her up for $1500.
      1997 Jetta GLS Automatic with 131k on it





















      Nice rocker dent
      ( will get pulled eventually )













      Got the car to my shop to start on the suspension first.

      Before

      Picked up this neuspeed brace locally

      Carpet cut for fitment.



      Then dropped the subframe for an overhaul, previous owner hit something and bent the Sh*t out of the drivers tie-rod.





      Both rack books where torn so....

      Lets replace

      R32 control arm bushings, BFI poly front bushings.

      New boots, clamps, tie rod ends & drivers tie-rod.

      Subframe complete with all updated bushings ( i know the sway bar is installed upside down i realized after i took the pic ) BFI .5 front motor mount, BFI stealth rear motor mount, Corrado G60 solid rubber trans mount.

      Now on to the rear

      Rear disc conversion from a 94 Jetta. Pressed in new axle bushings then Prothane inserts.



      More brake upgrades.





      Corrado G60 front brake upgrade ( i rebuilt all calipers before installation )

      Picked up this Autotech 28mm sway bar off the classifieds. Just installed new hardware for mounting it up.

      Then installed this Neuspeed strut bar i also picked up on the forums, mounted with black allens & threaded strut towers.

      The dropped it down on my freshly refinished Borbet Type Cs. Lowered on SuperSport's 60/40 kit VR6 HD strut mounts and Prothane rear strut bushings.

      More to come...
      Last edited by .T.o.n.y.; 05-31-2011 at 01:30 PM.
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    2. Member Kabinotar's Avatar
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      96 Jetta VR, 04 R32
      05-31-2011 01:27 PM #2
      Wow. Really nice start. Car looks super clean too. Seems like you have a plan for maintenance/upgrades to make a real nice daily.
      -Kevin
      Quote Originally Posted by Afazz
      Build cars, not drama.
      Low is a Lifestyle
      CNY VW & Audi

    3. Member 2.0_Nick's Avatar
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      1997 windsor golf
      05-31-2011 01:29 PM #3
      I like the maintenance work going on here. Looks like you cleaned up underneath nicley, like the break changes
      love the paint looks clean

    4. Member .T.o.n.y.'s Avatar
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      96' Jetta aba-t, 00' Audi A4, 01' Passat 30v
      05-31-2011 01:34 PM #4
      I have a laundry list of parts to install and work to be done, but by mid-end summer this should be rebuilt & installed. but we'll get to that later after i get the rest of my pictures uploaded.

      T3 off a Saab i think, picked it up from some guy on here.



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    5. Member wannabeeuroTR's Avatar
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      05-31-2011 01:41 PM #5
      damn nice work. you make it look like its super easy.

    6. Member
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      1993/ golf/ mk3/miller/mk3 four dr golf vr6
      05-31-2011 01:59 PM #6
      trans swap?anytime soon? but nice pics and love the color

    7. Member nfx's Avatar
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      MK3 2.0T, 2013 Elantra GT
      05-31-2011 02:05 PM #7
      I've got that same turbo... good choice for an intro build
      2.0T... it's back!

    8. Member .T.o.n.y.'s Avatar
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      96' Jetta aba-t, 00' Audi A4, 01' Passat 30v
      05-31-2011 02:23 PM #8
      Quote Originally Posted by joemiller1989 View Post
      trans swap?anytime soon? but nice pics and love the color
      Yep i got a 02A out of a 1990 Passat 16v. Just rebuilt it just finishing all the maintanance before the swap begins.
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    9. Member
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      05-31-2011 02:36 PM #9
      niceee

    10. Member .T.o.n.y.'s Avatar
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      96' Jetta aba-t, 00' Audi A4, 01' Passat 30v
      05-31-2011 03:19 PM #10
      Quote Originally Posted by nfx View Post
      I've got that same turbo... good choice for an intro build
      Yeah im trying to keep it simple on this build, because this is what i ended up with my last build.






      Fully built VR-T in this



      Ended up getting rid of it as gas mileage sucked ( clearly ) no traction regardless of LSD and it spent most its life being a garage orniment.
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    11. Member nfx's Avatar
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      05-31-2011 04:21 PM #11
      Don't be afraid to drive your car man. I daily drove mine until I had to park it due to an accident and picked up a daily. Drove around in the Hyundai while fixing the MK3, and while the car isn't exactly what I want (and probably never will be), I can easily pick up the keys on my way out of the door and drive it without issue.

      When my car becomes an issue where I'm afraid to drive it (I'm really only afraid to park it places because people are *******s) I'll probably sell it. Seems like that was your problem last time. Don't let it happen again
      2.0T... it's back!

    12. Member .T.o.n.y.'s Avatar
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      96' Jetta aba-t, 00' Audi A4, 01' Passat 30v
      05-31-2011 04:51 PM #12
      Yeah 300+ horse, front wheel drive and a VR... it just wasnt practical, it got worse gas mileage than my truck. This car im looking to hopefully get 200-225whp but with a much smaller turbo and more of a progressive power band for a daily.
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    13. Member .T.o.n.y.'s Avatar
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      96' Jetta aba-t, 00' Audi A4, 01' Passat 30v
      05-31-2011 05:03 PM #13
      AEG exhaust manifold

      Inner welds ground down & smoothed.

      Header Wrap



      Crapshield cut off













      Autotech 270 cam, TT cam gear.

      OBD1 head swap, started to refresh it.



      heads straight, cleaned, deburred, new seals, AEG lifters. Valves seated and complete.

      Yanked the old head & retarded hydrolic tensioner set up

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    14. Member
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      05-31-2011 05:22 PM #15
      Great work! Love the great number of pics! Unfortunatley people never give build threads the attention the deserve here on vortex..

      That suspension rebuild has got to make everything feel so good!

    15. Member zrace07's Avatar
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      8v
      05-31-2011 05:24 PM #16
      Damn, son.
      VWfiends

    16. Member .T.o.n.y.'s Avatar
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      05-31-2011 06:16 PM #17
      Quote Originally Posted by GnarPassatWagon View Post
      Great work! Love the great number of pics! Unfortunatley people never give build threads the attention the deserve here on vortex..

      That suspension rebuild has got to make everything feel so good!
      Thanks, the suspension set up is amazing it handles so good.
      I am a Vortex build addict, click the link below to check out my builds and join in on my addiction:
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    17. 05-31-2011 07:35 PM #18
      Awesome work. Subscribed

      I remember the last Vrt build, cleaaaan.

    18. Member euro4-DoOr's Avatar
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      05-31-2011 07:57 PM #19
      Clean

    19. Member .T.o.n.y.'s Avatar
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      96' Jetta aba-t, 00' Audi A4, 01' Passat 30v
      05-31-2011 10:42 PM #20
      The rear main seal looked rough.

      So i changed it out.

      Had the flywheel lightened to 10lbs

      Kind of a Frankenstein clutch set up - Passat 02A lightened flywheel, Corrado G60 Sachs clutch disc, VR6 Pressure plate.... smoooooooth clutch pedal

      Swapped in my freshly rebuilt 02A out of a 1990 Passat 16v.

      Bolted the head down

      Cam installed, new cam seal as well

      AEG oil splash shield

      Ported AEG lower intake manifold

      Yes those are OBX 10.5mm Spark plug wires lol, new cap & rotor as well with Bosch Platinum 4s.

      Ported & polished AEG upper manifold

      Needs a re polish after handling it.

      Installed the exhaust manifold & AEG aluminum heat shield.

      Started mocking up an intake, extending MAF & IAT harness as well as modifying the timing cover.
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    20. Junior Member
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      96 Jetta 2.0
      05-31-2011 10:57 PM #21
      SUBSCRIBED

      GL on this build, will be watching

    21. Member 16v2a2vr6's Avatar
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      05-31-2011 11:12 PM #22

    22. Member
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      05-31-2011 11:37 PM #23
      great build....hope to start mine some day....but this is the daily for now till my other love gets its rebuild done.
      Your friendly VW parts master since 2004.....Do work!! then have

    23. Member .T.o.n.y.'s Avatar
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      96' Jetta aba-t, 00' Audi A4, 01' Passat 30v
      06-01-2011 03:41 PM #24
      Picked up a Neuspeed exhaust from a guy locally on the cheap off a Cabrio, i removed the center resonator and attached a VR6 cat. Then had a buddy modify the muffler to fit my Jetta

      I love it and it sounds soooo gooood for an aba.

      Since im running the AEG intake manifold now i wanted to relocate the Battery, so i did some modifying.

      Then mounted in the trunk



      Needed to figure out the cables in the bay so i decided to modify a battery fuse panel off a Turbo S Beetle

      All closed up

      Then finished mocking up my cold air intake ( three 1.8T MK4 CAI choped lol ) Also swapped in my AEG throttle cable.
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    24. Member .T.o.n.y.'s Avatar
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      06-01-2011 03:44 PM #25
      I also tried a little experiment as it worked well on my last VRT, i swapped in a 1.8T intake air temp sensor and mounted it in the cold air intake just before the MAF. Lets see how it turns out Extending the harness and hiding the wires was no big deal but im hoping it was worth it, as i plan on keeping it once i get the turbo installed later this year.
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    25. Member PKstrategy's Avatar
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      06-01-2011 03:45 PM #26
      word, shiny.
      love the work going into this.
      will be nice and solid and tasteful mods will give it that extra pizazz.

    26. Member .T.o.n.y.'s Avatar
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      06-01-2011 03:54 PM #27
      Quote Originally Posted by PKstrategy View Post
      word, shiny.
      love the work going into this.
      will be nice and solid and tasteful mods will give it that extra pizazz.
      Thanks man im really taking my time on this one, almost 80% of everything on the car i got on ebay, classifieds on here, locally, or in payment for my work. I have everything i need for the car excluding all my turbo stuff and im only $2500 invested. Im guessing maybe another $1000 to complete my put together turbo kit and im in good standing.

      p.s. I finally power washed the engine bay too, hoping to have 50% of the current wiring removed/relocated once im done.
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    27. Member
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      06-01-2011 04:07 PM #28
      looks great man. quality work.
      welcome to the layer cake

    28. Member .T.o.n.y.'s Avatar
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      06-02-2011 01:41 AM #29
      Thanks man, so i hated the way the early 02A linkage shifted so i decided to change to the newer style ( late MK3 VR6 style ) since i had an extra shift tower & cables lying around.

      Had to buy new linkage though as my tower was missing them.

      Went a little over-board with grease, but got the new reverse switch installed.



      Got some Verdict Motorsports bushings to compliment my B&M short throw shifter.

      Got my manual pedals swapped in with new return spring.

      yay for TT pedals
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    29. Member nfx's Avatar
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      06-02-2011 07:52 AM #30
      Quote Originally Posted by 2.Quick View Post
      Got my manual pedals swapped in with new return spring.
      How hard was that to swap in? Mine gets stuck occasionally on my 2.0 so I figure it needs a new one. Do I have to pull the hole pedal cluster to do it or can I do it from the floor while it's bolted in?
      2.0T... it's back!

    30. 06-02-2011 08:54 AM #31
      Hey Tony, nice cam gear

    31. Member .T.o.n.y.'s Avatar
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      06-02-2011 02:11 PM #32
      Quote Originally Posted by nfx View Post
      How hard was that to swap in? Mine gets stuck occasionally on my 2.0 so I figure it needs a new one. Do I have to pull the hole pedal cluster to do it or can I do it from the floor while it's bolted in?
      Its not hard with some patience, you can install it with the pedals in just use a long screw driver to aid in compressing the spring, flat head driver of course.


      Quote Originally Posted by kcbmxer View Post
      Hey Tony, nice cam gear
      Thanks Karl! For supplying me with one of my many parts
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    32. Member PKstrategy's Avatar
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      06-02-2011 02:24 PM #33
      Damn dude, lots of quality parts and moving quickly.
      Makes me wanna actually give attention to my 2.0

    33. Member
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      06-02-2011 02:28 PM #34
      Some clean and fast progress! Any plans for the interior/seats/steering wheel?

    34. Member .T.o.n.y.'s Avatar
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      06-02-2011 03:24 PM #35
      Quote Originally Posted by VolodkaVR View Post
      Some clean and fast progress! Any plans for the interior/seats/steering wheel?
      Yep ive got a complete parts car ( 94' Jetta ) with black interior but its missing front seats. So im planning on swapping in the black carpet & rear seats for now until i can find some decent front ones to match locally. I already picked up the black fabric for my headliner and im doing all the side pillars Satin black. As far as steering wheel goes im still open to suggestions because i cant stand driving with a worn steering wheel.
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