Figured I'd share my Daily Driver build with my friendly locals :)

[.T.o.n.y.]

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.

[.T.o.n.y.]

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

[jazzcat2001]

[MrRline]

Looks good. man that interior looks uncomfortable though. Like sitting on a sheep during a hot day.

[jhayesvw]

now swap out that auto trans

[101vet]

The AEG exhaust is freaking sweeeeettttt, if the problem child stays around might pick one up....

[MAtkisson]

now swap out that auto trans

I think he already did. I'm pretty sure this is the auto trans that I installed in my Daughter's 97 Jetta.

[Jettin2Class]

Looks like the makings of a nice daily driver. No rocket ship by any means, but certainly an improvement in the MPG department.

[muttonchops]

Wow...you did some work son!! Isnt it amazing what a drop and some wheels will do? Its a completely different car. I miss my mk3

[.T.o.n.y.]

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.

[.T.o.n.y.]

I think he already did. I'm pretty sure this is the auto trans that I installed in my Daughter's 97 Jetta.

Yep, how did that turn out?

[.T.o.n.y.]

Looks like the makings of a nice daily driver. No rocket ship by any means, but certainly an improvement in the MPG department.

Well.... for the summer yes, but i'll be mounting this come September-October

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

[VR6 NRG]

looks good Tony. nice job

[Jettin2Class]

what a cute little turbo!

[jhayesvw]

now thats better.

with the turbo it will be a very fun car that still gets good mileage and good handling.

[vortexpert.]

that shop looks like ****

[MAtkisson]

Yep, how did that turn out?

Well, it is still a VW Auto trans.... As a whole it turned out good. The trans I got from you is a lot better than the one I pulled out, but it has some minor issues. I have noticed some issues with the 2-3 shift. The revs start to climb after it engages 3rd, then drop 3-400 rpm before starting to build rpm again before shifting into 4th.

I have topped off the fluid and reset the adapts to see if that will help. I'm hoping it will get better as it gets driven around town. My daughter hasn't really said anything about the shifting, so I will probably run it until it dies.

[.T.o.n.y.]

what a cute little turbo!

Haha i agree but i want a quick spool and dont plan on revving to the moon in every gear ( daily ) because this was my last build.

[.T.o.n.y.]

Well, it is still a VW Auto trans.... As a whole it turned out good. The trans I got from you is a lot better than the one I pulled out, but it has some minor issues. I have noticed some issues with the 2-3 shift. The revs start to climb after it engages 3rd, then drop 3-400 rpm before starting to build rpm again before shifting into 4th.

I have topped off the fluid and reset the adapts to see if that will help. I'm hoping it will get better as it gets driven around town. My daughter hasn't really said anything about the shifting, so I will probably run it until it dies.

Hmmm, yeah i would check fluid level because it drove great before pulled, but i just cant handle automatic. I need a clutch pedal and my choice of gear lol.

[.T.o.n.y.]

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.

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.

p.s. I finally power washed the engine bay too, hoping to have 50% of the current wiring removed/relocated once im done.

[MAtkisson]

What did you do with the stock exhaust? The muffler on mine is falling apart.

What are your plans for the stock wheels?

[urbancynic]

A lot of good stuff going on here. Just something I love about a clean white mk3 Jetta.

[.T.o.n.y.]

What did you do with the stock exhaust? The muffler on mine is falling apart.

What are your plans for the stock wheels?

Sorry man i put the stock exhaust and wheels on my girls GLS

[j-dub]

Nice build up, I am really enjoying all the details you are providing.

[VWnutAZ]

Nice build up, I am really enjoying all the details you are providing.

X2

[fatboyvw]

[jhayesvw]

Tony,
You always do a thorough job on your builds.
Keep it up.

[.T.o.n.y.]

Thanks guys, 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

[.T.o.n.y.]

Decided to make my own turn signals with a twist to help match my E-codes better.


5 amber LEDs per turn signal as "driving lights" to match the LEDs i put in my E-codes plus i want them to look a bit more modern.


Removed the amber lens and blacked out the inside for that "E-code" look






Started working on the harness


Almost complete


All done


Then took my DA with 600 grit to the clear lenses until all the pitting and "Hella" markings were gone. Once done i took it to my bench polisher with Meguires PlastiX for a completely clear lense


This picture came out bad but once the cars done i'll have more detailed pictures with a much better camera. This is with all the LEDs lit & my BFI brake ducts installed. ( i know people hate them but oh well )

[.T.o.n.y.]

Installed my ebay special clear marker lights, got all the sun faded side moldings repainted and i put them back on the car with fresh 3M molding tape



Anyone have 12-15mm rear wheel spacers with lug bolts they want to sell me?

[jhayesvw]

nice work.
did you install the clutch reinforcement bracket into the pedal assembly?

i didnt do it for a few years but finally decided to do it a few years ago.

[.T.o.n.y.]

Meaning the bracket for the clutch master which attaches to the brake booster?

[vwnut18t]

Very nice man

[.T.o.n.y.]

Started working on my sound system, build a quick and easy amp rack, 6 channel to power the whole car.


Bought two sets of these. ( i love ebay )


Mounted them in my doors




Heres my completed battery relocation - battery is temporary as im waiting on my Optima


L.E.D battery clamp for the win


Figured id just use the factory grounding location for the late TCM for my amp & cap.


My baby looking mug


And whats left of my trunk haha, i never use it anyway since i have my truck.

[boraIV]

nice. I like local build threads!