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    Thread: Insan3's GTI Build

    1. Member Insan3Vr6's Avatar
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      07-13-2011 11:09 PM #1
      Bought the car in October 09, loved it. 1998 T-Red GTI w/ DE leftovers. CEL came on the second I rolled out of the used dealer I bought it from, knew I was in for it This is a glimpse from the two years ago, to today with my car, so if you don't want to read, look at the pics.

      The day I brought it home:



      Strong VR, no mechanical issues, just needed an ignition switch and 02 sensors and was good to go. Deleted res on the exhaust gave it a great sound. At the time HS and barely a part-time job didn't give me much 'play money', but I managed the little things over time like smoked side markers and eventually smoked ecodes.

      Center dummies fell off


      Went through 2 Jersey winters so far, and the winter won. Rust got beyond bad, and got to the point of where it wasn't structurally safe anymore.


      This was after hitting a nice pothole caused by the weak pavement after the snowstorm:


      Car sat for a week or so until I could drop the extra cash on a replacement panel and then labor (don't want to talk about the price) But I was far too attached to the car at this point.

      All done:


      Threw in my Jahre belts:



      THEN the transmission went, could have avoided it, but my cheap ass didn't want to buy the bit to check the trans fluid, lesson learned But I got a used trans w/ a bonus B&M short shifter for a good deal and with the help of vortex got it all swapped and buttoned up, even got the billet shifter bushings while I was at it (SO WORTH IT).



      Fogs filled with water, so this was a cheap fix to my lack of fog lights, and pretty much how the car sits today.


      Now I'm hooked. Loved working on it before, but now I want more. Made the car last for another winter while I hoarded parts to rebuild the motor, along with coilovers and some go fast goodies. Also threw on some Passat bottlecaps and Inpro smoked tails. No point in installing suspension or go-fast stuff since that rust I was talking about? Got worse.





      Floor is completely fked, holes everywhere and bending down on the driver side, pass side needed love too. Fenders / fender wells had holes, both rockers went bent to hell (covered by sideskirts) and rusted, hatch was rusted behind plate tub, and the gas cap started bubbling up.








      THEN I found a DIY thread for the rockers, which is how I got in contact with Bob (silentdub on here) and when I can't say enough about what this guy can do with bodywork. Truly phenomenal. Awesome guy and he did an excellent job on EVERYTHING. The pics speak for themselves.











      So then I got it back home, ready to swap the motor from my recently purchased 96 GTI (brother's old car, he bought a 2011 GTI so I took his mk3 off his hands, lots of motor work done).

      I figure instead of taking the time to rebuild my VR, why not take one that has already been rebuilt a few months ago and swap it into the red one? Makes sense to me, so I proceed.





      Crane, meet motor:


      Out:



      That's as far as I got for now, I'll be working on it more tomorrow so I'll keep this thread updated. Plans for this season is to give it a nice T-Red respray and get the new motor running perfect. Next season is boost. My other GTI is in the background in the last pic, You'll see me at WF


    2. Member fatboyvw's Avatar
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      07-13-2011 11:27 PM #2
      hey i thought i was the only one with a SMASHED rocker
      I My MKV

      I Root

      InstaGram: euro_addiction

    3. 07-14-2011 10:38 AM #3
      I'm glad you are happy with my bodywork. That hood had more waves than a god damn ocean. I think we got them all though.


      Anyone with an MKIII with rotted rocker panels, the rockers are not the only thing rotted! The floor and other mount points are rotted too.

      This car took a lot of bodywork. The two lower fenders were rotted, wheel wells had hole, wheel well lip was blasted, gas cap area was lasted.

      New rear floor pans, structural support was replaced as well.

      While I was working on that and waiting for stuff to dry, we went ahead and fixed all of the dings on this car. The sides look like someone played morse code down each body line.

      The roof was in perfect condition and required 0 work though.
      alldubsconsidered.com

    4. Member tauntedmonster's Avatar
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      07-14-2011 11:44 AM #4
      Quote Originally Posted by silentdub View Post
      Anyone with an MKIII with rotted rocker panels, the rockers are not the only thing rotted! The floor and other mount points are rotted too.
      How do you normally go about replacing rockers? Floors are pretty straight forward, but do you source new rockers or search for a donor car?

    5. Moderator root beer's Avatar
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      07-14-2011 11:56 AM #5
      Nice!

    6. 07-14-2011 01:08 PM #6
      ECS sells replacement rocker panels. Check it out.

      http://www.ecstuning.com/Volkswagen-...ker/ES2180509/

      They also sell replacement wheel arches.
      96 GTI VR6.

    7. Member tauntedmonster's Avatar
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      07-14-2011 09:35 PM #7
      $33? You ****ing kidding me?


    8. Member Insan3Vr6's Avatar
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      07-14-2011 11:28 PM #8
      Quote Originally Posted by fatboyvw View Post
      hey i thought i was the only one with a SMASHED rocker
      USED to have a smashed rocker, USED to

      Quote Originally Posted by silentdub View Post
      I'm glad you are happy with my bodywork. That hood had more waves than a god damn ocean. I think we got them all though.

      Anyone with an MKIII with rotted rocker panels, the rockers are not the only thing rotted! The floor and other mount points are rotted too.

      This car took a lot of bodywork. The two lower fenders were rotted, wheel wells had hole, wheel well lip was blasted, gas cap area was lasted.

      New rear floor pans, structural support was replaced as well.

      While I was working on that and waiting for stuff to dry, we went ahead and fixed all of the dings on this car. The sides look like someone played morse code down each body line.

      The roof was in perfect condition and required 0 work though.
      Can't say it enough. Phenomenal work = understatement.

      Quote Originally Posted by root beer View Post
      Nice!
      And a to you for helping out in my trans thread last season.

      Quote Originally Posted by LambertJohn View Post
      ECS sells replacement rocker panels. Check it out.

      http://www.ecstuning.com/Volkswagen-...ker/ES2180509/

      They also sell replacement wheel arches.
      ECS didn't have them ready to be shipped when I bought mine, I got them from shermanparts for like $66 per side + shipping. It's the same brand so getting them from ECS now is a STEAL for them. Fit perfectly.

      Didn't get much done today, because I decided to go to the beach instead. Managed to get the front crossmember down to check the frame rails for rust. There's some, but it's not too bad.

    9. Member Insan3Vr6's Avatar
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      07-17-2011 02:21 PM #9
      Got some BFI .5's at Waterfest My stock mounts are SHOT motor used to shake like a mother.



      Been lazy with the car last 2 days, went fishing today Gonna take my grinder to the frame rails shortly.

    10. Member Insan3Vr6's Avatar
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      07-21-2011 02:08 PM #10
      Some progress. No more AC! Anyone know if I can leave the piece by the firewall open like that?




      You can see the rust on frame rails, so I took it down to bare metal and hit it with rust inhibitor.




      Had to get the underside of the rails also.

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      07-21-2011 03:39 PM #11
      damn you really fixed this up! i REALLY need to fix my rockers, they are so rusted out just dont think i'm that experienced at welding yet to take on that task.

      Looks good for all the work

    12. Member PKstrategy's Avatar
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      07-21-2011 03:48 PM #12
      this is super inspirational.
      Good work, Evan.
      and Bob, silentdub, will certainly be calling on you for body work stuff when my build starts, if ever.

    13. 07-21-2011 05:00 PM #13
      Quote Originally Posted by tauntedmonster View Post
      How do you normally go about replacing rockers? Floors are pretty straight forward, but do you source new rockers or search for a donor car?
      Nah, klokerholk makes replacement rockers, hell they make all the replacement parts for dubs. They are located in Holland or some country like that.


      The problem is, when the rockers are shot, the metal behind them is usually screwed up too. The rocker panel is just cosmetic, nothing structural about it, the steel behind it is a structure piece and you need to ensure it is good.
      alldubsconsidered.com

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      07-21-2011 05:08 PM #14
      Quote Originally Posted by silentdub View Post
      Nah, klokerholk makes replacement rockers, hell they make all the replacement parts for dubs. They are located in Holland or some country like that.


      The problem is, when the rockers are shot, the metal behind them is usually screwed up too. The rocker panel is just cosmetic, nothing structural about it, the steel behind it is a structure piece and you need to ensure it is good.
      yah, i dont think its all that messed up but what do i know without cutting into it. anyways just look at afazz build thread

    15. 07-21-2011 05:13 PM #15
      Quote Originally Posted by PKstrategy View Post
      this is super inspirational.
      Good work, Evan.
      and Bob, silentdub, will certainly be calling on you for body work stuff when my build starts, if ever.
      Yeah, I'm game. If anyone needs some work done, I'm in Newark De.

      I work out of my house, this is a side thing. I just need whoever to plan accordingly since I only have so much space. I just got a Pontiac G5 in that hit a deer, so this is what I am working on now while rebuilding a 1.6 Diesel.

      here's a link to my 1st MK3 Rocker Job. http://www.mk1dubz.com/forums/showthread.php?t=642


      That car took me 3 months. New Rockers, Floors, Dent/Ding removal, Shaved door handles, Shaved rear hatch, Shaved license plate area, gas filler, Shaved the side bodyline as well as the gutters on the roof, all perfectly smooth.

      Oh, we also modified the hood.



      The hood follows the contour of the car and covers the headlights. This took a little bit to get it right. There were two bends in it, so it took some time.

      Don't even ask me how much, because you probably couldn't afford it, that entire car was a major project.


      Oh, forgot to mention I also had to replace the rear QTR panel as well as the inner wheel well.
      Last edited by silentdub; 07-21-2011 at 05:20 PM.
      alldubsconsidered.com

    16. 07-21-2011 05:17 PM #16
      Quote Originally Posted by D R E A M View Post
      yah, i dont think its all that messed up but what do i know without cutting into it. anyways just look at afazz build thread
      I like what you did with the wheel well repair. Good Stuff.

      Looks good.
      alldubsconsidered.com

    17. Member Insan3Vr6's Avatar
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      07-21-2011 08:39 PM #17
      Quote Originally Posted by PKstrategy View Post
      this is super inspirational.
      Good work, Evan.
      and Bob, silentdub, will certainly be calling on you for body work stuff when my build starts, if ever.
      Thanks PK, you need to get back on to your own GTI

      And Bob, that hood came out cool, I wanna see that one when it's all done.

      Today I finished up all the rust on frame rails, primed and good to go. I went to take out the downpipe / exhaust and it seems my only options are cutting my exhaust and re-welding or dropping the rear beam.

      Wish I could just pull the fker out

    18. 07-22-2011 11:43 AM #18
      Actually Evan, the hood is done, it was actually sitting up against the wall when you were here. I should have pointed it out to you.

      hell it would have been easier to just swap hoods with ya! Your hood had more waves than the ocean.
      alldubsconsidered.com

    19. Member Insan3Vr6's Avatar
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      07-22-2011 04:39 PM #19
      Quote Originally Posted by silentdub View Post
      Actually Evan, the hood is done, it was actually sitting up against the wall when you were here. I should have pointed it out to you.

      hell it would have been easier to just swap hoods with ya! Your hood had more waves than the ocean.
      Really? I'll check it out next time (if it's still there). I wish I jumped on the $40 OEM hoods when they were still available, prob woulda saved you a ton of work. Looks just as good now though!

      Replaced my steering rack boots when I did the R32 / poly control arm bushings, but the passenger side boot is all ****ed up again. So I ordered another boot and got some poly sway bar bushings while I was at it. Found out that I didn't have swaybar bushings at all That explains some really dumb noises.

      Also decided to keep my current exhaust / dp on there. It's gonna be changed when I boost it next season so I'm not going through the hassle now.

      Now I have to start unboxing everything I have hoarded over the winter.

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      07-22-2011 05:03 PM #20
      nice

    21. Member 95jetta17's Avatar
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      07-22-2011 05:12 PM #21
      good work....in for this
      OG suede

      I survived epic thread 2011 never forget 11/11/11
      Quote Originally Posted by vastxpunk View Post
      You have a harness you forgot to plug back in, and you want to know where it goes? Back where you found it would be my guess..

    22. Member Insan3Vr6's Avatar
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      07-22-2011 10:02 PM #22


      Ah love me some BNIB parts, this isn't even all of it

      It's 10pm and 90 degrees out, not trying to pass out under my car. I got as far as taking the passenger tire off and started removing the tie rod when I said f-it. Tomorrow is another day.

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      07-23-2011 03:12 AM #23
      watching this

    24. Member EL CAPO's Avatar
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      07-23-2011 03:42 AM #24
      any more pics of the hood process?.... apreciate it....

      good luck bro

    25. Member noodlesdefyyou's Avatar
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      07-23-2011 03:51 AM #25
      Quote Originally Posted by Insan3Vr6 View Post


      Ah love me some BNIB parts, this isn't even all of it

      It's 10pm and 90 degrees out, not trying to pass out under my car. I got as far as taking the passenger tire off and started removing the tie rod when I said f-it. Tomorrow is another day.
      the power here in north east ohio was shot for about 8 hours. be glad you weren't here trying to do this work with no ac or power whatsoever.

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