damn this is so clean! and by the way a few at the dealer are interested in seeing this when it's all done.
Trust me, it's got it's flaws; nowhere near a car like Robin's. It's getting there, and will be a good build when done for sure, but I'd consider it more of an ultra clean driver than full on show car.
I gave up on chemically stripping and sandblasting the D90's myself and dropped them off at Blast Tech today. I just don't have the hours and hours needed to finish stripping them down. I'll still powdercoat them myself. Effing Porsche used some kind of epoxy primer that WILL NOT come off with any aircraft stripper I've tried or the mediocre sand blaster I have access to.
After some initial success at the junkyards looking for parts, I've been coming up dry lately. Still need an UNFADED drivers side front door handle; really don't want to spring the $$$ for new, but might just have to (and then get to re-key it to match; not messing around with multiple keys for door/ignition/etc).
Last edited by jaystone; 09-14-2011 at 10:00 PM.
I do powdercoat my own stuff, perk of being an adjunct professor and graduate from the Product Design program at MSCD. Unfortunately, I don't have the spare time to do something as big as a wheelset. Powder is about $15 per wheel, and stripping to metal is about $40 per wheel by Blast Tech. At that rate with all the running around, you're better off just having Woody's do it all.
Working on the intake manifold and some other stuff today. Photos later.
Last edited by jaystone; 09-17-2011 at 09:34 PM.
As usual, sorry for the crappy cell phone pictures.
Oil pan is installed. Trunk is aligned better. Got the serpentine belt installed. For some reason the alternator pulley wasn't aligning up with the ribs from the tensioner, ended up machining 6.5mm off the back of the pulley to align the belt (have a spare pulley if it doesn't work out right).
I also put on the sideskirts after having to bend out the body seam under the rockers. Need to scrounge up some more screws/plastic nutserts to finish up.
The plate for the underside of the intake mani got fit today, going to weld it up tomorrow.
Lastly...popped the top on my latest batch of homebrew IPA. What can I say, I like to do things myself
Last edited by jaystone; 09-17-2011 at 09:35 PM.
Finished up the intake manifold today, welded in some recesses in the bottom to make clearing the spark plug wires better. Also added a little detail on the side near the oil filler where the throttle cable cutout in the valvecover didn't align with the edge on the manifold. Cell phone battery died, so no photos tonight.
Had to order more powder for powdercoating, don't have enough to do all the wheels. Going to try and use what powder i have left to finish the intake manifold/valve cover/last charge plumbing. The company I got the brake lines from is being super cool and sending me a pair of correct front lines. The boost, A/F, oil pressure gauges I'm trying to source aren't in stock anywhere. Going to keep looking.
Need to get a bubble flare tool so I can finish up the hard lines. Also need to start picking up the parts and supplies to do the wiring.
Lastly, and more of a reminder to myself in case I lose my list, I need to source the following miscellaneous parts;
drivers door handle
passenger rear speaker grill
trim screw for plastic windshield trim (passenger side far right)
rubber seal around trunk key lock cylinder (between taillights and cylinder)
rubber grommet into trunk lid that VW logo pops into
front fender liner hardware (screws/plastic nutserts)
sideskirt hardware to pinchweld (screws/plastic nutserts)
hardware (scews?) for top edge of front bumper
Installed the 3 good door handles I've got with new rubber seals. Worked on some interior stuff. Thinking about yanking the headliner, this one is vintage 1995 gray with 16 years of dirt. Picked up wire, connectors, heat shrink, flare tool, bender, and battery terminals. Ordered a battery mount for the trunk. Hoping to powdercoat the manifold, valve cover, and misc boost tubes this weekend.
Picked up a bunch of miscellaneous hardware at Metal Movers. Also got a door handle for free. Gotta see if a passenger side door handle will work on the drivers side; anybody know for sure?
Class tonight, double work day tomorrow. Hoping to get some stuff done this weekend.
Valve cover and intake manifold ready to powdercoat. Detail work on the intake to valvecover alignment near the oil filler/throttle cable recess done. Had to do a bit of work on the valve cover and underside of the
intake to not squish the plug wires. The insulation is a lot thicker than OEM wires.
Going to powdercoat today I hope.