B4 Bomber

[15inches]

Aight so instead of bombing old threads with my own issues and flooding other thread with unnecessary posts, as I have witnessed others doing lately, I am, to the advice of some, starting my own build thread for my car, the B4 Bomber.

very short back fill:
The Car: 1996 Passat TDI sedan

Dad bought the car from a dude in SC ~10 years ago.
I inherited the car from him September '10.

Issues:
Speedo inop
Master light switch needs replacing
shifter boot and knob are severely worn
front seats need replacing - foam and upholstery worn
center console had a small fire? in the ashtray and ruined the A/C-Recirc switches along with the trim around them
Recirc switch doesnt close vents all the time to keep outside air out
A/C doesnt work apparently..?
Headliner fabric is gone
center console missing cover behind armrest for ashtray
Parking brake boot needs replacing
Cruise control inop
steering wheel deteriorating - temp fix with laced cover
need to investigate reason for rear dome lights not working
front corner lenses have detached themselves from housings from the frigid SC weather last week
front dummy inserts are cracked and faded
turn signals cracked
bumper has damage
grille trim needs refinishing
door handles barely operational
driver's window very slow to roll down
mirror adjustment knob broken at base
door strikers need replacing
2 wheels are alloys, 2 are steelies, all are bent...
driver's seatbelt doesnt want to retract without help..
brakes need replacing
pretty much all suspensions rubber needs replacing
CEL is on cuz of speedo
turbo goes into limp mode.. a lot
headlights are yellowed
clear coat peeling on hood, roof, trunk and rear bumper rub strip
rear bench seat needs reupholstering
foam bits blowing out of dash vents
huge flat dent in rear drivers side fender in front of tail lights
tail lights need replacing
shocks are bouncy
and just recently the right drive shaft started knocking. cant help it if i enjoy more spirited driving than the casual driver. :\
need to replace all of the grommets that go into the door that secure the side moulding in the doors and fenders.

Fixes:
modded air box for more cool air flow from fender side (thats where it gets the bomber sound from cruising at medium rpms) and replaced filter
Replaced front windshield because of severe pitting and wiper tracks(omg glare!)
Replaced tires with new set
Have new front rotors and pads, dad has new rear rotors
Installed boost gauge as a diagnostic tool to keep from over boosting the car while under heavy engine loads(i.e. hills)
blacking out corners (is it possible to take out the amber insert? it doesnt look like it, as it looks more like the amber part is molded together to the clear...)
ordered new door handles (all around) - installed
ordered new breather tube - installed
ordered new dipstick - slight leak around it - installed
Ordered 55w 6000K HID kit and have headlight lens resto kit

Future Works:
replace all vacuum lines***
order new suspension joint bits to tighten things up
convert to aero wipers
add side marker blinkers in place of the Wolfsburg Crest emblem.
rework corner lights to something more creative and aesthetically pleasing
waiting to order Racelands
waiting to order Konig 15x7.5 Candy's and tires
looking into BMW 3er projectors from ECS
single Borla muffler with upgrade to 2.5" tubing and perhaps a mk6 GTI dual tip setup.
volvo 940 lower spoiler or VR lower spoiler
G60 calipers and brake fluid flush
new coolant reservoir
convert to VNT turbo and upgraded injector nozzles and fuel pump
custom intake manifold with EGR toggling for inspection
custom exhaust manifold
larger intercooler or dual intercooler setup like the TT.
OEM fogs and euro light swtich
upgrade to LED bulbs all around
replace window tint
white out hood, roof, and trunk
fresh paint after fixing dent in d/s rear fender and bumper
reupholster headliner with something snazzy - perhaps orange plaid
retro fit B5 front seats
get new steering wheel
upgrade clutch and flywheel


Day 0:








Boost gauge:

[perickomx]

i'll be looking this thread.

looks clean man.

[dano17]

Damn dude, gimme that hood! ill trade you mine and a case a

[15inches]

Damn dude, gimme that hood! ill trade you mine and a case a

Whats wrong with your's D?

[dano17]

the clear is peeling.

[15inches]

lol, damn... well i could just wait to repaint the hood. it really just needs a good deep cleaning and waxing. I dont think there are any real deep scratches or chips from the once over I just gave it.

[dano17]

Yea it doesnt look bad, Im hopefully getting my car resprayed in the spring.

[15inches]

You should see my roof... its like a pair of Levis'.. lmao. The trunk is peeling, hence me wanting white, to go with the rims I showed you, too.

[rollercoasterracer]

Nice, man! I still think you should trade me for my Mk2 haha

[15inches]

Nice, man! I still think you should trade me for my Mk2 haha

eh, no.

oh, on a side note, I got my handles, strikers, breather tube and dip stick today. 2mrw is adventure day....

[15inches]

Also, I was looking at the corner marker lenses, and it appears the amber part is molded with the clear part, and there is no way to "remove the insert" as someone stated on another thread. Best you could do is Dremel grind the reflector part down to see if you can get to the clear, but then you'll have this outline left, and it will look weird anyways. Guess you could try to put the grooves in there and try to "match" the magnifier pattern of the clear part...

[15inches]

No work today... coold rain alll day.

[15inches]

Fixed 3 out of 4 door handles. Finally got my R/R door open. Problem with the Hans' Autoparts.com rear handles, is they dont line up right and wont hit the latch mechanism. they cant inward and dont really travel far enough to actuate the latch. At least I can get all of my doors open again and my driver's door handle is at the point of complete failure.

We used an angle grinder to cut a hole in the handle to gain access to the inner latch lever.


This is what the rear handles dont actuate.


there are 2 clips for the lock switch you have to pull the power cable out of, this is the one on the inside where the window is located, to the outside of the door.


the other one is on the door frame in plain sight. the main plug for the door switch is the blue arrow. it plugs into the middle orange arrow.


The front Passenger handle is a mirror of the front driver's side. The handle needs the power setup like the drivers side, but I didnt know that, so i actually didnt end up needing to replace it, just tighten the locking screw.

Not too bummed about everything because it isnt like I paid a ton of money for the handles. If you need a new driver door handle, get one from this site. if any others, dont worry about it. They prolly wont work. Less than $7 a handle and you cant go wrong. New vent tube went on, also, now both parts of my dipstick tube match with the bright orange parts.
Just need to work on my rotors and pick up a pair of rear pads and bearing kit.

Waiting for HID kit to come in... O.o

[15inches]

Also had to replace the R/R latch because it was sticking really badly. Good thing dad and I sourced one front parts yard last year. It came in handy. Dont forget to lube all of the springs and joints of the handles. Will make them last longer.

[15inches]

Got my new Europlate right as I was leaving for the road! FedEx lady was passing me and I was like wait a minute.... so I backed up and sho nuff!

This is what I got, though it was before I had thought about possibly swapping over to an AHU at some point down the road, lol:



and this is what I shouldve gone with...:



I edited out the blue EU banner on the side, as mine are just plain.

I am deff going to put the state plate to the low right and mount the europlate in the middle. I just need my dremel so I can mod and use the existing plate holder.

[15inches]

Corner lights and brake rotor replacement yesterday:

Wound up rebuilding caliper carrier guide pins. Just typical rotors and pads from Oreillys, nothing special as I'm saving for a 15" G60 setup and calipers.


So the lenses on my old corners pretty much separated on their own last month. I blacked out the chrome and RTV'd them back together. Also palsti-dipped the grille while I was at it. Waiting on E36 projectors to show up.

[15inches]

Today, my brother and I performed a mufflerectomy.
went to Autozone and bought a 2" 90* bend, and a straight section of 18". Only needed the flared bezel end of the straight section. That thing was filled with soot and weighed significantly more than what replaced it.





we cut off the hanger were able to reuse it later.




finished!

[15inches]

the welds need a lot of work because we got 2.25 tubing because the OEM measured just over 2.0" and required a lot of filler material.

[mtngoat3]

But now you cant channel air to cool or warm your left hand

[FaithInMkIII2.0]

center console had a small fire? in the ashtray and ruined the A/C-Recirc switches
Recirc switch doesnt close vents all the time to keep outside air out
A/C doesnt work apparently..?

headlights are yellowed

tail lights need replacing

I have the parts you need mentioned above. PM sent

[15inches]

waiting for E36 projectors.... hurry up already!

[15inches]

Nothing new to report, and I think it will be a while until the next post. I did manage to pick up a roll of vacuum line from the dealer the day I bought my Jetta, lol. The car seems to hold boost better now, since the mufflerectomy. Deff need to pull the intake manifold off and clean it and the EGR valve out. Can only drive one car back to Polk...

[15inches]

Going to shoot some SeaFoam in the intake to see if that doesnt help clear its throat, lol, this weekend. No work to report, but still waiting for a chance to bring it back.

[854door]

how did you mount your boost gauge there?

[WannaCorrado]

the clear is peeling.

I got one in NJ
http://newjersey.craigslist.org/pts/3037826701.html

[dano17]

Damn $100?

[WannaCorrado]

Damn $100?

is $100 for a hood a lot???

[pos85gli]

is $100 for a hood a lot???

deals.

[BelkeVR6]

finished!
[/QUOTE]

Soundfile? Viedeo?

[15inches]

I'll try to get one next week. Sorry I'm just now responding. Its funny when I talk to my while hes driving it, I can hear it quite loudly in the background.

[15inches]

how did you mount your boost gauge there?

it was very tricky. I ran the vacuum hose through a hole in the flow block off plate, and that's what keeps it in there. it isnt actually hard mounted. so if i wanted to, i could remove it and the line and regain full functionality of the vent.

[15inches]

But now you cant channel air to cool or warm your left hand

thats what the window and sun roof are for... lol

[15inches]

Okay, I'm finally in town for a bit and going to work on replacing the vacuum lines and cleaning the intake. Hopefully it warms back up a bit so I can work longer. I got this thing about working in the cold and my previously frost-bitten hands not jiving together..gloves don't help, either.

Sent from my Atari 1200XL

[psst97]

You would be surprised how much cleaning your intake will liven up the car. I am sure its pretty clogged if its never been done. While placing the VAC lines I would recommend a new N75 valve. Although it may still be functioning, I can almost guarantee its not 100%. Here is a good solid method for cleaning an intake. And fun.

[15inches]

Lmao!! Awesome... I might just try that. Yeah I bet it isn't working either. It goes into limp mode under hard acceleration, like rapid and WOT. I'll have to look into a new one.

Sent from my Atari 1200XL