Saving a Jetta

[Pat @ Pitt Soundworks]

So my buddy had a jetta. He let his drunk friend move his car and at 5mph in a parking garage, somehow managed to run it in to a concrete barrier, totalling it. My buddy carried liability only, and got nothing for the car. It wasn't worth it to pull parts and scrap the body. I wanted out a car payment, so I traded him my 425whp saab for the wrecked jetta and some cash, and am now fixing it up.

About this time last year, the car started out as a heavily molested 2.0l automatic semi-base model. Power windows were the only option, and poorly done plad headliner and door cards. First thing was to swap the 2.0 and auto out for a 5speed and 1.8t. Second, was to get rid of the plad, and put cloth door cards back in. Third, retrofit heated seats

This is how I received the car:
02 body, ~185k
01 Aww 1.8t, 115k
01 2.0L 02J tranny
ls2 coils
g60/vr6 clutch/flywheel
kw v1 coils
poly bushings all the way around
uni 830 ecu
siemens 830 injectors

How the car will progress:
fix body damage
golf front end, r32 front bumper, r-style side skirts, vortex rear bumper
built 2020 with hy35 turbo
custom nubworks surge tank
awic
climatronic swap
heated mirror/washer nozzles
6spd quattro swap
20th brakes, tt spindles & control arms
and some other stuff

Current list (as is):
stock 1.8t longblock

Custom turbo manifold
Custom 3" downpipe to catless 2.5" exhaust
Custom intake manifold
Custom intercooler piping
31x12x3 CXracing front mount
Tial MVS wastegate
Tial 50mm BOV

LS2 truck ignition coils
Siemens 830cc injectors
Uni830 cc tune
Hemi throttle body
Bosch inline 044 + stock intank

Audi Quattro TT DQB transmission and axles
Clutchmasters FX400 clutch on stock DM flywheel

Custom coolant res
Mishimoto radiator

20th front brakes
Audi TT control arms and ball joints
Audi TT drop spindles
KW V1 coilovers



On to body repair stuff:







Tomorrow, I'll weld out the front end, get the 1.8t back in, and make sure everythings kosher. Then, I'll started on some other body repairs that need done.

Harvesting parts from the tt:




Transmissions:

[_MASH_]

5mph

$0 car payment is a good feeling....

4wd jetta with 6spd quattro swap... win

[Pat @ Pitt Soundworks]

That's what I was told. I don't believe it.

[85vrcoupe]

[24ValveGLI]

Do you have the TT fuel door and cap?

[dopesauce]

everything sounds good minus the golf front end
but good luck with everything

[projektmk1vr6]

I'll be watching this.

[JayDD007]

everything sounds good minus the golf front end
but good luck with everything

^^agreed but ill definitely be watching

[2.slowerr]

.:R front end

[02vwgolf]

Projects are always fun Cant wait to see what you do with it because I have seen your work in the fabrication forum and you sir have skillls

[mwedwards]

gnarly

[Symphony]

I am giving you soooo much props for trading a fully finished Saab car for a f-ed up Jetta. It's gona take hard work but I know you'll make the car great.
Good luck man.

[Pat @ Pitt Soundworks]

Knowing the exact history of the car (I pretty much built it for my friend), all the extra parts that come with it, and all the spare stuff I have warehoused, the only problem is the bodywork. Speaking of which.....

front end is welded on. I found out the divers side frame rail is also bent, so I'll be cutting and re-welding that tomorrow to line it back up right. It wasn't nearly as bad as the passengers side was, though.


and I started mocking up the motor. I'm pulling off the k03 and putting on the hy35. I'll run it on a stock block, low boost, for the month or two until I finish building the real motor. I will be test-fitting the motor with a quattro tranny in the AM, and working on the new downpipe. I'm still going to drop the 02j back in for now, until I get a chance to pick up some TT axles, control arms, and 02m clutch.

[

[vortexpert.]

[Herleybob]

[1.8tCrayon]

Promising thread.

[03_uni-B]

im down to see this

[jolf43]

damn, good work here. not a fan of golf front ends on jettas though.

in for this

[SirSmokeAlot]

in

[GtIVR6-RJ]

oooh

[SATXBrokeGTI]

I suppose I'll have to see what comes of this.

[agentmaddock]

[Eeaazzzyyy]

Interested

[Easy Dubs It]

Lets see that Saab!

[Pat @ Pitt Soundworks]

Not much got done today. Didn't get started until almost 1pm. Calling it an early night at 9:30, instead of 2-3am like I've been doing. Most of the day was eaten up by relocating the drivers side frame rail to get everything to line up. It looks a little funny with the bay stripped out, but once it's painted and the bay is full, it'll be fine. I spent a bit of time pissing around with my friend on the engine, looking at coolant and vac lines, and doing minor stuff.



Mocked up passenger side bay with surge tank. The small AC line for some reason needed a little massaging to get back in place. I need a replacement, unbroken, fuel/evap plastic conduit piece, that goes under the ac lines. Does anyone have one?


Here's the rerouted coolant lines, ready for an external oil cooler. I stripped the wiring harness off to clean and fix it. The car has a PCV leak and everything's covered in ****.


Welded up an oil return flange. Turns out I can still weld aluminum - I haven't done it in a few years. This is anodized to anodized, hence why it looks so unsmooth and unshiney. I don't know why the camera went crazy on the AN fitting....



I would have had the turbo drain flange done too, but I can't seem to find where I put it this morning? I really want to get the engine back in and downpipe done tomorrow. That'll be the first thing I work on, for sure. That, and pick up a new saw for cutting pipe.

[Pat @ Pitt Soundworks]

me guesta le boosta





Can't start on the exhaust till tomorrow - had to order solar flux

[Kujiwara]

MADD! but isnt the quattro on TTs are just 4motion?

[Pat @ Pitt Soundworks]

Correct. Sames as in the R32's

[eurolicious]

Watching


Sent from my toolbox using pliers and a screwdriver.

[Pat @ Pitt Soundworks]

Doing more werk.

[Pat @ Pitt Soundworks]

Intercooler is due in today!

[Fastvolks]

[GliGirlDriver]

5mph

$0 car payment is a good feeling....

x2 on $O car payment

That's what I was told. I don't believe it.

And I believe it, my first 01 golf managed to be totaled by another car that crossed in front of me and I was going about 10-12mph since it was a small downtown area. Sucked, but if that didn't happen I wouldn't have gotten a fat check and my GTI


in for progression..

[2003 golfer]

20/20

4wd (assumed from 'quatrro trans')

[foundubbedriver]

watching this..