BARELY LEGAL's Barely Legal Budget Build Thread. *20v Content Inside*

[BARELY LEGAL]

this is not acceptable. i'm only coming to dub dash to see this whip.

man up and fab a tow bar and tow it up to the dash. i have faith in the 1.7 in your other ride. should be more than enough hp to tow.

Oh, don't make me feel worse than I already do. As of now, the car is on stands and without a transmission. I simply can not get it done or else I would have. Sorry for letting you down buddy. We'll chat about it this weekend.

[rabbit_rot]

French Canadians

[35i 2000]

first of all let me say remarkable thread!!

you've done a really good job of documenting stuff love the details

at first I was a little hesitant when I saw how MINT the shell was, but this is way cooler, the diesel pumper gladly gets dumped for a refreshed 20vT

i can't wait to see this at H20i

[absentee]

Great build!

[BARELY LEGAL]

first of all let me say remarkable thread!!

you've done a really good job of documenting stuff love the details

at first I was a little hesitant when I saw how MINT the shell was, but this is way cooler, the diesel pumper gladly gets dumped for a refreshed 20vT

i can't wait to see this at H20i

I hated to yank the poor Diesel out, but I needed something with a bit more pep. Don't worry though, the diesel lives on in another vehicle.

Great build!

Thanks!

[BARELY LEGAL]

So I've been a busy boy getting ready for H2Oi. First off, I finally got the parts in to finish up the transmission. TDI 5th gear came from someone more reliable in the states, instead of our neighbors up north. Ring gear bolts came from MJM Autohaus for only $70 shipped!

All torqued down.


Got the trans back together and when I went to tighten the selector cradle for the 5th gear, one of the mounting brackets cracked down the middle. FML.



SO, I had no choice but to weld it back together. Unfortunately there is no great way to do this, especially with the 5th gear on. So I was only able to tack the outside, but I was able to weld the inside pretty well. I v-notched the area first to ensure good penetration.








That job fücking sucked. Especially since I had to do it twice. After the first time I welded it, it cracked again.

Anyways, moving on.

If you didn't know, this swap shredded a timing belt when I first put it together. It's was my fault, and was a result of a flipped cam gear and poor belt alignment.
Thread can be found here: http://forums.vwvortex.com/showthrea...lt-Broken.-WHY

Well, I had a couple bent exhaust valves. Not bent enough to hinder performance, just slightly bent enough to create a noticeable "tick". I put it back together and ran with it for awhile, but since I am gonna be driving a lot in the next week, I felt it was time to finally replace the noisy valves. So I yanked the head off and ran it over to my buddy's shop to borrow his factory 20v valve spring tool.

Valves out.

Guts.

The noisemakers.

New new. Supertech SS valves with inconel coating.

All back together.

And back on the block.

All back together and super quiet now!


BTW, I got the parts for the trans on Friday, reassembled on Saturday, installed on Saturday as well. I did the head work on Monday. I'm leaving for h2o on Thursday. Cutting it a bit close. Still need to drive the crap out of it tomorrow to make sure it's road worthy for the upcoming 11hr one way trip.

Thanks for watching.

See you in Ocean City!

-Nick

[BARELY LEGAL]

UPDATE,

This car drove to Ocean City and back with out any problems. Around 13hr each way with stops. Sorry I didn't get to make it to the MK1 G2G, I was working for APR all weekend and the BBQ and show kept us pretty busy with installs and such. Some of you might have seen my dirty little car parked over by the lifts we were using to install exhausts. Anyways, got to work with some cool people and get my car chipped. APR Stage 2 FTW!! It's like a whole new car.

I should post up some more shots when I get a chance to clean her up and get out with a good camera, and a better photographer.

Thanks!

-Nick

[benjaminobscene]

was that your jetta?

I remember watching it leave while this was going down next to the APR lifts:

[BARELY LEGAL]

was that your jetta?

I remember watching it leave while this was going down next to the APR lifts:

Yes sir. I spoke to you guys for a bit on Saturday night while you we're ripping that trans out. I'm glad to see you get that thing back together so quickly. Props for a clean car too! I want OZ Turbos so freaking badly!

[smeatonvw]

So, I was hoping to get some help. I'm doing the same motor swap (Passat AEB into a diesel Caddy) I bought a Bentley, went thru the wiring diagrams, but I don't know what i need to make the motor run. What did you use?

[rabbidmk1]

Looks great! How is the 3"exhaust with the cut out in the rear beam? Do you have any pictures pf the amount of clearance there is now?

[vdubjim]

how do you fill the hydro reservoir with dash in?

[BARELY LEGAL]

how do you fill the hydro reservoir with dash in?

Very Carefully.


Actually, It's not THAT bad. I do have to take the cluster out, but if you had a very steady hand, you could pour it from a small brake fluid container.

I haven't needed to refill it, or mess with the hydro clutch at all so far.

[stealthmk1]

Nice thread.
Just getting going on mine, with a goal of H2O at the latest.

[BARELY LEGAL]

Nice thread.
Just getting going on mine, with a goal of H2O at the latest.

Once you get going, it's easy. My problem was collecting all the parts before I started.

[floridabmx]

great write up, love build threads like this. learned a lot!

[stealthmk1]

Once you get going, it's easy. My problem was collecting all the parts before I started.

I hear you there. I've not been able to buy a single thing for it since I got the actual shell. So far I've just been working with parts I've had from picking them up over the years, and have yet to run out of things to do.

[BARELY LEGAL]

UPDATE!!

Wow, it's been a while since I've posted in this thread. Car is still going strong. Drove it through most if the winter without any issue, except for skinny tires and too much power.


Then I picked up a beater to get me through the heavy stuff. It was all stock except for suspension, and I added the wheels, adjusted the altitude, catless mid pipe, and a couple other odds and ends. Here she is next to the coupe:


I took the coupe to Water By The Bridge in Louisville in March. Didn't take a single photo of my car, but here it is the night before. I gave the bay a quick cleanup and rattle can job the night before because the primer was getting filthy.



Have got another local show this weekend that I'm taking her to. She'll be posted up next to my buddy's MK2 Jetta Coupe 1.8t.

I'm actually tempted to sell the car these days. I don't get to drive it all that often anymore and I've got another project that requires my attention these days:


Maybe I'll post a feeler up soon. The car is ready for someone to drive as is, or put the last little bit of work in to make it a show winner.