Buy welder, grinder, good pair of gloves and get to work...
About three days after installing a TDI in my 81 rabbit, my fuel tank started leaking. When I went to look and see what was leaking I discovered the floor has come apart from the body from the seat mounts back. When I removed the carpet and dash I also found that the passenger side door pillar has mostly rusted away. Not sure what the best plan of action is yet as I can't afford another car right now. So if anyone has the lower right half of a 4 door rabbit let me know. I will try to post photos soon. One more thing anyone contemplating a TDI swap I would recommend it, it was a blast before I had to tear it apart.
pictures of said rust and splitting in half
would be more entertaining if you said
"then one day while driving on the highway my rear end just fell off"
Last edited by ford500; 09-18-2012 at 10:14 PM.
Thats almost as bad as the one I repaired. Note: remove all glue prior to welding or grinding because it is nasty. Just buy some sheet metal and get tacking, cut out as much rust as possible, soundd like for the door you may have to tack some support in place first, then button up.
If it ain't diesel, get outta my way.
ouch, my rear axle mounts were okay, I had to mend one side just a tiny bit. Its gonna be a ton of work!! If I had to do it all over again, I would put the car on a rotisserie for sure. But I will say the end result is rewarding
If it ain't diesel, get outta my way.
why not buy a less rusty shell and start over?
thats too much cutting.....
can be done
have fun and post progress pics!
I would love to by a new shell but that is not going to happen any time soon with my finances. This weekend I am removing the rear axle to asses the mounts and get the fuel tank out. Probably cut most of the passenger floor out too. I plan on posting photos of the engine swap soon as that worked out pretty well.
I have driven that car... so hard that the rear view mirror broke off
I gotta say I was expecting worse from how the car just looked overall. I gotta come up and see it in person. I love doing floors and general sheet metal work. I am surprised you didn't post up the pictures of the engine swap first... and didn't tell them where you got the engine from and how many "miles" are on it.
And more pictures without shadows and such would probably be better so everyone can see what you're working with. The new shell idea would be ideal but I hear ya on the finances part. Not everyone's pockets are fat and mine included.
This thread might offer some help. I couldn't believe what he fixed/bandaged and it was much worse than yours. So there is hope but it will take time and it's worth fixing. I'll quit complaining about mine now
Well I thought I would post an update. I replaced the passenger rocker panel, the front half of the passenger floor , and about half of the rear passenger floor. Had to remove the front seat support to replace the metal underneath. Now on to the driver's side.
The bucket is what was left of the passenger floor after removal. The last photo is the drivers floor which is in much better shape so I think I can get away with just patching it.
yeah man thats pretty good
doesnt matter if its not form fit to factory standards
make sure you rust treat and POR-15 over all of that
looks good to me bro
Figured I could post a few pictures of the engine swap. The transmission was repaired at some point as the bearing support has been welded and there is evidence of metal floating around in the bell housing. The engine is an ALH that came from an engine research facility that has very few hours on it. The price was very very low and the computer was setup from VW with no security so just hooked up power and was ready to go. I was able to get rid of the new fuse block and use the old solenoid wire from the 1.6L to power the relay for engine power.
The exhaust gasket was from the old engine and someone had installed it backwards which explained why the car was fairly loud. The Cadillac is a 63 and is a another future project.
wow nice engine
sounds like a good swap
this is concerning of course....good idea but...the seal is supposed to seal the shaft, not the flange
Last edited by rabbitnothopper; 10-09-2012 at 01:12 AM.
That is how it came out of the car and it didn't leak so I didn't mess with it. I was more concerned with why it was welded and how fifty horsepower caused it to break in the first place.this is concerning of course....good idea but...the seal is supposed to seal the shaft, not the flange
It still had the original fly wheel which would have contained the clutch if that had happened. I think the bearing must have exploded which was why the case was welded. Finally got the fender off.
Explains why it seemed the door was falling off when it was opened. Any one in Minnesota have an extra fender laying around?
Well finished all of the metal work a few months ago. Been driving it daily and with that TDI it has been a lot of fun. Only issue so far has been a hose clamp failing on an intake hose. The door works a lot better and the passenger side stays pretty dry now.