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1992 VW GTI Build Notes - 2007


1-8-2007
Click to EnlargeThe holidays and a couple big snow storms here in Denver have kept me busy and away from the body shop, but I finally have an update. She's in primer and should see paint this week!

I also have the engine picked up and ready for cleaning / paint if the weather cooperates for long enough.

Finally, I found my tail lights!

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1-30-2007
We have paint! They shot the car yesterday morning.

We're still a little more than a week out before I can pick her up. They still need to do buffing, sanding, undercoating and cleaning, but it's so good to see it in color again! Click to Enlarge Click to Enlarge
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Also a couple weekends ago, Wendy and I went down to Hardey's Motorwerks and worked on cleaning up the engine. I can't find the pics this second, but I'll post those up soon.
2-17-2007
The car is done at Apex and moved down to Hardey's Motorwerks! Thank you so much Ian for the help with moving and the trailer!

I want to say here another big thank you to Apex Autobody in Denver. David, the owner, is one of the most honest, customer driven business owners I have ever had the pleasure to work with. They did a tremendous job with the paint and body work and even though there was a mix up at the shop about hours spent on the car, he stuck with the original quoted price even taking a H-U-G-E loss on the deal. The pictures turned out pretty nicely, but they don't go the distance showing the quality. Hats off to all the gentlemen who worked hard on my car, and to David for everything. I know I mentioned it before, but even though it took nearly five months for the work to be done, there was never any rush on my part to have it finished since I certainly won't be driving during these Winter months. David and I had an understanding about the timing, and I have not one complaint about the job or the level of service provided.

Now the interesting part of installing the various bits and of course the engine. I've picked up a few more items I haven't mentioned yet including a set of G60 Corrado front and rear disk brakes, 15" Corrado steelies to cover the brakes in the winter, a Kamei golf ball shifter and euro / early quarter flares.

I'll probably go out this weekend and get some all-season whatever tires mounted on the steelies and see about getting the Porsche phone dials refinished. I'll also see if I can meet up with Dan to look at getting some or all of the sub frame installed and some painting on the under-carriage and engine done.

I also got all of my interior plastics collected together, including my no seatbelt hole c-pillars, b-pillars, a-pillars, interior mirror plates, lower center grille, rear seat trim, hood vent back-plate and a few other things painted with some SEM trim paint. They turned out great. I may need to hit them with another coat, but the paint is so easy to use and coats so well that it will be no problem even if I have to go back and do another coat later.

That about wraps things up for now. I'll see what I can do about getting some pics of the new wheels and what-not. Click to Enlarge Click to Enlarge
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2-26-2007
Went out to Hardey's Motorwerks to toss on the Corrado steelies I had mounted with some Kumho all-season tires today and install a few plastic bits I had laying around. Next time I'll get some of the interior put back together to get the parts out of the house and maybe the door handles etc.

I also dropped the Porsche phone dials off at Woody's Wheel Works in Denver. They will be refinishing the wheels and we're looking at the possibilities of polishing the lips since polishing the whole things just doesn't seem cost-effective. More on that later!

Here's the Corrado wheels mounted up.
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3-14-2007
I just got back from vacation in Florida with Wendy. Had a great time and came home to find my wheels were ready. It may be hard to see in the pics, but I had them polish the lips which should really stand out when I've got rubber mounted on them, and I've got a set of correct valve / stem caps with the Porsche crest raised on them. Woody's is finishing up the center caps. I'm having them media blast them, polish the faces and raised areas and then clear-coat them. Should be done in a couple days.
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3-24-2007
Things just took a huge leap forward! We decided to get together today and I THOUGHT we were just going to get everything layed out and organized, identify things we were still missing, that sort of thing and well... the VR went in!

There's still quite a chunk of stuff we have left to do including wiring it all up, fitting the brakes, changing out the rear tranny mount, putting the interior back together, bolting up the exhaust and other things. I'm sorry to some of the guys who had offered to help, but we have one more big day that should include firing it up and first drive and I'd still like you all to be there!

I've pretty much given up on the Corrado brakes at this point. They guy back East has turned into a flake and it looks like I may have to make a claim through PayPal to get my money back. *sigh* I found MSD's 11" front kit on Performance-Cafe and a 22 mm Autotech front sway bar that we'll need to keep this thing planted.

There's also some parts from RS Motorsports including the correct rear tranny mount, correct fans, and a clutch slave / master and a OBD2/VAG-COM port that I still need to get from them this week.

On to the pics!
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4-07-2007
We're getting VERY close now. The fans are turning into an issue, but I think we may have that sorted. We got the Autotech 22 mm sway-bar, (upside down the first time), new spindles, new 11.1" rotors, Girling 54 Calipers, Pagid pads, stainless lines front and rear, rebuilt CVs installed and power steering hooked up. Wiring next weekend and those fans working and hopefully we'll be firing it up!
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4-21-2007
Wiring mostly done, custom power steering bracket installed, intake manifold re-painted, radiator & fans mounted, sunroof lubed up and put back in, door handles in, steering hooked back up and passenger mirror delete installed.

Braille 15 lb battery on the way.
Looking for a Corrado VR Air box, if someone has one laying around.
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6-02-2007
Had a couple productive Saturdays and figured it's time for an update.

Last weekend Hardey and I pulled the brakes to get the rotors on the correct sides. I noticed the venting was pointed in the wrong direction, which was a product of too many people around when we put them on. We also lubed everything up and gobbed on some anti-squeal.

Next, I started tackling the dash and working on how to get the MK3 cluster in there but looking good. I ended up doing a lot of cutting and cleverly miss-cut the mk3 bezel I had so I had to find a new one at the junk yard. Luckily an easy part to find. I also found an extra sun roof metal wind deflector which I started sanding down to polish at home, an extra set of rear hatch plinths to work on smoothing later, the rear defrost connectors which were lost at the body shop which I wired in, and we finally got the rain gutters pushed in correctly. I still need to put a bead of silicon in there to seal a couple spots where it has separated, but that's easy enough.

After that, we bled the brakes and clutch and put her back on the ground for the first time in a long time.

This week at the yard Wendy and I found a '90 G60 Corrado which I promptly snatched the power steering reservoir out of. I know we did a lot of work getting the mk3 one fit, but this one looks much more factory which I like a LOT. When I pulled the old bottle out, we found that we had a leak on the line running from the bottle at the pump. The metal hose connector on the pump has a sealing ring that doesn't run the complete circumference of the connector and Hardey thought the hose clamp may have been on top of that creating an imperfect seal. When we reconnected the line I made sure to not put the hose over it and make sure the clamp wasn't on top this time and I hope we keep that seal this time. We also ran the vacuum lines and replaced one of the brittle plastic fittings.

Dan, Mark and Hardey worked on the dash / fuse block wiring which should be pretty much complete now. We plugged in the battery and started testing everything but ran into a snag where the starter motor started kicking even without the ignition on. The guys think they know why and we'll be tackling that next weekend and hopefully burning some gas.

After finishing up the power steering, with Wendy's help I pulled the struts off the hatch to see if the extra set of polished hood struts would fit back there and they do! They are a bit shorter than the stockers, but they look so nice, I don't mind.

Next we looked at the intake a bit and while I'm STILL looking for a Corrado VR Air Box(!) we'll need something on there for now so I grabbed my extra cone filter for my MK4 and stuck it on there. We also deleted some of the case venting so I slipped an extra small filter on that for now.

The new windshield is in too. I got a great deal on some really nice glass, and it looks superb, except that they didn't ask me if I wanted the eyebrow tint on the glass, which I didn't, but I got it anyways... I'm not really happy with it since it really doesn't work with the rest of the car, but I can live with it I suppose.

This week I also found a euro Golf CL console on VWVortex.com which matches my minimalist interior to a T!

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6-10-2007
The swap meet at RS Motorsports was today. They did a great job making the space and providing food via the grill and beverages. I sold my GTI red stripe seats for $50, a pair of speaker grills for $10, my red stripe grille and a pair of headlights for $50 and a set of rear door cards for $20. I made an easy $130. The fellow next to me with his kickin little brown Dasher that arrived packed to the roof with parts for sale also hooked me up with a set of four chrome Audi door handles for $50, so I still managed to walk away with $80 dollars net.

I already have a set of chrome door handles, but three of these came with the chrome latch triggers mine don't have and since it looks like I'm going to have to modify the handles just a little bit to get them to sit flush with the door, I'll have an extra set to play with if need be and I can always sell the extra two sets and at least get back the money I just spent. Plus, since these handles came off of a four door, two of them have no locks and I'm thinking I will use one of those for the passenger side.

MORE CRAP TO POLISH! :eek:
No work directly on the car on Saturday since Hardey was busy with his dad and Dan must have been too but Wendy suggested we go to the junk yard. (Can you believe this girl?!). We pulled a set of good looking door latches that I'm going to get started polishing. We couldn't find a golf hatch latch, but we will. I also grabbed a set of the early style oh sh!t handles, the clips I need to hold the hood release cable and vacuum lines, a new plastic under hood grill piece to replace my sagging one, a set of four Fox door handle centers I need to play with putting chrome strips in my chrome handles (which are normally black plastic) and a few other odds and ends.

I also found some metal polish I actually like so far: Mothers Incredible Billet Metal Polish. It puts the Eagle One Nano-Nonsense stuff I was using to shame. Here's pics of my Eibach strut bar, folding sunroof wind deflector and intake manifold.
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Pics of polished parts is tricky. I'll see if I can find a way to get some even diffused light and try again. I'd still like to get more of an even finish on the pieces, and I'm looking into buffing wheels to see if a machine and wheel can do it a bit better and I'll be trying the Dremel on the latches when I get to those.
7-14-2007
We're up and running. Though not very well.

The heater core was leaking so we couldn't get it up to operating temp.

Here's the VW MK2 VR after we swapped out the leaking heater core that stopped the first run. It's running poorly now because of an air leak on the intake that wasn't plugged and really, REALLY old gas. It's a short video because we shut it down to drain the gas tank and refill it. Ran like butter after that!

Hardey drove her down to the alignment shop and he says it feels good. I'll be going down this week to put her more or less back together to get her home. Wendy and i also will be signing a lease for our first place together this week which will include a two car garage to keep her safe!

I'll make sure to record a new video of how she's running now with at least my regular camera.

Hopefully all future working photos will be at the new house!
7-21-2007
Here we are, just getting the front end back together to take my first drive and bring her home. We aren't in the new house just yet, but the mk4 can sit on the street for a week or so until we get keys.

She ran just beautifully, and sounded great!

It's going to be a rough month getting the car ready and moving Wendy and I into the new house and the rest of the family into the new garage and prep for Dubs Along the Rockies which will be our first "unveiling". The list of to-dos is not short, but nothing to do but get on with it.
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8-18-2007
Alrighty! We're more or less moved into the new house / garage. It's been a long damn month but the space for us and the cars makes it so worth while. David helped me get the euro tails wired up as well as figuring out the "fast blinker" issue. Turns out the bulbs that ship with the euro small bumpers don't have enough pull to let the circuit think there's a bulb in it. Since I'm using single filament bulbs and foregoing the running lights for the time being I ended up using the bulbs out of my old big bumpers which worked the treat.

On to tackling the list of things to get ready for DATR next Sunday, i pulled the rear wheels to test fit the Porsche wheels with their new Yokohama S.Drive tires all mounted up and finish spraying the undercoating in the rear wheel wells. Spraying went simply as seen in the pictures. I just did a lot of masking to be sure and went to town. The wheels turned out to be a different story. The lug bolts that secure the spacer / adapters to the hubs use conical 6mm allen bolts, some of which are slightly stripped. If I'd known these things wouldn't take the torque i wanted to apply to them I would have ditched these, sold them and bought a set of the H&R adapters. I'm waiting to see if someone can get a hold of a set of them for me before Friday... I'm going to check the local hardware stores for new bolts but I may need to get these things torqued as best I can with some releasable Loctite for this weekend. I'm not happy about that, but I'll just be taking it real easy on the way down and back.

I also got the dash back in and a few bits of the trim repainted. I'm not going to have time to modify the bezel to work with the cluster this go-around at DATR, but that's okay -this is meant to be a work in progress. Hell, I'm not even going to have the headliner in I don't think.

Last few things on my list of wrap up include getting the Happich windows put in, installing the Eibach strut bar, fitting the wheels, finishing the dash and tons and TONS of detailing. Click to Enlarge Click to Enlarge
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8-24-2008
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