Philips Mk1 Jetta 1.9 TDI PD130 Project

Well after starting a usa import resto to another jetta back 2 years and failing to really get more than 5% progress on it, the project was doomed, rust had spread to almost every structural part, so i took what i could and went hunting for another

I came across a 1983 Irish mk1 jetta that had the engine removed, the front seats and the headlights aswell, made an offer and after 450 miles from co antrim to port laios south of dublin, i was a proud owner of this beaut.

The plan is to restore and modernize the car so its classic looking but can easily do 70mph on the carriage ways, have good old fashioned torque for getting up to speed yet still being econmical.

Being that i had made a 240bhp monsterious seat ibiza with a 1.9TDI engine, i felt thats what i should fit
So i bought a side damaged GT TDI 130 mk4 golf and stripped it for all it was worth, engine, loom, aircon, full loom etc



So far ive stripped the car full excluding front and rear windows and the headlining,
Removed the rear axles getting rid of the brake drums and installing the 5x100 stud axle & brakes from a mk4 golf
I welded the orginal threaded holes over and re taped them for the mounting plate for the mk4's rear axle.
and the rest is in the form of pictures for the time being

Here goes As i brought her home











And the cars home



after stripping the car down, i thought about things that would make this car a little bit different from others
Power steering? theres a thought lol
after researching over and over, i found that with a few modifications i could adapt a steering rack from a toyota starlet as they are very similar
the mounting backets needed wedge plates made and welded on so after sourcing the rack and a sheet of metal to do the adaption, the results follow

This is the manual compared to the starlet rack



The adaption needed is to allow the union joint point move away from the fire wall as it leans against it so i made 2 of theses



I welded a long bolt through the most outer hole and kept the original as a reference when refitting

Next was trail fitting the rear axle brakes







Then stripped it for painting









It wasnt ideal but needs must when it comes to bringing the engine and gear box home lol



Trail fitting the PD TDI 130 engine






Anyway started on some body work while my welder is off for a month, until then the engine mounts cant be made to fit







and since the engine bay is going to be tight, ive removed the plenum chamber





Some thing that had been bugging me was i wondered where the toe eye was! so i checked my old jetta to see the difference and found that mine had been ripped out completely so i cut the old section out of both cars and welded the good section into it, seem welded perfectly and very impressed but it











That concludes todays update, more to follow in a week or so

Epic  

This is  a really impressive buid thread dude, look forward to following this !

I think I'm going to get addicted to another Jetta thread!

Thanks chaps, I aim to please

The list of things I'm keeping from the mk4 will be the pump to rung the rack, the air con cause I melt on cloudy days and the dash clocks minus the airbag system.

Over the past 2 days the fire wall section has been cut out to allow the same sized section of mk4 fire wall fit and be welded in, the chassis leg in the bay has been modified to allow the mk4 brake servo fit on the drivers side (where it always should have been

Welded the drivers rear inner arch today as a 50p piece of rust going in the chassis leg had turned into a hole, great job done on it too! Pics going up soon

A bit of an update! i knew there was a small patch of rust on the D/S/R arch behind where the spring would be, so i took off the underseal on it and found a 50p size hole, i cut it back until it was metal only and welded a patch in then seam sealing it nicely.










I also managed to go to toome at the top of lough neagh after seeing an advert in a classic car mag selling parts off mk1/2 golf/jetta/sicrocco, so i bought the plastic trims that go around the headlights and my goodness, they are soooooo fragile.

So i had a trail fit yeooo



I also cut a section of the fire wall to allow the same section of mk4 golf firewall to be fitted, it looks nasty in its cut up looks but the new section slots in nicely allowing the mk4 servo to fit nicely and means the pedals will just bolt on behind nicely, i also notched the chassis leg beside where the brake servo would be to allow clearance which will be smoothed off soon enough

really interested to watch this build as im on with a very similar project which should resume at the end of august after not touching it for months.

dany_sims said

really interested to watch this build as im on with a very similar project which should resume at the end of august after not touching it for months.

Progress has been slow the past month as the fella that was doing the welding can't weld for medical reasons so I've been sanding and filling the body work on the drivers side! Luckily my mate let me borrow his mig welder so I'm going to give a go over on a few things like tack welding the engine mount templates in and fabricate the dogbone mount assembly! I'll have a picture update done this weekend!
I'm glad to see another project similar to this taking hold as there too few and far between and no one seems to upload pictures as to how things where done and pictures of how things look!

Any updates? looks like a cool build  

Well yesterday I had the passenger side rear axle drum mount bolts arc welded over so I can tap new threads for the new 5x100 disc brakes stub axle ! I was only able to get one side done and after a month, I can finally get this side done! I'm on the look out for dark blue front seats if anyone has a set? Again I'll post some pics this weekend of the progress!

Big update coming up! I'm getting both engine and gearbox mount platforms welded tomorrow and the rear gearbox mount welded together! Should be fun lol

nice work mate

foxy

well today i got the drivers side engine mount welded, It took longer than anticipated but after 4 hours, it was finished

 






After tacking the platform in it was time to make sure the bolts welded under neath to it line up perfect and they where




We then beefed up the welding and strengthened up the joints as best as possible






a small bit needed welding up on the inside of the arch to make it tidy





That concludes todays update, more to follow in the next week or so

Philip

I decided to get a few things done like the rear axle made ready to bolt on so i continued the sanding and eventually painted and fit the mk4 Rear stub axle, with fresh discs and pads.
meanwhile the mk2 sirocco 16valve handbrake cables will hang on the wall untill its ready.
I bought 3 cables, just in case :-D

I also bought a fuel filler neck from GSF



The orginal bottom arms seam welded and new ball joints from the mk 4 hubs which have been re drilled to fit snug



I trail mounted the steering column aswell with a stabilizer plate at the back of it

 





The Brakes



note the abs sensor ;-)







after making sure that the brakes fitted fine, it was time to strip them all off and paint them up









The finished artical :-D



Cross fingers that i can get a car jig/rollover frames on the weekend

I got it ……. finally! the roll over car jig, and within hours the car was mounted and on its side













so ill be grinding at this for the next few weeks to get it spotless

I checked out the Fuel tank before painting it and found it to be rusty inside so i bought a new fuel tank on Ebay which wasnt to pricey at £88 delivered and 2 days later, it arrived






I did alot of grinding and some welding to the floor where it needed to get it perfect













more progress to follow

Nice one Phil

Good stuff so far!