Philips Mk1 Jetta 1.9 TDI PD130 Project

I cleaned down the rear gearbox mount and bought the rubber bush mount for the gearbox painted and bolted on

I created new looms for the front speakers to where the radio will go, but I installed new water resistant sheets to protect the door panels and then the newly acquired black mint door cards where fitted! I also replace the drivers door lock as I noticed it wouldn't lock via the key! Working nicely now

I fitted the newly acquired black parcel shelf and a retro pair of speakers from my neighbours, he bought them for as a gift so I said I'd fit them! They actually turned out quite well… I'll fit the passenger side tomorrow as it was getting late . 









I also fitted the drivers rear seat belt, I noticed there wasn't a hole on the top c-pillar on both sides and never seen them fitted before, no doubt the car didn't have rear seatbelts from the factory, I'll be fitting a brand new looking kit 😁

Finished installing the rear speakers with a massive 14watts each haha
Also finished the wiper mech and wiper arms fitted too

I Managed to fit the passengers rear seatbelt but since it was 0oC lastnight, that's all I did before my fingers got too cold! 

one of the things that has been plaguing me for years literally is the rear taillight connectors, I used the mk4 wiring pins inside the mk1 connector which wasn't the correct size meaning with a hard enough tug, you could pull the wires out of the connection, so with the correct size pins in a replacement connector I cut and heat shrinked on a donor mk1 loom with connector,

 



More updates coming soon 😋

14 watt speakers - reckon you'll need an alternator and battery upgrade to run those!  

Haha your not to far off about the alternator 🤓 I had to stroke the alternator for my vw bora, it went faulty and seeing as mine wasn't currently being used…lol
So yes I need a replacement one.

Today I spend a few hours replacing both connectors to the original wiring pins, including the twin rear fog mod! This is a load off my mind as I've known about it a long time 

 









I even installed the protective plastic tubes that the original wiring had

Today I spent 5 hours doing bits and bobs around the car, one was cleaning down the rear number plate template and painting it satin black which turned out well, fitting the seat belt buckles and building the rear seat up again, tidying up the last of the wiring in the boot 

 

I managed to fit the rear number plate template, I'm not all that fussed with it but what with the project never having one ever, it will probably just take some getting used to.
I applied some padding behind it around the edges so it's not buffing or contacting the paint work in any way

a couple weeks ago, I bad put my back out by……… sneezing, long story short, I don't trust any chiropractors in my local town of Ballymena, so I went to south Belfast and checked out a place called the back clinic, they found the lower back tendons over lapping the upper pelvis which would be caused by sneezing badly lol! The guy worked a wonders and it's now on the mend, honestly it was crippling but I'm on the road to recovery! 

I managed to get the rear carpet which I recovered from the donor car, cleaned it down and started spraying it with satin black, which has left the material still soft and now matching the front carpet, half way through the can ran empty so had to do a trip to the shops lol

 

I've heard of people cracking ribs by sneezing!! Glad you're back on the mend  

Thanks matey, I really should take a few days off from the project but I'm off for a few random days from work till Monday so going to work at it all day Tomorrow, take Friday off and back at it Saturday and Sunday.
 

Tonight I had a few friends over modifying the battery cable going along the floor so it is now routed under the passenger seat front mount support and painted the seat runners gloss black because the when the carpet goes in shortly, it would leave the red oxide paint visible! Having the lads around certainly helps take a load off 😉

On a lighter note, a good mate of mine is a cnc technician at the local tech and has designed the rear gearbox mount adaptor plate for the six speed box, we mocked up a piece of cardboard cut to the correct shape and from that he's designed this for me, he should have it fabricated within the next few days so that'll be great.


 

 

Today I painted the seat rails and support areas because I realised once the carpet is fitted, them areas can be seen where the front seats mount



Next was dealing with the lose handbrake lever, I removed the lever and sound the mount that the pivot pin goes through was worn down, the holes had been squashed moved open that they should be so using a metal block put between the two holes and a numerous whacks with a block hammer, it brought the holes back to there original circumference and the pin now slots in tight, I refitted the lever and it tested perfect with no play




Also spent ages going through my shed to find the handbrake switch, eventually found it and fitted it

Today I installed the rear floor carpet, modified more looks running along the passenger floor and instead of buying factory style floor foam / padding, I found that a thermal matt used for lying on in a tent under a sleeping bag has the same thickness and would act as a good sound dampener so I trimmed the two rear pieces from it.

 

Having a few hours to kill today, I decided to trim down the loom abit, cutting out both passengers rear canbus, door lock and window motor sections, whilst rerouting the speaker wires, I had a old radio laying around so connected it up and attached a battery charger to the car…
It had an old CD in it from possibly a decade ago but still it was so good to hear music coming through the rear speakers 😉

Some foam adhesive sound deadening arrived in the post today so I fitted a lot of sections of it to the interior firewall area, best thing about is it can stretch and is more pliable than the normal bitumen material, I had to use some spray glue before applying but so far it's looking good

 

 

 
 


 Also I've nearly finished the last of the sound deadening, just a few more areas too do

 

Hey folks, we managed to get a 1 mm thick prop of steel made without the ribs to get a rough idea if the bracket would bolt on directly, it matched up perfectly and we've made a couple of adjustments so it's more stronger, so going to make another now complete Version and see what happens