VW Heritage's Mk1 Jetta Coupe project.

It is safe to say, it won't be making its debut at Early Edition this year… there's a danger it might get done for Last Edition, but we'll see how things pan out.

We're getting closer to having it running and moving under its own steam, but it's a part time build around other stuff.

We'll keep you posted though!!

Andy

So, this is probably due an update………..

We decided to have the original 1.3 top fill rad re-cored to much larger proportions. Still drops in to the original mounting holes and bolts up exactly how the oe one does. Pretty smart. If we can get these produced at a reasonable cost, it may be something we can offer.





I have mocked up top and bottom rad hoses from old cut off's, these have been sent off and are being made into single piece silicon items!


Removed all the crusty original suspension parts….



We booked this exciting pile of parts out from the warehouse, felt like Christmas!



Seam welded the lower arms to add a little strength, not that it probably needs it.


Then repainted them black.



Andy managed to find this gem off ebay. A lift pump from a cabriolet that will drop straight in to our tank, this should be ideal for our PD as it'll supply fuel at a steady low pressure.




Set about mounting the dbw pedal, the easiest way of doing this would have been to nut and bolt it through the bulkhead, but obviously wanted to avoid this if the bay is being smoothed. Measured and cut out a steel plate, welded some studs on to mount the pedal to the steel plate, then welded the plate to the bulkhead, also added some 'L' bracing to the lower part of it.






Also got the 02m gear shifter mounted up and working. The cables from an ibiza appear to be shorter than the golf equivalents, suits the mk1 perfectly!

 




Received our downpipe flange from Darkside (very speedy service), started making a downpipe using a couple of stainless bends.




Added some of our black heatwrap, cable ties are temporary

Finished item all bolted up.


Had to extend the maf and map sensor wiring as their position was finalised now.

Got that through the front crossmember and up to the relevant position, this meant that the wiring on the os inner wing was complete so finished this off. Welded some m6 studs to the inner wing so the wiring could be p clipped. Finished article looks pretty good!



Set about cutting out the other side of the valance to get a bit more air in to our rad and cooler.


First sat the cooler lower down…


Then tried it a little further up, I think we'll go with this position as it suits the pipework a little better.


Worked out the best position for the map sensor too, going to make a boss for it and tig it to the coolers end tank. You can see our small pipercross filter sneaking in on the picture.

Nice progress  

You should get membership here though, you'd get discount on all those parts then!    

Cant wait to see this finished ,will be some job when its done

hi guys hope the fire didnt cause to much damage and this came out unscared

"hi guys hope the fire didnt cause to much damage and this came out unscared"

Fortunately the fire happened outside in our yard, far enough away from our warehouse, and not enclosed at our workshop, which is actually off site.

Thanks for your concern.

Andy

It seems Beige is the color of choice.  A two tone would look nice.

How is progress coming on

Nice!

Another update….

Machined out the end tank of the intercooler to accept the pd's map sensor, drilled and tapped some holes to secure it. The end tanks are really thick which can't be a bad thing!





Decided on a mounting position for the battery, the original Ibiza battery tray fits on the n/s rear like a dream, drilled a few holes and bolted it up.





Stripped the hubs down, cleaned them up and gave them a coat of black enamel. After the paint dried they were fitted up with a new set of Meyle wheel bearings.







Made a start on the mk1/02m driveshaft issue. I rebuilt our shafts using Meyle T4 inner cv joints and mk1 outer cv joints. T4 inner joints fit directly onto mk1 shafts and bolt up to the 110mm flanges on the 02m 6 speed box.



Here's the issue…. way too long….



Chopped them down…



Measured.



Cut it down, made an interference fit sleeve to press over each side of the shaft, tig welded the sleeve as well as pot welding each half of the shaft 8 times. Looks pretty good!



Fitted item,



Made some brackets to hold the ecu and vacuum block under the dash, chuffed with how these worked out. This meant the wiring could be tidied up in this area with some conduit and p clips.





The rear end of the car is currently stripped and awaiting a steam clean, its pretty grim under there! But pretty solid! every cloud……

Any more progress on this

Its slow at the moment..

We have moved it out of our workshop, and its now over at our new place awaiting the workshop area to be constructed!

Here it is, as it stands!


Believe us, we're itching to get it done, just a small matter of moving (and doing some "proper" work in between to take care of first!)
We'll keep you posted of course!

Andy

Just commenting to subscribe!

So much beige    

just had a read through the whole thread, love this build, cant wait to see it done