Jessie the tdi mk1 jetta (haldex conversion begining...) 12/09/17 update!

So the syncro rear axle got a seeing too with the grinder tonight, all old bracketry cut away and dressed back, tried the haldex in to try for size, and started mocking up the bracket kit for it, looks to be a snug fit!!

Ok so got some more work done on the rear beam today, all welded up haldex fitted properly without the jig, just need to get it blasted now and ready for Powdercoating, collected my gearbox yesterday from martin Emment of gas and gears in Bridgend, it's been fully rebuild with new bearings and seals, preloads adjusted and arp crownwheel bolts, vagabonds rear mount fitted along with a pinion brace too, got to strengthening the clutch fork today too, just incase……
So next job on the list is to collect my rear arms tomorrow to mock up the rear disk setup and then they can be coated too…….

Welcome back Jamie

That's a bit of a beast now!    

So rear arms are back, blasted and ready to modify for the caliper carriers, loosely fitted the arms to the subframe tonight, MY GOD it's wide! Looks loads wider than the mk1 beam!!!! Time will tell when I remove the original this weekend! Trial fitted the axle mounts with new bushes too, all looks good there, just need Timorese some correct pitch bolts as the temp Ines I have are not what I want,
Car stripdown begins tomorrow night hopefully, engine and box coming out…… stay tuned……

This is just incredible!  Fantastic work.  

Today was a busy day, engine and gearbox out, all suspension removed, fuel tank removed, jig mounts built, car mounted to the jig and rolled over, now to asses the car, few little bits I need to sort, axle mount drivers side needs a repair as one of the studs snapped off, and sill lower lip has been folded over due to being jacked up on, so nows the time to get that sorted too, 
Tomorrow's jobs are
Remove spare wheel well and rear crossmember
Clean off sealer and trial mount the axle 

 Lots done today, let's the pics do the talking!!

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Plenty done the last couple of nights, spare engine block and gearbox mounted within the car to mock up for the propshafts length's, also measured up for the o/s driveshaft, propshafts needs shortening by 8 inches and the drivers shaft also needs shortening, but I had a little brainwave this afternoon, I would strip the 4 motion skoda rear shafts and check them for length, low and behold the n/s/r 4 motion shaft looks to be the correct length for the o/s/f shaft! Result!!
Got to making up the rear axle mounts tonight, got one side made up and tack welded into the car, took a good three hours to get that right! But kept all the cardboard templates so the other side should be much quicker! 
So tomorrow nights plan is to get the passenger side mount finished off and then set about fabricating thebdruvers mount, more to come…..

Getting very interesting now.

Lots done in the last week, axle mounts finished and ready for sealer,  finally found me a pair of rallye rear caliper carriers 😍😍, rear axle rear mounting plate made up and bush fitted, rear crossmember fabricated and welded into place, boot floor template made up and cut from steel tonight, screws into place for now until final trimming is done and then that can be welded into the floor…… rear arms off for Powdercoating tomorrow, I decided on and colour as of yet tho…….

Great working going on there. Loving the fabrication work.  

I would love to have a haldex on mine.

You're a boss man! Mine next! 😘

Plenty done since last update,  boot floornin and finished, fuel ya k situation worked out and organised (mk2 escort efi boot mounted tank) battery rocation box built into the spare space u see the rear seat, sill ends capped off and welded up, camber and toe adjuster kit welded to the rear beam so we have some geometry adjustment,  axle and all accounted parts been for Powdercoating with all new power flex polybushes, tunnel fully raised and gear selector sorted, seam sealed most of the floor pan apart from inside the rear arches, one rear turret Finnish last night, just needs dressing back and some sealer, steering rack mounting points lowered to allow room for the prop shaft, each column joint extended….. drivers turret to do tonight….. planning to get the underside cleaned and coated in raptor this weekend 

Plenty done since last update,  boot floornin and finished, fuel ya k situation worked out and organised (mk2 escort efi boot mounted tank) battery rocation box built into the spare space u see the rear seat, sill ends capped off and welded up, camber and toe adjuster kit welded to the rear beam so we have some geometry adjustment,  axle and all accounted parts been for Powdercoating with all new power flex polybushes, tunnel fully raised and gear selector sorted, seam sealed most of the floor pan apart from inside the rear arches, one rear turret Finnish last night, just needs dressing back and some sealer, steering rack mounting points lowered to allow room for the prop shaft, each column joint extended….. drivers turret to do tonight….. planning to get the underside cleaned and coated in raptor this weekend 

mad skills that's a great project you have  

Really need to update this post, car was completed one week before gti spring fest at Santapod, and some testing was required, so we loaded her up and trailered her down, just incase anything broke 😂😂 pics and vids to follow