16V Turbo VW Cabriolet Build (for the wife)

[juicedz4]

Pretty sure itll never even be close for the Ridler award (i did have to look it up).

This project is my mix of my own idea on what it should be and using pieces of what others have done that I liked.

Dan

[juicedz4]

Worked on the wiper box a bit last night. Trimmed the lip off of the heater box hole, and cut out the one bump above the pedal area.

Created a paper template and transferred it to a piece of steel. Hopefully if we have enough dies Ill bend the edge today after work.







Finished welding the other end of the core support to the frame rail. Didnt get a chance to do the small pieces under the frame rails yet.



Overall shot looking forward.



Dan

[juicedz4]

Rain tray panel is tacked in! I had to trim a piece of the firewall out in front of the heater box hole and hammer it back about a 1/4" to allow the panel to sit back all the way and maintain a nice straight line at the bend. Added a few holes around the middle of the panel to attach it to the OE panel below and hopefully stop any rattles or vibrations. I may also add a few small welds from the inside to do the same.





Dan

[TheBandit]

Nice work. That looks like a ton of careful fitting.

[juicedz4]

It honestly wasnt too bad. I think it took under an hour to make the template. But Ive made lots of templates like this before doing interior work.

Dan

[TheBandit]

What method do you use for transferring the geometry to your template?

[juicedz4]

In this case to get the right line, since it was on a curved panel (where the firewall goes vertical), I dragged a straight edge laid across the horizontal part to scratch the paint on the vertical section, thus creating the shape I would need to copy.

Then I use poster board, and roughly cut out the shape, more or less by eye. Next, Ill set the poster board back like 1/2" or so and draw a line offset to the line I scribed, again just offsetting the distances by eye. Cut that out, repeat until fit. Finally I cut the straight line at the outer edge.

If there was room I would have used a compass to transfer the OE panel shape (along my scratched line) to the paper. Im sure I could have gotten creative with bending something up but this was a pretty simple shape.

Dan

[350 Vortec]

Super savage project and work,I've only just gone through it now,great to see a Golf getting such great treatment

[juicedz4]

Thanks 350!

Lots of progress last night.

First, I thought Id see how the OE master cylinder brace looked with some dimpled holes. I was going to make something new but I think this will look nice cleaned up and coated.



Next I tackled the seams between the upper core support and fender.

Orig


Much better


Drivers side


Filled this random "dent"




And this groove or whatever by the pass shock tower


The lower piece was fun


Much better


Next, there was this huge molded in dent (for who can remember what) at the base of the drivers shock tower. I failed miserably at trying to pull it out with the spot weld puller, pounding it out from a hole i drilled in the wheel well (its double steel here), so I finally cut out a piece of metal, hammered it into roughly the right convex shape and welded it in.


Finally, to try and get an idea how its really coming along, as its very hard to see I put a light coat of rattle can primer on..


Dan

[CarterKraft]

BUT that is exactly Ridler type work...

[juicedz4]

Ok so looks like Im going to HAVE to do the firewall now. I just used my ballR MSpaint skills and came up with this.



Dan

[entropy]

. . .just make sure that nothing on the engine sticks out there. . .

[juicedz4]

Ya. The only thing Im worried about is the down pipe. I need to check back in the pics to see if I need to put the motor back in or not.

Dan

[CarterKraft]

It does like nice smooth.

[juicedz4]

8 out of 11 prefer it smooth.

Dan

[TheBandit]

Jaysin and E made a few good points in this thread when I was considering sheeting over my firewall area. It might be worth reading through quickly.

Those flat panels you paintbrushed in might look good stamped or bead rolled to stiffen them up.

[juicedz4]

Thanks for the link, def something to consider.

Dan

[juicedz4]

Back to work after a week in FL and Thanksgiving etc.


Started on my makeshift paint booth this weekend. For reference its 16x12x8



And started on the fire wall smoothing. So glad I decided to do this, its going to look so much better.


Still need to do a bit of welding along the wheel well but for the most part its good to go.


Dan

[juicedz4]

Got a good start on the passengers side last night until I ran out of wire. Lame. Should finish up thrusday night.

Before


Cut out


Tacked


So much better


I did get the top, one side and part of the bottom welded before running out of wire. I managed to get a little smoothed out before quitting time.


Dan

[Chassisguy]

Nice work.
I did a VR6 swap on a Mark 1 GTi a couple years ago. Fun project and even more fun to drive. :)