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Discussion Starter · #1 · (Edited)
Thought I would share a timeline on the build, hope it helps a few doing theirs :beer:

The car static: http://forums.vwvortex.com/showthread.php?5119765-I-won-t-lie


So here are the goals:

1- keep everything hidden
2- maximize usuable trunk space
3- Maximize compressor noise reduction with Accuair Exo Mount and insulation foam
4- Easily removable wood frame
5- minimize frame weight

The toys (still missing the rear strut and Accuair Exo compressor Mount)





The build should take me a month ish, slow i know but I don't have much time with work nowadays :mad:

progress today: trunk cleaned up / come up with a frame design (two vertical boards in the spare tire, one holding the air management and one for storage compartiment) / assemble first frame support piece with curve for the driver side compartment door

ps: I'll be getting a donut spare tire for long trips and drive without one in the city since I'm covered with BCAA





Got everything laid down, storage compartiment at the bottom like i said earlier and air management above with the Sub Amp sandwiched in between the two





Installed the rocker switch, not my favorite location but one of the few places where the cable can reach behind. I trimmed a little too much on the edges but it can barely be seen once the switch in place so i'm pretty satisfied



 

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Discussion Starter · #6 · (Edited)
and that, is the beauty of the rocker switch.:thumbup:

looking forward to more updates.
The rocker rocks, saved $200, girlfriend won't be confused, no need to look at it like the touchpad. It's just more time consuming to adjust corners but I will rarely do that anyway :beer:

the only thing I suggest is place the manual button someplace more convenient. From time to time, i just want to raise the front/or rear. and you have to hit the button to get it in manual mode. It might be a pain if you have to open your door and take the fuse cover off each time.

I like the location of the switch, and your layout of the truck.:thumbup::thumbup:
Thanks, I haven't mounted the manual button yet but I want it to be easily accessed of course, I'll find a good spot for it today :)

That remote thingy control my Iphone charger, love that thing, no cable to mess with, plug the iphone and click play, done ! :thumbup::thumbup:

It's the Kensington LiquidAUX deluxe model

 

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Discussion Starter · #9 ·
hopefully your using that shag carpet for the false floor.
hell no lol, IKEA is for homes...not cars :p

Pictures are hosted by dropbox, some companie block that website, try again at home :beer:
 

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Discussion Starter · #10 · (Edited)
My metal screws were too small to mount the sensor properly so I just did a quick grinder cut for the aluminum (no rust) extension. Hopefully I can finish the sensors setup this week end....SLOW PROGRESS LOL :eek::p

ps: thx to those who posted sensor placement pics here: http://forums.vwvortex.com/showthre...s-of-AccuAir-levelers-install(hopefully-a-MKV)

I used a shorter FSB bolt purchased at home depot: the OEM spec is M10x50mm


 

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Discussion Starter · #12 · (Edited)
Got the Passenger side sensor done today. I decided to mount it a bit closer to the front to avoid contact with the future notched frame hole




Here how the sensor is fully extended and fully compressed on Raceland coilover, Hopefully the Airlift XL doesn't extend more or I'll have to cut a longer aluminum bar


I had to mount the sensor arm backward to increase the tire/sensor gap when the wheel was fully turned left.
 

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Discussion Starter · #16 ·
Waiting for the last shipment, hopefully next week :peace:

ps: if i'm not lazy, i'll finish the air lines and sensors this week end :facepalm:
 

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Discussion Starter · #22 ·
Thx guys, coming along nicely, received the LOCTITE 545 yesterday, woot

Got your email Will, I'll do a manual adjustment, using the automatic feature might damage a tire/fender/axle i think, agreed :beer:
 

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Discussion Starter · #25 ·
Driver side done, I kept the sensor closer to the center this time to prevent tire/sensor damage when turning

 

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Discussion Starter · #26 ·
Since i've got no welding skills nor tools, I've decided to tap the hole (tap size 5/16-18 NC with 1/4" drill bit)

Added some thread locker and black adhesive sealant, that thing won't come off now :thumbup:

last shipment due next week, woot :beer:



 

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Discussion Starter · #27 · (Edited)
Trimmed the fender liner (a little too high as shown below). I used two washers to keep the sensor mounting base flat. Pictured below is the suspension fully extended and fully compressed


 

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Discussion Starter · #32 · (Edited)
Intuitively this statement makes good sense, but the reality with our sensors and the e-Level system is that as long as you have over 1" of travel, you will not see a noticeable difference in accuracy or performance. This is because the sensor itself puts out an infinitely accurate output by using non-contacting magnetic technology. The e-Level controller will then calibrate to the lower sensor travel and span the total travel to 100%. So definitely staying on the safe side of sensor travel is better than over extending the things :)
thanks for the clarification Reno, I'm glad I didn't waste time :D

Rear Driver side done, last sensor picture promised :p

EDIT: OffLineR was right, the rear sensor travel is too short. After doing the auto calibration on page 2 the rocker switch showed a warning about that. I'll have to move the ball further in the rear. I'll post picture :beer:

 

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Discussion Starter · #34 · (Edited)
Some Exo Compressor mount and rolling action today, FUN ! :D

Note: I re-arranged the compressor feet using a few washers to line up the holes and keep the EXO mount+compressor balanced (both side equally weighted)






 

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Discussion Starter · #38 ·
how much of that did you pick up? and where?

I should apply some while the truck setup is getting redone.
I used 9 sheets of 1.67 sq. feet each ($100 CAD total) locally picked up at Hotrod Corner in Surrey BC,

check out the dealer page on the secondskin website :thumbup:
 

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Discussion Starter · #39 · (Edited)
another test fit before drilling and screwing. Also added an insulation foam layer on Compressor/tank vertical board

 

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Discussion Starter · #42 ·
I've always enjoyed taking picture while working on my car, a good habit i'm sure :)

thanks :beer:
 

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Discussion Starter · #44 ·
What do you do for a living? You should give it up and become a carpenter ;)

Looks good btw

Why did you choose to mount things off vertical panels instead of on a floor panel? Do you think that it will lessen the vibrations from the compressors?
haha, carpenter?, you should see what my neighbor carpenter built at our place, stairs / storage house / etc..., my little project can't compare :D

I run a freelancer IT consultant company and work as a full-time Infrastructure Support Specialist as well, doing a smooth transition from employee to employer :)

Good question on the vertical board, I chose this design because the compressor EXO mount needed it and I wanted to maximize space usage in there. With a floor panel, there would be no room for a storage area like i have now.

You'll see for yourself hoepfully this week end :beer:
 

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Discussion Starter · #45 · (Edited)
Ran the air line and sensor wire for the rear driver side (thanks goes to kiarash for sharing his creative ideas)

And started assembling the compressor/tank board





 

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Discussion Starter · #46 ·
Valve mounted (I'll use some elbow unions for the 90 degrees angle air lines connection)




 
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