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Discussion Starter · #1 · (Edited)
Black and Blau Project Thread

I've been working on this for a while now. Wasn't going to create a project thread until it was done as my progress has been slow. I think there is enough to keep everyone interested for a bit. I was shooting for SOWO, but with work and home projects, I have pushed my goal back to Motorstadt 8

I bought the car a few years back as a driver while my Audi was down. It was in great shape and a California car with no rust to speak of. Unheard of in MI. 1.8l 3 speed auto.


I swapped over a Westy grill, lights and support to replace the 12 bar and spent aeros, threw on a set of Vmaxx I had sitting around and Helios interior. I cleaned the car up a bit, swapped the black dash pieces for blue and rocked it like that for a while.



I started to really enjoying the car even with the auto. I had never driven a MKII auto before and they are actually quite fun. As fun as it was, I still liked rowing the gears and just happened to have everything for a 5 speed swap in the garage. As soon as the Audi was back on the road, I brought the car back in, repainted all the black trim and bumpers, swapped in the 5 speed, gave it a good waxing and threw some borrowed Panasports on.
This is how she looked at Motorstadt 6


A friend was moving to Texas and needed to dump some of the stuff he collected oever the years. Can't pass up a good low mileage ABA

I tore it down to clean and freshen up with new gaskets and such. I rewired the engine side harness to come out the front of the motor while this was happening.



Spent alot of time in here poking away at stuff

Time to pull the old lump. She was a good runner, but it was time to go

Before pic of the engine bay


More coming, time to save.
 

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Discussion Starter · #2 · (Edited)
Started Cleaning up the engine bay filling hols and making plans. I want to keep all the OEM lines, just clean it up a bit.


What to do with this battery tray area to clean it up? I like the look of the welded panels, but didn't wan to go that route


Started in on the seam sealer removal. This sucks btw.

It was really hard to remove behind the strut tower around the rain tray. Out came the rain tray, some thing I wasn't originally planning on doing.

Next was this little gem. There are like 6 angles that converge in this area and I wanted to retain that

To the OEM!

A little welding and blending

Won't be needing this guy anymore

Borrowed this form my buddy Joe Zeeuw. some of you may have heard of him, he does some nice work.

Once I was able to remove more out of the engine bay, I got to finishing up my welding

And done. For now at least.


If I might, I would like to mention I am no photographer, and I've been here before ;) This was my last 2.0l swap, shaved bay project.
 

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Discussion Starter · #10 ·
Winter began setting in, so I put any body filler/paintwork on hold and turned my attention to other things that needed to get done. This is the beauty of making a build thread after the fact. The work was slow, but things got done.
Cleaned up an old 2y trans I was given. This included replacing the 5th gear with a diesel unit.

Hit it with some POR-15. Not sure this is the trans I will end up with, so I didn't want to go through all the trouble of splitting the case and having it coated. The POR should hold up quite well while it is in the car.

Cleaned up all my welds inside the car, POR'ed them and threw on some Dynomat for sound deadening.


 

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Discussion Starter · #11 · (Edited)
While the car is up and the box is accessable I thought I would make use of the shifter rebuild kit I had sitting around. The box was pretty rusty, so I ran it through the blasting cabinet and coated it.



I always make the mistake of leaving the wiring for last. Not this time.
The good thing about the early Jetta is the fact that it uses the same fuse box and harness as the Cabriolet/Scirocco/Caddy. I had already done this swap and had my notes to work from.

I spliced the MKIII engine harness into the MKII as opposed to rewiring the whole car for CEII. Once this was done, wire were numbered and the harness split. The harness was taped and the section to run through the frame rail wrapped in loom to protect it from vibrations and chafing.

There is a convenient plug in the floor to access the chassis leg


I reamed it out a bit to accept a factory grommet

Ran the harness through. The larger one is for the engine and smaller for lights, turns, fan and horn.

If you remember, I rewired the engine harness to come out of the front of the motor. I wanted to retain the stock barrel connection for quick disconnect. a spot for this was chosen and the soldering began.


 

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Discussion Starter · #13 ·
Not much to report. Been giving the ol' Blasting cabinet a workout cleaning up some bits that have yet to be addressed.


The sound deadening in the footwells was pretty nasty. A friend of mine works at the dealer and found me OEM replacements. I didn't want to simply remove it as it's actually functional and helps the carpet sit right.
 

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Discussion Starter · #14 ·
Small Update.
I spent a couple days wiring the lights.

Here you can see the harness on the right. It starts at the passenger turn signal, picks up the passenger light, travels across the rad support, picks up the drivers light and turn and ends. I am going to use the stock MKIII barrel connector so I can remove the rad support with everything attached.
Here's a pic from the other side.

I wasn't sure how these ugly bastards were going to look coming through the firewall.


So I did some Mcmastering and came up with these:

Funny I need two and they only come in bags of 10. I'm sure I'll find somewhere else to use them. I drilled out the hvac and put them in.

as you can see in the first pic, they are knurled and slotted. They push out on the plastic when a bolt is inserted.
When I ordered the Fender bolts, I got extra so I could use them here


I did a couple more things like mounting the coil, cutting a hole for the wiper wiring, re-assembled the hvac, etc. that I don't have pictures of and laid the final coat of filler. Finish sanding has started and it should be in primer by tomorrow and painted by sunday.

I have the next 5 days off and hope to get quite a bit done.
 

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Discussion Starter · #19 ·
As promised
I was hoping to get the bay in primer friday, but spent the whole day sanding and running around instead. Johnny B stopped by and helped me erect my temporary paint booth. Although the day was pretty well burnt up, I was happy to get the finish sanding done, the garage cleaned and beer consumed.

After a long day on saturday, the bay was in primer. This took several trips to the hardware and a gun exchange at HF. I had every thing set, went to adjust pressure to the gun and noticed a huge crack at the back. Grrr. The plus side to the day was garrett and Corey stopping by to help out. Garrett spent a good part of the day wrestling with the headliner which had previously been recovered with liquid iron and would crack every time you tried to remove some material. As well as removing the material from the headliner and repairing all the damage with fiberglass, he brought over his Bissell AutoCare ProHeat® cleaner and gave the carpets a proper bath.
I was in full work mode and this is the only pic I have from saturday

Today was much better. After taking the dog to the dog park only to have him hid from the sun under a picnic table, I got right to work. Color went on great with only a couple snags. Clear went much of the same direction other than me spilling a cup of freshly mixed clear all over my bench thus reducing my supply of hardener. After 3 coats of color and 3 coats of clear the painting is done. Let me tell you after putting seriously close to a hundred hours into the bay, the paint was giving me a heart attack. I was a sweaty nervous mess. Here's the result.



We got the lips 3/4 done on these too
 
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