I don't usually make threads like this... but I figured, why not show you what ten years with a MK3 has looked like from my view and where I think this car will be heading (and obviously as many pictures and updates as I can provide). If you don't care about the story, scroll down, and I'll talk about what I've got planned as the winter goes along and you can decided if you're interested.
Anyway, let's begin. My Dad drove this home one day after we spent a few weeks searching for a replacement for my last car, which was just totaled. We had actually looked at a few MK3s prior to the Hyundai, but never found anything that I wanted to spend the money on. This was a beautiful GLS - 2.0, 5 speed, 54k miles and only 5 grand.
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It didn't take me long to make rookie mistakes. Had an aftermarket muffler welded on that wasn't actually designed for the car, found a europlate, bought smoked tails and didn't seal them properly... oh, and got into an accident.
~

Eventually I started doing things right. Picked up a used FK 60/40 from Dave (not sure if he remembers, but thanks for the good deal :wave
, found some amber turns, and bought some leather seats from a friend of mine (they actually had more mileage than my car at the time :laugh
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I can't remember exactly how this next stage started. I remember reading about some Vortex guys using the TDI manifold/turbo on the ABA with some other odds and ends and having a fun turbo setup. And I remember my friends saying I'd never do it. At some point, I was taking a piss on a Saab 9000 at at junkyard in New Ringgold and found this gem. About an hour of struggling through the cold, grime, and corrosion, I slapped $20 down at the front window and walked away wondering what I just got myself into.
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I did my research. Rebuilt the turbo myself. Pieced together parts. Was this actually going to ****ing happen?
~

Yup. Half-assed. But it ran.
~

At that point, my buddy and I shared rent for a small garage in college. It barely fit a car in when you closed the door. But with the space, I decided I'd start piecing together a front mount setup and grab a new exhaust. Unfortunately, the exhaust never came and I wasn't finished with the FMIC setup, so I dyno'd it open downpipe and that intake setup up there. I've lost the digital copy of the readout, but I netted 156hp and 161 ft. lbs. of torque. And the sound was hilarious :laugh:
~

A few months later, the FMIC setup was finished and I headed up to Waterfest and threw it on the dyno. No video this time... no printout again (although I have it somewhere)... but 10psi on a 95 degree day, 80-something percent humidity netted by 166hp and 179 ft. lbs. of torque. Disappointed, but I kept up with some MK5s on the way home, so it wasn't as slow as the numbers suggested I guess.
~

The obsession with the car ultimately ended up as a point of contention for my long term girlfriend at the time and we split. Obviously, more reasons than that, but no doubt the car was brought up. Stupidity ensued. Ulimately, the car ended up in a ditch a week before student teaching. My parents refused to put it through insurance because they figured it'd be totaled.
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So, in-between a new girlfriend, lesson planning, working a side job on campus at night, and trying to find a job, I got to work piecing the thing back together. I had no experience with body work, only a garbage Harbor Freight flux-core welder, and barely any money to make this happen the right way. Everyone told me to part it and move on. But hey, I owed this car a comeback.
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The car sat around like that for a while. I even thought about selling it. But after securing a job, it only took me about a year to put together some cash and finish things up and keep moving forward. I picked up a set of new rollers, coilovers, a MK4 intake manifold setup, salvaged the FMIC, and did some other odds and ends, including finish up the body work. Other than paint and a replacement damaged rocker panel, I got the entire front end lined up and sent it off to a local shop to make it look new again. I let them keep the thing for a month and treat it as side work, helping keep the bill down. Right after my 24th birthday, I got a call that it was done.
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It only took me a few weeks to make a bad financial decision now that the car was clean again. Traded the steelies and some cash for a setup of minty staggered Borbet Type As. Did I have the money to spend? Not really. But damn did these wheels look good.
~

As happy as I was with the new look, the trip home ruined the mood. Got all the way back to Harford county and a deer pops up and attemps to slide across my hood... you know, Dukes of Hazzard style. It didn't work out so well. Ironically, the only two parts on the front end that weren't new were the driver's side fender and the windshield. I thought about selling the car again at this point. Instead, I had some fun with the vinyl cutter, laughed it up, and moved on.
~

~

After a quick trip to the body shop again, car came out looking new for the third time. Or was it the fourth? I've lost count. Car was still fun... but odds and ends started to drive me nuts. Exhaust leaks were giving me fits. Stereo began showing it's age. The coup de gras was the clutch - an ACT Stage 1 setup, which was new with the intial turbo setup, was slipping after only about 15k miles. Pulled the trans to find a rear main seal leak... again, only 15k miles of use. Replaced it with a part from GAP. Thew new part leaked after 40 miles. Gave up on the car for the season and it sat at my parent's house.
~

The fall rolled around and I got a chance to pull the trans and slap together a clutch setup using the ACT Stage 1 PP, a Clutchmasters CF Stage 2 disc, and a lightened flywheel. Setup was great. Got the car back to Lutherville (living with my girlfriend at the time) and after a trip back from work I got a loud CLUNK, THUD, and an awful dragging noise. ****. Limped it to the side of the road. Driver's side axle was on the ground. I guess in my rush to get the car back together, I never completely torqued the bolts. How the axle ever ended up on the ground without smashing a hole through the trans case still baffles me to this day. But, it was a sign to keep moving. So I did. Girlfriend was not happy with this situation... and we fought about it... and I left. I already had my foot out the door at this point, but this was now the 3rd serious girlfriend that pretended to like the car and ultimately decided to come out and tell me she hated it.
Odds and ends for another year. Decided to entire it again at the Deutsche Classic in Fleetwood. A fun show, different setup, didn't expect to win, or even place, just like the last time.
~

But I decided to stay and see who won. There was a black MK3 GTI, sick turbo setup, a good looking car... his name is Kyle... if you see this man, I still think you deserved first. But, after all the hell I put this car through, it deserved some kind of award.
~

The car hasn't changed a whole lot. I found some money to throw in a TT 266 cam and the appropriate hardware about a year and a half ago. The ex-girlfriend had bought me the USRT Smart Shift kit before we split and I finally got to install that. But other than that, I hadn't had time or the space to do much other than drive it. Issues would creep up here or there. I was starting to get sick of it. Then I made an honest women out of my current girl. In the process, we had began looking at houses. She insisted we look at a set of townhouses with garages which I had initially veto'd (I was not a huge fan of the layout initially). She was right (I didn't tell her that though)... we fell in love with one of the houses and threw in an offer. The current owner was actually one of my current students (well, their parents) and I worked that angle as hard as I could. The day we closed, I parked the MK3 in a garage that it could call it's own for the first time.
Took me sometime to get the garage to make sense for my needs. It had a single GFCI outlet... installed a new 20 amp breaker and ran conduit for new outlets. It had a single incadescent lamp holder... installed two shop lamps. I needed a bench that would fit the space... I repurposed 2x4s that made up previous shelving in the garage and made a corner bench. Storage was an issue without the shelves... took a metal shelf from school that was serving me no purpose in my classroom and built a storage shelf above the bench area. Eventually, I brought all my tools down from PA. It was only ten years in the making, but this past week, a real tear down finally began.
~

So, where am I going from here? I've got a ton of ideas in mind... but I need this thing running by the wedding. I'm driving it to the venue, it's being parked out front, and it's allowed to play a cameo role in a few pictures (I think you can see why I'm marrying this one).
I've got some issues that I've put off that I'll be taking care of. The list goes, in no particular order:
That list is boring... here is the "build" portion of the thread (if that's what you want to call it) I can't guarantee this is all gets done, but at least I finally have a damn list
Proof I got **** done today.
~

I'm going to start working on the AC compressor this week... plan on cleaning it and painting it... any suggestions on paint? I know Eastwood makes a product everyone seems to like, but I know you've all got your own experiences.
I plan on keeping you guys up-to-date as much as I can. That should be pretty easy throughout the winter and early spring... might get tougher as I get close to the wedding. Hope you stick around to see what the next ten years brings :thumbup:
Anyway, let's begin. My Dad drove this home one day after we spent a few weeks searching for a replacement for my last car, which was just totaled. We had actually looked at a few MK3s prior to the Hyundai, but never found anything that I wanted to spend the money on. This was a beautiful GLS - 2.0, 5 speed, 54k miles and only 5 grand.
~

It didn't take me long to make rookie mistakes. Had an aftermarket muffler welded on that wasn't actually designed for the car, found a europlate, bought smoked tails and didn't seal them properly... oh, and got into an accident.
~

Eventually I started doing things right. Picked up a used FK 60/40 from Dave (not sure if he remembers, but thanks for the good deal :wave
~

I can't remember exactly how this next stage started. I remember reading about some Vortex guys using the TDI manifold/turbo on the ABA with some other odds and ends and having a fun turbo setup. And I remember my friends saying I'd never do it. At some point, I was taking a piss on a Saab 9000 at at junkyard in New Ringgold and found this gem. About an hour of struggling through the cold, grime, and corrosion, I slapped $20 down at the front window and walked away wondering what I just got myself into.
~

I did my research. Rebuilt the turbo myself. Pieced together parts. Was this actually going to ****ing happen?
~

Yup. Half-assed. But it ran.
~

At that point, my buddy and I shared rent for a small garage in college. It barely fit a car in when you closed the door. But with the space, I decided I'd start piecing together a front mount setup and grab a new exhaust. Unfortunately, the exhaust never came and I wasn't finished with the FMIC setup, so I dyno'd it open downpipe and that intake setup up there. I've lost the digital copy of the readout, but I netted 156hp and 161 ft. lbs. of torque. And the sound was hilarious :laugh:
~
A few months later, the FMIC setup was finished and I headed up to Waterfest and threw it on the dyno. No video this time... no printout again (although I have it somewhere)... but 10psi on a 95 degree day, 80-something percent humidity netted by 166hp and 179 ft. lbs. of torque. Disappointed, but I kept up with some MK5s on the way home, so it wasn't as slow as the numbers suggested I guess.
~

The obsession with the car ultimately ended up as a point of contention for my long term girlfriend at the time and we split. Obviously, more reasons than that, but no doubt the car was brought up. Stupidity ensued. Ulimately, the car ended up in a ditch a week before student teaching. My parents refused to put it through insurance because they figured it'd be totaled.
~

~

So, in-between a new girlfriend, lesson planning, working a side job on campus at night, and trying to find a job, I got to work piecing the thing back together. I had no experience with body work, only a garbage Harbor Freight flux-core welder, and barely any money to make this happen the right way. Everyone told me to part it and move on. But hey, I owed this car a comeback.
~

~

~

~

~

~

The car sat around like that for a while. I even thought about selling it. But after securing a job, it only took me about a year to put together some cash and finish things up and keep moving forward. I picked up a set of new rollers, coilovers, a MK4 intake manifold setup, salvaged the FMIC, and did some other odds and ends, including finish up the body work. Other than paint and a replacement damaged rocker panel, I got the entire front end lined up and sent it off to a local shop to make it look new again. I let them keep the thing for a month and treat it as side work, helping keep the bill down. Right after my 24th birthday, I got a call that it was done.
~

~

~

~

It only took me a few weeks to make a bad financial decision now that the car was clean again. Traded the steelies and some cash for a setup of minty staggered Borbet Type As. Did I have the money to spend? Not really. But damn did these wheels look good.
~

As happy as I was with the new look, the trip home ruined the mood. Got all the way back to Harford county and a deer pops up and attemps to slide across my hood... you know, Dukes of Hazzard style. It didn't work out so well. Ironically, the only two parts on the front end that weren't new were the driver's side fender and the windshield. I thought about selling the car again at this point. Instead, I had some fun with the vinyl cutter, laughed it up, and moved on.
~

~

After a quick trip to the body shop again, car came out looking new for the third time. Or was it the fourth? I've lost count. Car was still fun... but odds and ends started to drive me nuts. Exhaust leaks were giving me fits. Stereo began showing it's age. The coup de gras was the clutch - an ACT Stage 1 setup, which was new with the intial turbo setup, was slipping after only about 15k miles. Pulled the trans to find a rear main seal leak... again, only 15k miles of use. Replaced it with a part from GAP. Thew new part leaked after 40 miles. Gave up on the car for the season and it sat at my parent's house.
~

The fall rolled around and I got a chance to pull the trans and slap together a clutch setup using the ACT Stage 1 PP, a Clutchmasters CF Stage 2 disc, and a lightened flywheel. Setup was great. Got the car back to Lutherville (living with my girlfriend at the time) and after a trip back from work I got a loud CLUNK, THUD, and an awful dragging noise. ****. Limped it to the side of the road. Driver's side axle was on the ground. I guess in my rush to get the car back together, I never completely torqued the bolts. How the axle ever ended up on the ground without smashing a hole through the trans case still baffles me to this day. But, it was a sign to keep moving. So I did. Girlfriend was not happy with this situation... and we fought about it... and I left. I already had my foot out the door at this point, but this was now the 3rd serious girlfriend that pretended to like the car and ultimately decided to come out and tell me she hated it.
Odds and ends for another year. Decided to entire it again at the Deutsche Classic in Fleetwood. A fun show, different setup, didn't expect to win, or even place, just like the last time.
~

But I decided to stay and see who won. There was a black MK3 GTI, sick turbo setup, a good looking car... his name is Kyle... if you see this man, I still think you deserved first. But, after all the hell I put this car through, it deserved some kind of award.
~

The car hasn't changed a whole lot. I found some money to throw in a TT 266 cam and the appropriate hardware about a year and a half ago. The ex-girlfriend had bought me the USRT Smart Shift kit before we split and I finally got to install that. But other than that, I hadn't had time or the space to do much other than drive it. Issues would creep up here or there. I was starting to get sick of it. Then I made an honest women out of my current girl. In the process, we had began looking at houses. She insisted we look at a set of townhouses with garages which I had initially veto'd (I was not a huge fan of the layout initially). She was right (I didn't tell her that though)... we fell in love with one of the houses and threw in an offer. The current owner was actually one of my current students (well, their parents) and I worked that angle as hard as I could. The day we closed, I parked the MK3 in a garage that it could call it's own for the first time.
Took me sometime to get the garage to make sense for my needs. It had a single GFCI outlet... installed a new 20 amp breaker and ran conduit for new outlets. It had a single incadescent lamp holder... installed two shop lamps. I needed a bench that would fit the space... I repurposed 2x4s that made up previous shelving in the garage and made a corner bench. Storage was an issue without the shelves... took a metal shelf from school that was serving me no purpose in my classroom and built a storage shelf above the bench area. Eventually, I brought all my tools down from PA. It was only ten years in the making, but this past week, a real tear down finally began.
~

So, where am I going from here? I've got a ton of ideas in mind... but I need this thing running by the wedding. I'm driving it to the venue, it's being parked out front, and it's allowed to play a cameo role in a few pictures (I think you can see why I'm marrying this one).
I've got some issues that I've put off that I'll be taking care of. The list goes, in no particular order:
- Strut bushings/bearings
- Downpipe flex section needs to be inspected, cleaned and re-welded
- Remove junk turbo blanket (smokes like a bitch)
- Flush brake fluid
- Replace driver's side axle (torn boot on non-OEM axle... might find a used axle and rebuild it)
- Replace rear o2 sensor (banged up from half-assed o2 bung from college)
- Replace tires (195/40 S.drives most likely)
- Fab up new shift linkage/clean up the USRT Smart Shift setup (it's all corroded and I half-assed the install... want to do it right)
- Install Samco coolant hoses (found a used set of green hoses for cheap a year ago)
- Replace/repair radiator (slight leak from end tank)
That list is boring... here is the "build" portion of the thread (if that's what you want to call it) I can't guarantee this is all gets done, but at least I finally have a damn list
- Re-paint frame rails and other exposed color matched metal in engine bay
- Pull trans, clean case and paint (I want to go with a basic aluminum silver color... any suggestions, fire away)
- Pull exposed accessories, clean, prep and paint/powder coat (alternator, AC compressor, belt tensioner... basically, anything you can really see, I want it cleaned up)
- Clean up block (not sure I want to pull the whole motor, but if the trans is out and I've got everything off it, I might as well just do it... most likely using POR15)
- Re-route power steering reservoir behind frame rail on driver's side
- Re-route some of the obnoxious exposed wiring (not shaving the bay, but attempting to clean it up a bit... more on that when I get to it during re-assembly)
- Clean up evap/emissions hardware by passenger frame rail (half-assed this last year, time to clean it up for real)
- Replace fittings and lines on BBM fuel rail to clean up how it looks
- Ceramic coat hotside of turbo and downpipe (I need to find somewhere local to do this)
- Slim electric fans
- Relay ecodes
- Find clean bumpers to begin shaving (more on this later if I get to it)
- Figure out COA for roof oxidation
- Install MK3.5 cabin filter setup
- Buy and install MBS 2.5 exhaust (most likely not going to happen this year, but it's on list damnit
Proof I got **** done today.
~

I'm going to start working on the AC compressor this week... plan on cleaning it and painting it... any suggestions on paint? I know Eastwood makes a product everyone seems to like, but I know you've all got your own experiences.
I plan on keeping you guys up-to-date as much as I can. That should be pretty easy throughout the winter and early spring... might get tougher as I get close to the wedding. Hope you stick around to see what the next ten years brings :thumbup: