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Discussion Starter · #1 ·
This build thread will be rebuilt from the beginning. Have patience with me. I have uploaded all my pics to my new Photobucket account.

Screw Hostdub.


This weekend begins year four of my build.

I thought I would start a thread that I could make regular posts to...
So I'll fill in the intervals from my lack of consistent forward progress by including some of the mini projects that I have completed so far.
This was a fun weekend, as I finally got my Porsche 914 mirrors mounted that my wifey got me for Christmas. I like 'em. I think they fit the squared off lines of the body.

To mount them I had to make new rubber seals to make up the 17 degree difference between the mirror base and the slanted door. Contact cemeted the rubber to a piece of wood and ran it through the table saw at work. Worked like a charm.

I have enough of the cut rubber to make two extra seals if anyone else would like to mount these mirrors.
The stock mirrors have a wider mounting hole spacing and the cable access hole that all need filled in by weldng.

I used a piece of 1/4" x 5/8" bar stock to fill in the cable hole, because the rear 914 mirror mounting hole will need to be drilled and tapped through it. The front mounting hole is drilled and tapped at the origional front hole location.
All filled in.

And drilled and tapped using a 6mm. x 1.0 tap. Use the same screws that are used on the 914. They will be long enough, and they have a nice chromed oval phillips head.

My project will hopefully show some of my detail ideas that have not been done before, stay tuned... Like or don't like, don't hesitate to chime in.




Modified by All VW All the time at 9:35 PM 12-13-2007
 

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Re: "Old Guy" It may take a decade 16v build thread (coolerow)

Those do look good. I thought about picking up a set a few years ago for my cabby. nice work , but couldnt you have possibley switched bases on those mirrors to perhaps a set of flag mirrors? that was my idea if the holes didnt match up.
 

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Discussion Starter · #7 ·
Re: (addictheadvw)

Quote, originally posted by addictheadvw »
I think it looks great! What are you welding with, o/a?


My Hobart is now my newest best friend. I keep learning but I have a long way to go.


But now, lets to go back in time three years...
One of the first things I did once the car was all stripped down and cleaned (you don't want to see those pics, way too boring, and you've seen them before in most every other build thread) was to install a custom hitch that will be hidden when I am not towing. I will make a removable fiberglass rear valance panel that will attach using Dzus fasteners. Haven't started the valance project yet. I have to make the mold first from the metal panel I got from Far Out Parts, then I will make a couple of new valances pieces off the mold.

The hitch bar looks way off center, but the bar only extends out so the relocated hitch endplates can bolt through the off center spare wheel well on both sides and also through the floor. I welded backup plates on both sides of the floor to spread the load out. There will be seven bolts total. Its not going anywhere!
You can just see the 2.0 16v short block on the stand. Bottom end is done. Long way to go to finish it. Lots of head and manifold porting. Finishing the engine will be this winters project.

Far Out Parts came through for me on the rear valance. No problems, and it only took two weeks to arrive http://****************.com/smile/emthup.gif Now, they are no longer in bidness! Or so I've read. Bummer because they had a nice selection of the kinds of things we all need to rebuild these cars.


I won't be running a spare so I needed to make a recess pocket to provide clearance for the hitch behind the wheel well.


I also made a battery tray in the wheel well to hold the Optima at a low enough height that will still allow a nice flat floor. There will still be room for a 12v portable compressor and a can of fix-a-flat along with the obligatory complete tool kit.


Back to the present: Engine Bay
Making hole plugs. Slow and boring. Cleaning up and shaving all the crap I won't be needing. Keeping the rain tray and heat though. (Cleveland can get cold)

Shaving the rail lip. The first step in the long process.

Thats one side.

All for now. Way more to come.



Modified by All VW All the time at 7:22 PM 12-13-2007
 

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Discussion Starter · #10 ·
Re: "Old Guy" It may take a decade 16v build thread (All VW All the time)

My custom bumps...


I want them tucked up nice and tight and tapered to match the fender lines. I have always hated the rubber endcaps.
I will paint them body color and make a polished aluminum center strip with hidden mounting bolts. The removable valence hiding the hitch is not done yet, but the bumper will hide the top seam.


The front was more challenging because it needs to work with the GTI spoiler shape, the fender lines, and the side of the grill. I have always liked the Westy/GTI front end and intend to keep it. No rounds for me!
SAVE THE WESTY!
The original bump with about 1 1/4" shaved off the top surface to get it tucked in tight.

Trimed the ends to match the tapered fender line

Made 1/2" end plates and Weld 'em on. Chop, cut, weld, grind, fit, file, sand, file, sand, file, sand and repeat.


Notched the back edge of the bumper bottom so the air spilling off the spoiler can still get in through the lower radiator opening below the grill.

I used the original brackets that were then sectioned 3" and rewelded for both the front and rear. I cut almost 10lbs. off the original bumpers and brackets in the process. http://****************.com/smile/emthup.gif



Modified by All VW All the time at 7:46 PM 12-13-2007
 

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Re: "Old Guy" It may take a decade 16v build thread (2manyprojects)

Quote, originally posted by 2manyprojects »
The custom bumpers are killer http://****************.com/smile/emthup.gif

x2 http://****************.com/smile/emthup.gif http://****************.com/smile/emthup.gif
 

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Re: "Old Guy" It may take a decade 16v build thread (avw4me)

Those mirrors are nice, good work http://****************.com/smile/emthup.gif
 

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Discussion Starter · #20 ·
Re: (opusdestructo)

Quote, originally posted by opusdestructo »
are you welding the bumpers with the hobart as well? that's a mig correct?

No, I tapp into a friend on all things aluminum. He has a welding shop and is very good.
My next welding step is to get a TIG. Any real welding fabrication should be TIG.


Modified by All VW All the time at 12:13 AM 7-11-2007
 
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