4 struts, 17 inches, 2 switches: my built thread by Afazz

5 minute(s) of a 341 minute read

I realize the mk4 front brake hoses I purchased would not work on the mk4 GLI rear calipers. I couldn't use the mk4 GLi rear brake lines because they're not flex lines, and I assumed the banjo bolts would be the same size front and rear. They're not, so I had to order a custom steel braided brake hose for the rear.

The mk4 GLI rear brake hose on the left uses a 12mm bolt, the mk4 front brake hose on the right uses a 10mm bolt. It can't just be drilled.

August 5, 2009 

Got the trunk floor all in primer

A few days prior, I forgot to take pics, I welded in these stiffening ribs to strengthen the rear towers a little bit. They admittedly don't add much, but I wanted to keep it low profile so I could hide everything under carpeting in the future. Every little bit counts, and they didn't take long to make, so why not?

August 11, 2009

Started routing the rear brake hard lines

August 13, 2009 

Got the tabs welded onto the rear wheel wells to hold the brake lines.

Got my new custom brake hoses. $100 for the pair from Detroit Flexible Metal, custom to my specs. I think they were 18" long, female flare on one side and 12mm banjo on the other.

August 16, 2009

I got the hard lines finished up.

The brakes feel fine, and I think I got most of the bubbles out, but I'm not so sure about the way I chose to route this part. Will this collect bubbles that won't bleed out? I have a Motive pressure bleeder if that matters.

I got the two Wilwood proportioning valves mounted and plumbed

I had to grind down the ridges on the caliper to fit the new banjo, which is shaped differently than the stock banjos. Before on the right, After on the left

I did a bunch of reassembly work. I'm using four stock mk3 front struts just to roll the car around. No springs, just some bumpstops to hold it up but still pretty low.

Figured out a boot for the inner tie rod, which is just a cut down stock tie rod boot clamped on. It just has to pivot since the rear doesn't steer anymore I don't need the whole boot.

August 17, 2009

Did some planning on the fuel pump wiring/plumbing bulkhead.