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

5 minute(s) of a 341 minute read

I welded up the mounts, very slowly to avoid warping in the large flat panel. It ended up warping just slightly, but I couldn't avoid it.

Then I made this coverplate from 1/8" aluminum and flat-head M6 screws. I needed it to be completely flush so that I can easily integrate it into a flat false floor later.

That 4th hole is supposed to be in a weird location. If you look at the shape of the opening, I made some clearance cuts for the vent tubing in that corner and had to move the 4th hole really close to the edge. That was planned, and unavoidable unless I made the square cut larger, which I didn't want to do.

I also made a few more stiffening ribs, these will get welded to the bottom side of the big flat section later to keep it from vibrating and stiffen it up so I can pile heavy crap in the trunk if necessary. Like dead hookers. My last name is Italian...

June 4, 2009

I think these pictures are actually from both the 3rd and 4th, but whatever.

Trunk floor is almost done! Lots of little sheetmetal work. I also started making ribs underneath the hydraulic pump mounts, so I could just bolt the pump directly to the floor. It appears unreinforced, but there is heavy bracing on the bottom side. Hidden and clean is how I prefer!

More welded inserts built into the floor where the hydraulic pump will mount

June 6, 2009

I got the floor just about finished up. You can see how the ribs extend under the pump and directly into two crossmembers, giving plenty of strength to the area where the hydraulic pump will mount. It's a heavy bastard!

All my research led me to the mk4 GLI/337/20th rear brake calipers. They were designed for a 22mm thick vented rotor (stock mk3 front is 20mm) and can handle a 10.1" rotor. I took a gamble and ordered a used set from Unedrgorundvwprts. I intentionally misspelled that so they don't seach and Ethug because I'm going to talk some trash. These came in horrible condition, they were useable only because I wasn't using all the parts that came in the "100% complete" kit. I can't be too upset though because the price was right, so whatever. I ordered a caliper rebuild kit just in case, and the boots were all torn and bolts were all stripped but nothing I couldn't deal with. The paint was terrible too, but whatever I'm repainting them black anyway.



The current and final plan: MK4 GLI rear calipers, MK3 rear pads (same as mk4), mk3 2.0 front rotors, mk4 GLI rear pad carriers machined and modified to mount to the mk3 2.0 front spindle. Say that 5 times fast!

I also received my Wilwood inline proportioning valves, since I deleted the stockers with the whole rear beam. I bought two of these, which will be mounted under the floor on the diagonally split rear braking system.

And I got some flaring tools. ISO Bubble for the VW stuff and 45º double flares for the Wilwood stuff.