My True Blue Jetta Coupe (225hp Swap Project) by beetlevdubn

5 minute(s) of a 30 minute read

I was able to make some decent progress today, in preparation for it going over to my local shop for the FMIC tubing fab work. I was able to mount the FMIC, the radiator (with the fan), and the euro grill (to ensure there was plenty of room for mounting). I had to do the sacriligious, I trimmed the euro grill 

In order to fit the IC, I made two cuts in the core support bracket, and flattened the support bracket as seen below:

Here is a pic of the trimming that had to be done to the euro grill. This was necessary because the FMIC was so close to the core support, that the clips of the grill were interfering with the IC and weren't able to snap all the way in.

I was able to roll the car out, with the BBS RS installed, so I could take a couple pics, and sweep out the garage (it was getting pretty messy under the car):

I was also able to get the timing belt cover trimmed to fit nicely over the mk1 mount:

I fit one fender, and definitely will need to use a heat gun to melt all of the fender glue, then use a putty knife to remove it all, in order to get the new fenders installed. Here is a pic of all of the glue still on the fenders and the car. If anyone has any good write-ups on how to easily install mk1 fenders, I'd love to see it.


Finally, for today, I did some looking over the radiator hose situation, and wanted to show the upper inlet of the radiator, just curious if most are taking the lower outlet, shown at the bottom of this pic, and running it to the top or the bottom of the radiator, and if there are any good sites that discuss the heater hose and radiator hose fitment on a mk1 install of 1.8t? I looked at the funksoulkitty site and a few others, and the radiator and heater hoses (and coolant hose rounting for the turbo) seem to go unmentioned. Hopefully someone can offer some suggestions or links.

I'll have more later, just need to run off to kids football game.

9-26-2010

I didn't get a chance to take any pics tonight, was busy getting as many things fitted as I could. I was able to get the shift box and cables installed and connected. Still need to fab up a bracket for the rear of the shift box, to keep it flat. bonus is that the stock console and shift boot fits nicely, can't even tell that there is a cable shifter in the car.

I also swapped out the stock AMU steel water distribution hose, for an AWP steel hose. This allows me to simplify the hoses, and gives me an easy place for the lower heater hose to connect. I'll show some pics of the heater hoses, and the plan for radiator hoses, since most of the other swaps seem to skip over these details.

I also found out that the sweet stainless 3" downpipe that was supposed to be a direct fit onto this mk1, isn't going to fit as is, so it will get chopped up and refitted when the IC tubing is fabbed. That is a total bummer. It appears that the mounts that were used on the old car that the DP came out of, probably tilted the engine farther back than this setup does.

I also decided to totally toss the stock 225hp TIP, its just too bulky and the ugly corrugated rubber is hideous. I want a super clean look on all of the intake and IC hoses (will be running steel tubing that is black wrinkle coated with black silicon hoses... just keeping it all clean and low key... no bling zone under the hood other than a polished Diverter Valve). 

Hoping to get the car over to the shop by Tuesday.