Project Death Kart by Goofydug

11 minute(s) of a 63 minute read

After much deliberation I decided to use a headliner.
Then after more deliberation I decided to spend a few bucks more than I originally wanted on some sweet fabric.







I used Spray 90, it means bidness when it comes to stickiness.

Now I just have to install it without messing it up...

6/10/2008

The headliner is 90% installed. I still have to put in the hatch seal, and also figure out how to fix a little scissor-happy section up front by the windshield. I trimmed a little to much away, kinda bums me out but I'll mend it somehow.

The lighting in these pictures sucks, so it looks a little yellow and crappy. It looks sweet in real life, I swear.





I also managed to install my lexan rear windows. They shave a few pounds, but nothing crazy. I really just installed them 'cause they were a good deal and I wanted to try it out. If they suck I'll put my glass back in.



My sunroof was painted gold when I got the car. Although it was kinda cool, I couldn't deal with it so I painted it the same satin black as the interior.

7/19/2008

I've made some decent progress in the past few weeks. This car is like a giant puzzle, I do a lot of research and prep and make slow progress, but then all of a sudden I get to put some of those pieces together and I make giant leaps.

Nice short ratio quaife steering rack with new boots, tie rods and poly bushings.



Matt got busy on welding an AN fitting to my block-off plate to run to my catchcan.



I've been sanding down and painting the cage satin black to match the interior, I'm very happy with the results thus far.



Mmmmm Southbend kevlar clutch





Halfway installed Techtonics SS 2.25" exhaust with a Borla muffler





A couple motor beauty shots





We made some great progess last night too, but I have to sort through the pictures. I'll post more tonight/tomorrow.

My fingers are crossed to have this running by Dreamcruise.

7/22/2008

Major progress! The motor is in the car!

I want to thank Matt again for his continued help on this project, I would be crying in the corner if it weren't for him.

We bolted the transmission up to the motor.



Then put that mess o' parts onto my creeper, crossing our fingers it didnt crush it, then slid it under the car. It's funny too, the alternator was hitting the front core support a bit, so Matt and I lifted the car a few inches by hand while Kelsie slid the creeper under the car. You didn't realize how strong we are, did you?



We then ghetto rigged the cherry picker with an airline grade ratcheting strap and hoisted the engine into it's new home.





Torqued down the ARP head studs and slapped on the itb's for a test fit.





Is there supposed to be a cover here? If there is, does someone have one I can buy off you?



This TT race header is a new design made specifically for this head/block combo. Some of you may remember Joe Zeeuw's beautiful ABF Jetta Coupe. He used the original TT 16v header but had issues with it because of the extra height of the aba bottom end. This newly designed header is taller so I don't need to have Joe's skills to make it fit



The USRT shift linkage is being worked on now.



At rest in the garage.

8/4/2008

My arbitrary Dreamcruise deadline is quickly approaching, and I don't think I'm going to make it. It's ok though, I'd rather take a couple more weeks than mess something up in a rush to finish.

I made a nifty little radiator cover/holder






My air horns are a bit too long and my radiator is a little too thick. I can't use my filter box because it will hit the radiator inlet (and the hood won't close). I'm going to use the long air horns for now, and keep this radiator. Over the winter I think I'm going to have to fit one of those fancy CRX radiators and buy some shorter air horns and a new smaller filter box. $$!




Then I modified my fuel accumulator holder to fit the smaller (read: cheaper) scirocco 16v accumulator.




I need the lines that run off both ends of my fuel filter, anyone know any easy way to make these with some braided line?




While I was installing my USRT shift kit I realized I was missing a piece. I don't think BFI ever sent it to me either, I've written them about it but they have yet to respond. I really need the long piece with the two heim joints on it, anyone have one sitting around? ha.




A little trimming was required to fit my seat bases to the rails, a few metal splinters later and voila




I was having a hell of a time finding another oem scirocco proportioning valve, so I just opted to get some Wilwood adjustables. I needed a clean place to mount them so I cut up some more metal and drilled a few holes...








Miles says "wtf"

9/26/2008

Here's a partial progress update. More is being done, but not all of it is either fun to show and/or ready to show and/or photographed.


I got the prop valves mounted up.




Then I reflared the brake lines to the proper 37º flare, as opposed to my horribly wrong 45º...
(thank you matt for the tool loan)




I stayed on the liquids path for a bit and finished up my fueling situation. Instead of junkin' up my bay with the fuel filter I threw it under the car by the fuel accumulator, added some AN lines for the hell of it and called it a day.




I made all the connections and mounted all the other fueling stuff (pump, accumulator, misc tank hoses) and connected the appropriate lines to the stainless buggers that run up to the engine.




I connected it all to this POS with a shiny new powdercoated valve cover (thanks to 'four by ken')




Thanks to Johnny B. I got a sweet external hood latch. Bye-bye cable.
I had to trim the inside of my grill a bit to make it fit, but it looks badass. Thanks again John!




Then I decided to cut up my fingers a bit more, so I cut some more AN lines for this badassmofo catch can that Matt made for me!








We sneakily hid the can on the back of the motor, tucked right under the headers. It fits great.






Matt is working his magic with the wiring, I'm bolting together some lame old wheels, battling some radiator hoses, and a bunch of other fun stuff.

Onward.