Dirtydubbers Resto Corner MK2 Jetta 8v GTI.

jedi16v wrote:Inspiring work as always bud can't wait to see the finished car at a show

Thanks Jedi we are hoping to have it finished as soon as! so we dont totally miss this years show season.

Starting from were we left off before, There was only a couple of things to do to the block now first the pistons. Getting the coke off the pistons has to be the worst part of any bottom end rebuild this took me and my business partner Matt a good couple of hours to get done but worth it in the end.

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Finding a good set of piston rings for a 2e tall block is a tuff process and there not cheap too! Set a budget for around £250 and you want have to much left over . But it only seems right to put the good stuff in.

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And just a handfull of the many genuine seals and gaskets that are finding there way onto this engine.

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Right back to the pistons, all finished and ready for the final position of the rings before they go in. I wont bore the hell out of you on "how to fit your pistons and rings" but i will say that it is well advised to do your homework first and make sure you know what your doing because if you fit them wrong you will have to strip the block and start again!!!

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Now to get um in . With plenty of oil on the cylinder walls we like to us a mix of engine oil and GT85 this seems to give a nice PTFE coating to the cylinder walls this will help reduce friction on the first start up.

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And from the under side.

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Now the oil pump, This is not ment to sound snobby but we only fit genuine OE parts in are engine rebuilds we are aware that there are cheaper ways to build an engine and if you dont intend on having the car for more than two or three years or maybe you dont intend on clocking up the miles then thats fine but we like to put are name to something that lasts and we like to "fit and forget" so its a genuine pump thats going in this lump.

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Right well after that was done we had to pack the block away so it stays clean till we get this filthy, rusty lot sorted out! Oh joy .

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There was alot of detailing ahead of us at this stage but we will get on to that next. See you all soon D.D out.

Looking good guys..really need to come over an have a look in the flesh.. can't wait to see this on the road!

If I ever win the lottery i know where i'm taking my jetta, amazing work as always

bodyinboot wrote:Looking good guys..really need to come over an have a look in the flesh.. can't wait to see this on the road!

Thanks mate hows the tooth coming on, hope your feeling better mate, be good to catch up give us a bell.

jedi16v wrote:If I ever win the lottery i know where i'm taking my jetta, amazing work as always

I would love to get my mits on your jetta. it reminds me of how mine used to be (many years ago, before you say it for me Andy!) Ive been following your build with interest anymore progress?

just little bits and bobs, got the black headlining and carpets to fit out of my black car and i've hopefully got a few treats coming from my mates golf that hes breaking

Ok where do i start with the next bit? We had another epic leg of decruding, priming and painting to do so i will cut to the chase with some before and after pics.

Before :

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After :

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Nearly all of these items were fully stripped, Acid etched and then coloured. Jettafan stated at the start of the build that he wanted everthing to look as stock as possible and that included the engine so we have tried to use the colours in a way thats factory but still lets the well trained eye know theres a bit more to it! .

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After a couple of weeks detailing and drying all the bits it was time to start building again. First the sump we chose to reuse the original 2e sump because we have found some aftermarket items to be a bit on the thin side so this got a sand back and a repaint in gloss.

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Fitted with a new gasket, sump nut and washer.

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Next the crank case breather box which went through the dishwasher then had a new oring and gasket fitted, Oh and new stainless steal allen heads aswell.

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We started to put a little colour in at this point aswell, the dipstick tube has been done in the same grey as the gearbox.

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Now the oil filter housing with new gasket and bolts, same grey again.

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Fitted.

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Onto the waterpump again with a new oring seal we chose to reuse the old 2e bolts and pump as there is nothing wrong with them and plus you wont really see um. This also helps us keep the budget in order a bit (fingers crossed!)

During detailing.

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Fitted.

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This means we could fit the new altinator setup Jettafan has mentioned some kind of ICE install in the future so we decided to upgrade to the 2e set up as it offers much better charging and is alot easier to service in the future. Plus it meant we could keep the cost down a bit. So first things first the mounting bracket. Again, Acid etch then marine grey with new stainless fittings.

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Fitted.

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Then the altinator and tensioner spring. I know we couldnt help are selves we got are red on again! . We have added some red to the bay area but only on very subtle items .

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Slowly starting to run out of bits to bolt to the block now. Next was the rear engine mount support and more stainless .

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Fitted.

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That seems a fitting place to pause because we had to wait for some more parts at this point so till i can get on here again see ya later, cheers everyone.

BLING BLING

loving it

Thanks guys as for you venturbo i fear you my be giving me a bad name ( V-dubphile ) As a matter of fact a have a very unhealthy obsession for a great many things! You cant beat the smell of Autoglym and GT85 on a hot sweaty afternoon .

slightly off topic just thought you might like to meet are new shop mascot, Lilly. Fresh from the Dogs trust in shoreham if any of you are thinking of getting a dog you want go far wrong with the Dogs trust they were great and supplied us with everthing to get her settled in. Well an extra pair of paws around the workshop is always helpfull!

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Right anyway back to the job in hand (stop it venturbo!) After are wait for parts it was time to mate that new block with the box (its innuendo bingo again) but first a few little things to run through so you dont make any mistakes yourself. First thing first the clutch, if you are using a 1.8pb mk2 box then use the clutch and flywheel for that gearbox if in this case you are using the box from a 2.0 mk3 (2y code) then you will have to use the clutch kit for a 2.0 mk3. There is about a 1.5mm shaft size difference, if you use a 2.0 clutch on a 1.8 box then the input shaft will just spin freely and not give you any drive Doh! Here it is fitted with the new LUK kit and detailed backing plate.

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It is worth making sure you note were the timing marks are on your old flywheel before fitting your new one as you can fit some flywheels in two different positions if you fit it wrong you will have no mark to time it upto later . Always fit your new clutch with new crank to clutch mounting bolts as they are a type of stretch bolt so will not be reusable. After all that we could get the gearbox on with the aid of some new bellhousing bolts.

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And the new detailed front engine mount support, 2.0 2e starter motor and new bolts.

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And new oil cooler, gasket and filter.

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All the above fitted.

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We also detailed the rear bell housing inspection cover and replaced the worn gasket for a new foam one.

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Fitted with stainless bolt and washer.

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And finally before we can get it back in the bay, The rear left engine mount and new mounting bolt.

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After fitting the 2e knock sensor, dipstick and guide tube it left us with this just hanging around .

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Well thats were we are going to leave it for now we will fill you in on how it looked fitted and why we are fitting the engine without a head on it next time. Oh and what we did about the exhaust issues when fitting a tall block. Cheers for reading as always.

Can i have it and i wont call you names!!!!

So very nice!

Dirtydubber,
Absolute pleasure to see such workmanship.
Only wish I had the time and money to bring my '84 Mk1 up to your standard.
Regards
Alex

Top work gents.. and nice work with the woofbag!! will have to pop by and say hi...

If this was in a magazine it would be on the top shelf-proper car porn
top work

venturbo wrote:Can i have it and i wont call you names!!!!

If you play nice i will make one just for you

1984mk1 wrote:Dirtydubber,
Absolute pleasure to see such workmanship.
Only wish I had the time and money to bring my '84 Mk1 up to your standard.
Regards
Alex

Thank you so much were very humbled. Nice to hear of another mk1 out there im starting to get worried that there all going missing! Welcome to the club by the way have you put any pics on here yet?

07jettamk5 wrote:So very nice!

Thanks chap, My detailing skills still arnt a touch on what ive seen some of the americans come up with in the past! Plus some of you guys have mad garden sheds and mad bagging skills you just love to low ride

As for you Andy and you Jedi we are all included in Venturbos club (V-dubphile) . Pop round to say hello to the woofer any time mate cupper waiting as always.

Dirtydubber wrote:

1984mk1 wrote:Dirtydubber,
Absolute pleasure to see such workmanship.
Only wish I had the time and money to bring my '84 Mk1 up to your standard.
Regards
Alex

Thank you so much were very humbled. Nice to hear of another mk1 out there im starting to get worried that there all going missing! Welcome to the club by the way have you put any pics on here yet?

Yes, Dirtydubber
Only just started working on my mk1. See link below.
regards

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Ok to start, Thanks everyone as always for the great comments since are last post it always puts a smile on are faces. The next bit is the tricky bit getting a detailed engine into a detailed bay without scratching anything! First we had to take care of both front cross members these were treated with a good thick coat of Hanmmerite gloss black.

Before.

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After.

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We chose Hammerite because we wanted to get a really thick coat on first time. This area of the car is always so exposed to stones and road grime that we find its the best form of protection, it my not look to pretty but it lasts. So now were ready to put the block and box in so here goes.

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As you can see we had to use a few fresh towels and cloths to protect some areas plus it helps if you grease your engine mounts up aswell.

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Almost there just the front cross members to put in and were done.

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The front cross member has been fitted with new stainless bolts and washers along with the rear engine and gearbox mounts.

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Also at this stage an old collapsed front engine mount has been used! Dont worry it wont be staying its just to help us work out and check clearances, all will be revealed later on! Its at this point that i feel its worth mentioning that putting your block back in without a head on it like this is to be done with a great deal of care if you are doing this yourself then make sure you use at least six old headbolts, tighten them into the block and spread the tension evenly across all six bolts also make sure you dont bounce or jolt the engine walst in the hoist this way you will not damage the threads in the block or the block itself.

Now that the engines in we can relax a bit and have a bit more fun! Thanks to Jettafan these turned up!

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But we have a few little bits to do before that so till next time cheers and we will be back soon.

epic win guys!!!