Dirtydubbers Resto Corner MK2 Jetta 8v GTI.

Trust us on this one the more jettas we have in the better. This one has been a pleasure to do so far. I just wish i had time to get on with my valver i miss that car. What ever path you chose dont hesitate to give us a bell even if its just for Q&As. Also you might want to take the route that jettafan has taken with his engine upgrade so stay tuned!! Just out of interest what mk is it?

sorry for my reply.
venturbo's jetta is a mk2 (alpine white)

No worrys popeye sounds interesting thats one of my two favourite colours that and tornado red. Is there any pictures on the site?.

this is vic's jetta "mavis"
sorry vic... again
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That looks like a perfect base for a little revamp. Is a 1.6?

Dirtydubber wrote:That looks like a perfect base for a little revamp. Is a 1.6?

Hi mate, just caught up on this as im sat with Ron (popeye) now.

The car is or (was) a 1.3LX but now has a 1.8 Gti lump from my Golf but has covered quite a few miles.

The car is extremly clean but does require some work to make mint, thats where you come in.

Sounds perfect i dont think i have ever come across a 1.3lx before well not in a jetta form anyway. It does look super clean though. Well what ever you require just let us know we allways try to build your vision as you want it (god that sounds cornie can some one get me a bag!!) Jettafan is keeping us in the loop all the time so this really is his build as much as anyones.

Well on that last note..... On with the said jetta. We start with the back end chassis stuff and just look at the state of this lot.......

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This sight will probably be a common one to most of you that have ever taken your gti of the road for a while.
But as you can see here we have two totally useless rear calipers due to the seal around the calipers handbrake axle shown here by the tip of the screw driver they have both seized.

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With the rear brakes and bearing componants stripped things looked a little like this.

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Also had time to remove the fuel pump componants aswell. This also reminded me that we still have alot of scrubbing on that floorpan still to do DOH .

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Its at this point we reached the point of no return.... time to drop the beam!! So here it is in all its rusty glory although this is by far NOT the worst weve seen.

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But just look at the state of the rear beam bushes.

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After a good drilling.

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Then we could get the centre out

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After that we could push the rest of the metal sleave out.

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The other side was alot more solid so we had to make a small cut and fold the metal in on itself (if you try this yourself at home please make sure you only cut half way through the sleave then carefully use a punch to break the metal the rest of the way this will make sure you dont score the inner face of the beam). We did try to press these out but this one just wouldnt budge

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Trust us on this one slow and steady wins the race after all you dont want to have to get a replacement beam!!!!

We are at that stage again were we seem to have a mass of bits and bots that need derusting, cleaning and then painting so as always we will keep you posted as we go. Again cheers for keeping tabs on us.

this is a more insightful read than a haynes comic!

keep up the good work guys.. more pics more pics.. work faster, i need another fix!

your post might find its way onto the a main web page befor long buddy

Really nice work there!
Reminds me of the six million dollar man...."we can rebuild him"

Thank you everyone as always. Ant if that does happen im sure that it would make jettafan very happy indeed and us at D.D Very honoured thank you.

This is what weve been getting upto the last couple of days. Firstly some more floor pan cleaning.

Before :

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After :

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Not a vast difference but we will work on that as time does on.
Then we popped the fuel lines back in, we cleaned the lines and the clips then copper slipped the studs on the floorpan for extra rust prevention.

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Then on with some detailing as always a full derust first.

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Then as you have come to know us for..... the acid etch primer again!

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Then the final coat this stuff came out so shinny if you look at the first pic you can see the red spring reflecting on the metal bracket

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Hope you all like and we will post some more updates tomorrow but for now i need to

this is a PROPER resto!
What more can i say but huge respect for the attention to detail and standard of work
A+++

I say this alot on here which is a really good thing. Thanks re2 watching yours with interest mate.

Over the last couple of days weve had some great progress matched with a bit of a downer so im going to put this part of the progress in almost as a peice on its own, mainly because as all my friends will no i cannot stress the importance of this next part strongly enough (here comes the big grown from all my friends ) Its ......... wheel arch cleaning!!!!!! (i dont know if the powers at be would like to copy this into the tech section or if i would have to do it myself? let me know guys) This simple little task can save you a hell of alot of money in the long run and can be done in just 30mins if done the right way so here goes.......

First remove the C clip.

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Then carefully pull back the rubber boot around the tank neck (keep the tank cap on to stop dirt from dropping in the tank).

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Once you have worked the boot all the way round WITHOUT twisting it from side to side as this will release a pipe at the top that feeds into the tank ventilation system if this does happen you will need to reconnect this to stop any dirt from blocking it when you get to the cleaning part. You can now pull the boot down to inspect behind.

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Just look at the filth that builds up here.

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This simple maintaince tip can be done on so many vag vehicles and can really help keep the man with the welder at bay.
If the bolts that hold the tank neck to the inner arch panel look like these then i am almost sure there will be a problem behind the neck itself.

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You can clean this area without taking the tank out quite successfully by spending time just washing around the boot and up under the arch but also dont forget to rinse out the moisture drain pipe at the bottom of the neck boot (shown here with the tank out but you can get access to this from inside the wheel arch).

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With the tank out we can show you just why and how dirt builds up to cause such a moisture trap.

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This is half way down the back of the tank neck so you will also need to blast water around there to rinse this away.

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With the tank out we can highlight the pipe to the ventilation system we mentioned earlier so this might give you an idea how to tackle it if you do dislodge it.

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We can also show the inner wing panel and were it bolts to.

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This is the damage this moisture build up has caused to this vehicle.

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I hope that this will help you address what we think is a very serious problem that left unattendid will cause serious damage to your vehicle and in extream cases right off a good car. In are case here it has caused some corrosion to the inner wing but we can fix this so dont worry its not the end of the road for this Mk2 ooooooh no!

Ive now posted the last section in the tech section aswell. I really cant stress this enough check yours when you can it really does apply to alot of the VAG range upto about 2000 Polo mk2, mk3, mk4, Golf/Jetta mk2, mk3, Audi 80, 100. We even harp on about it to are new customers when they first come to us. Anyway enough of me harping on like some old nag the show must go on and i have some rust to attend to..........

Right then lets get on with that rusty little mess in the rear wheel arch.
First we had to get the tank well out of the way.

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Then we can get to the rust effected mount alot easier. Im sure you could repair this problem in situate but as you've guessed by now we dont do things the easy way we do things the proper way. So after a good clean we drilled the spot welds and out it came.

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We chose this route because its really important to us that we try and get the car back to original no matter how hard it gets. This route is not for the faint hearted as the metal this mount is welded to is very thin. The eagle eyed will have spotted that on the left side we drilled through the inner wing This was the only spot weld that had rusted so even though we went very steady it still went through we will deal with this victim of war later but for now this is what we are faced with.

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We have a bit of rust to deal with here but most of the mount is still intact and as you cant buy this as a replacement part we will have to rebuild this one .
So we start by cutting out the bad metal but at the same time keeping as much of the old so we can keep to the original form as much as possible.

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Then we can rebuild the sides and ends (sorry about the weld quality we will tidy that up later ).

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Then we can grind the centre sections down to match the old ones.

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Then its just a case of remaking the mounting faces. After we adjusted the sides to a height that we were happy with we then spotted in some small plates.

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Then complete the rest of the welding.

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The final stage at last Tidy all those welds up then make two bolt points for the tank to secure to. We modified the bolt points buy welding two 13mm nuts to the inner side of the mount its a bit over kill but this way we can use new stainless steal bolts to secure the tank neck instead of the rubbish self tappers that Vag used.

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Well there you have it as good as new well almost Its not perfect but one things for sure this one should out last the car.

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We also made a little tab on the left side of the mount to help us deal with the hole that we made when drilling the spot welds out and for the mean time till its ready to weld in for good we gave it a good coat of acid etch aswell that should help beat the rust too.

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So the next step for us is to get this back in the car then the tank and were back on track with the rear beam so till then please clean those rear arches (sorry could'nt help myself its like a nervous twitch). See ya soon D.D.

Awesome!! Your both mad.. i'd of patched that beastie and be done with it...'spose thats why your getting paid, and the reason we all tune in for the next installment..

so what are you waiting for, wheres this powdercoated beam?
and rumours of a mk2 project too? any teasers?!

Catch you soon dude!

cheers andy stop hunting for my secrets all will be revealed soon enough you will just have to wait. cheers buddy will catch up with you soon hope the heritics xmas meet went well sorry i couldnt be there mate really gutted.

Right everyone this is just a bit of a teaser before xmas as we have had the rear beam back from are metal finishers and they have done a top notch job as always so here is a couple of shots to wet your festive appertites.

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We had the beam shot blast then powder coated. I asked for the powder to go on nice and thick and they didnt disappoint.

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Only the rear beam was farmed out the rest was done in house.

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Well thats your lot for now as i said its just a teaser. Just leaves us to say thanks for all your nice comments and taking the time to read are build threads look forward to seeing you all in the new year. Have a great christmas the lot of ya and drive safe THE DIRTYDUBS TEAM (probably in that order )

again the car is coming on well. cant wait to see this when its complete. will be a shame to drive it then

MMMMMMMMMMMMMMMMMMMMMM!!!!! Car porn!

Well were back again no rest for the wicked and all that, still no beam back in yet as we have had a couple of little patches of surface rust and a little hole around the filler cap to deal with it wasnt that bad so i will just post the finished pics so you know were to check yours if you wish.

So the hole had appeared just to the right of the petrol cap point it was only small (about the size of a two pence piece). We just cut it out and butt welded in a fresh piece of metal, ground it down nice and flush, then covered it over with a very thick layer of Grey strip seam sealer.

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There was also slight surface rust on the body work around the strut tower so we delt with this as well. We packed about three layers of seam sealer on so that we could build it up to about 5mm thick that also makes sure there will be no little gaps or pockets that water will get into

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So FTW they both looked like this .

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And just to make sure we cleaned the area around the petrol cap point and sealed that aswell This will be painted later as there is a small area of damage on the rear quater panel that we will need to fix and paint so till then it will stay as is.

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Next step is the bracket for the tank neck and some surface rust on the floor pan then we can get everything back in and on the ground .

Oh and that reminds me thanks to Andy (bodyinboot) we will have a blog page up and running very soon so that you can spy on us day to day gulp!! But dont worry we will be keeping this build tread on here were it belongs we wouldnt want it any other way.

Cheers again andy it looks great mate. Always there to give me the techie boot up the arse i need.