Part 9 - Its Alive!

   There's nothing like free time on your hands to get some much needed work done.  After recent world events contributed to yours truly being laid off, I found myself motivated like never before to get Project Golf, which up to this point hadn't run since April, back on the road.  You may recall from Part 7 (aptly titled "Arrrgh!") that my first attempts to upgrade the exhaust system from toilet bowl to Techtonics were scuttled; first by a stripped intake manifold bolt and later by a broken exhaust manifold stud.  Since the broken stud meant I would have to pull the head to extract it, I decided it was time to get on with the engine part of Project Golf.

   In addition to the suspension and brakes already on Project Golf, my Jetta continued to produce an almost endless supply of good parts.  Many components, like the radiator, air conditioning system, and intake boots were recently serviced or replaced, while others, like the alternator were in far better shape than Project Golf's.   In addition, I collected many parts, including a new fuel distributor, lines, and cooling fan/shroud assembly to replace Project Golf's rusted or deteriorated pieces.   Once I installed the new head assembly, followed by the Techtonics exhaust system, I took the car off the jack stands, and went to work on the engine compartment.

Before long, anything that could be swapped between a CIS-E Jetta and a CIS Golf was, and the engine compartment began to take shape.  To ensure reliable performance, I threw in a new timing belt, new drive belts, and did a complete tune up.

   This is not to say that work did not have its problems.  After having the A/C serviced a year or so prior, I hoped to transfer the under hood components from the Jetta to Project Hole-In-One with a minimum of exposure time for its moisture sensitive parts.  Unfortunately, a damaged fitting on the compressor killed any hope of that happening.  I installed the compressor anyway, since its needed to drive the alternator.  Replacing the compressor, drier, and recharging the system will be another step in the project; something I hope to have done before it gets hot again.

   With the battery out of the Jetta installed, and a double check of all the under hood wiring, it was time for the moment of truth.  It would be nice to say the car fired right up, but after sitting for so long, and having just installed a new injection system, the fuel system was full of air.  After several minutes of cranking, and fiddling under the hood, Project Hole-In-One sputtered to life, idled briefly, then died.  Unbeknownst to be at this point, the in-tank transfer pump also decided to pack it in, starving the engine for fuel.  Once again it was my old Jetta to the rescue.  I remembered that the first time I took my Jetta to the dealer, the transfer pump was replaced under a recall.  Swapped the pump assembly in, and with a twist of the key, VROOM!!!  Sweetness!  Success!  I can't wait to drive this thing.  Until I get it registered, I'm limited to short rips up the driveway.  At least I can get the rust off the brake rotors...

   With Project Hole-In-One finally running again, I took another crack at lining up the front bumper.  Unfortunately, the brackets still don't line up right.   Either I will try to work with the existing brackets, adapt some U.S. spec brackets, or I might get something fabricated.

    With the bumper more or less on, I installed and wired up the Euro-spec side and front signal lights.  For now, there are no "city lights", since the E-code lights did not include provisions for them.   I don't have much use for marker lights anyway, so hooking them up isn't a high priority.  

   With the car back together, the look begins to make more sense.  Instead of following the "big bumper" trend, we decided to go in the opposite direction with the Euro-spec bumpers and 16v GTI chin spoiler.  We also went with the later style, "big door" look.   For consistency, the rear quarter window seals will be replaced with the newer style to match the doors, giving the car a cleaner look.

    While not necessarily trying to create a GTI clone, several GTI design elements are being used throughout the car.  Among those are an amplified Fuba Betaflex antenna, which pulls in radio signals to the Blaupunkt Colorado head unit.

   The next system to work on (that we already had the parts laying around for) was the audio system.  Unlike many magazine project cars, the only requirement for the stereo in Project Hole-In-One is that it be loud enough to hear on the highway.  With its part-time sporting intentions, we decided against amps and subwoofers and the associated wiring.   Besides, I like to be a trendsetter, and the whole "big stereo" thing is getting old.

  While installing the head unit, I debunked a myth about Votex consoles.  Common wisdom says that there isn't enough room behind a Votex console to mount a stereo head unit, unless you want to give up your air conditioning, or at the very least the center vents in the dashboard.  While fabricating the roll cage for my rally car, I realized

that this is not necessarily the case.  While the vent ductwork is behind that top opening, there are no doors or other mechanicals back there.  I simply removed the duct, altered it slightly for clearance, and reinstalled it.  The stereo slipped right in, freeing the bottom for a possible in-dash CD changer at a later date.

   At this juncture, there isn't much left to do before getting the car to the body shop.  I'm going to register the car, and run it through emissions before that happens.  With the goal of completing the car in time for the first show in the Spring, minor rust and dent repair is up next.

Who says you can't put a head unit in the top slot of a Votex console?

Random Notes

• After fiddling around for a while, I realized that I ordered the wrong size rear speakers.  I'm sending them back to Crutchfield to swap them for the correct size.

• I haven't installed the short shift kit or the weighted shift rod yet.  The linkage needs to be rebuilt, and the spring in the transmission case that provides the side to side loading on the shift lever is broken.

• Before I drive the car any distance, I need to replace the tires.  Look for a set of new tires for the already mounted ATP Spas before long, with a nice set of autocross/track tires for the VW steel wheels.

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