Topic: A Can O Worms (Read 1081 times)

Smokestack · « **on:** March 16, 2010, 08:24:20 PM »

So I decided to tackle a rather large project on the 16v before I move next month. I picked up a passat as a parts car mainly for the transmission, but I'm actually going to use more than I thought off of it. The 9A 16v that was in it was in better condition than the one I had and the dash that it had was in really good condition, which the one I have isn't. I'm also going to be installing an ABS system out of a 97 passat that I pulled from the junkyard along with a 14lb ECS flywheel. All this started because I needed to fix damage from me sliding into a curb this past winter and grew into a "While I'm in there..." type of thing. On with some pics

The start

Engine pulled

Missing the old dash

The new dash with all of its components sitting on the roof.

That's it for right now. I've mostly been and will be wiring. Once I'm done with that I'll start back on the mechanical again.

Random_Task · « **Reply #1 on:** March 16, 2010, 08:25:37 PM »

what you doing with the old dash?

Smokestack · « **Reply #2 on:** March 16, 2010, 08:29:06 PM »

It's trash. The thing was falling apart as I took it out. I'm surprised it held as long as it did.

scurvy_bandit · « **Reply #3 on:** March 16, 2010, 08:33:56 PM »

Do what I did to my old dash and stomp it to releae built up frustrations.

greggearhead · « **Reply #4 on:** March 16, 2010, 08:43:07 PM »

I saw this in person today. It scares me a little.

Barry · « **Reply #5 on:** March 16, 2010, 08:55:15 PM »

Quote from: greggearhead on March 16, 2010, 08:43:07 PM

I saw this in person today. It scares me a little.

coming from a guy that used to cut limbs out of a tree to fix an iac problem in a porsche shop....

this scares me a little!

Smokestack · « **Reply #6 on:** March 16, 2010, 10:06:56 PM »

I'm getting WAY too familiar with the wiring in this car. First it was wiring in Megasquirt and tieing it into the factory harness, and now I'm replacing another good chunk of the harness. The only wires that I haven't touched/replaced are the ones going to the back of the car. Just think, if I ever find the stuff to convert to power windows I'll be doing this again. $:-\$ Hopefully I'll be done with the wiring this time next week. I'm sure by then I'll have some frustration to release on the old dash.

scurvy_bandit · « **Reply #7 on:** March 16, 2010, 10:33:57 PM »

awesome man.

Smokestack · « **Reply #8 on:** March 18, 2010, 08:33:57 AM »

Got the wiring done in the engine compartment and the ABS in. Next up is yanking the k-member to fix the damage done to the steering rack from my curb slide. Once I get that back together I'll put the steering column back in and start assembling the dash.

ABS installed

Rat's nest behind the brake booster/ABS controller.

This is where those wires all enter the bay from the cabin side.

The large grommet at the top is for the engine harness. The one below that is the light harness. To the left of the light harness is the cooling fan/AC wire bundle, and to the right is the harness for the ABS. It's kinda hard to see, but the last wires going into the bay is the cruise control harness and it's just below the light harness. Not too daunting, ehh?

snoopy · « **Reply #9 on:** March 18, 2010, 06:30:46 PM »

Good gravy ~ what have you done!?!

Smokestack · « **Reply #10 on:** March 18, 2010, 08:00:32 PM »

Quote from: snoopy on March 18, 2010, 06:30:46 PM

Good gravy ~ what have you done!?!

I'm playing mad scientist.

snoopy · « **Reply #11 on:** March 19, 2010, 07:35:19 AM »

You're definitely mad, but Scientist?

Smokestack · « **Reply #12 on:** March 20, 2010, 07:36:01 PM »

You all thought the wiring was the headache part.

I'm now at the point where I need the dash components in to finish the wiring, but that requires having the dash installed in the car. The passat dash I'm using was either going to go to the scrapper with the rest of the car, or I was going to make it work. The problem with making it work is that the dash is a little over an inch wider than the MK2 dash, and that makes for a lot of trimming on both the dash and the components around it. There's a whole lot of "measure twice cut once" going on right now. Once I get it fully mounted I'll work on trimming the door cards to fit around the dash.

Pics for clicks.

I've seen pictures of the finished product and it turns out nice. The only thing that tends to look weird when it's done is where the door cards are clearanced for the dash, but looks fine when the doors are closed.

scurvy_bandit · « **Reply #13 on:** March 20, 2010, 10:42:23 PM »

passat door cards??

looking pretty good scientist

greggearhead · « **Reply #14 on:** March 21, 2010, 07:41:02 AM »

Nice work!

Smokestack · « **Reply #15 on:** March 21, 2010, 08:03:45 AM »

I wish it was as easy as using passat door cards. Here's a pic I found that describes what I'm talking about:

I got the dash fitted last night. Now I need to work on finding something more permanent than jack stands to hold it up. I'll also have to do surgery on the center console to make it work later. Where the dash meets the console versus where the shifter surround needs to be gives me about 2 inches I need to cut out.

Trimming it so that it will fit up against the windshield and close the gap at the door.

Finished product roughed in.

scurvy_bandit · « **Reply #16 on:** March 21, 2010, 08:21:29 AM »

awesome work man.

Smokestack · « **Reply #17 on:** March 22, 2010, 03:11:41 PM »

Got it mounted in a more permanent fashion now. I'll post some pics when they'll actually look like I made progress.

Now I'm hooking up all of the controls and doing the under dash wiring. Maybe by the end of this week I'll have the car put back together and chasing down electrical "issues" that I know I'll have, and cleaning everything up.

LOS · « **Reply #18 on:** March 22, 2010, 04:16:27 PM »

Nice work. I realize you bought a passat, but a rado dash from the yard would probably have involved alot less trimming. LOL
Either way, keep it up.

scurvy_bandit · « **Reply #19 on:** March 22, 2010, 05:30:22 PM »

where is there a rado?

LOS · « **Reply #20 on:** March 22, 2010, 06:35:36 PM »

You could probably find one in denver.

scurvy_bandit · « **Reply #21 on:** March 22, 2010, 07:04:21 PM »

no U pull and pay has a corrado

found this....
http://denver.craigslist.org/pts/1628047596.html 185 ouch

Smokestack · « **Reply #22 on:** March 23, 2010, 07:18:56 AM »

Quote from: scurvy_bandit on March 22, 2010, 07:04:21 PM

no U pull and pay has a corrado

found this....
http://denver.craigslist.org/pts/1628047596.html 185 ouch

That's the reason why I didn't go with a corrado dash. They look good, but people seem to think they're made of gold. I also only really had the choice of making the passat dash work or running around with a busted ass mk2 dash, and I figured that "while I was in there" I'd do the little bit of fabricating to put it in. The only things I've picked up for the swap was a GLX cluster (so that I could keep the MFA), and a VSS for the cluster since it has no provisions for a speedo cable. I could have used the GL cluster, but why keep things simple.

The job's a bit tedious and I don't recommend doing it unless the parts fall in your lap like they did with me.

Smokestack · « **Reply #23 on:** March 23, 2010, 05:08:45 PM »

Center console is fitted along with the majority of stuff on the dash. It's coming along nicely, but there's still a lot left to do;
1. Finalize the underdash wiring (90% done now)
2. Fabricate brackets for the kneebar and install
3. Modify the door cards to fit the dash
4. Redo the headliner and reinstall
5. Trim the A-pillar covers to fit around the dash
6. Finish running the ABS wires to the rear of the car
7. Put seats back in

Once I finish the wiring I might take a break and move back into the engine compartment and install the engine and transmission.

And because it's soooo fitting

snoopy · « **Reply #24 on:** March 23, 2010, 06:33:46 PM »

Quote

Once I finish the wiring I might take a break and move back into the engine compartment and install the engine and transmission.

Its the little things.

News:

Author Topic: A Can O Worms (Read 1081 times)