Project 1.8T Rabbit

[Paul]

Well, I have made some progress in the past few weeks. Finally have some time to post up the footage so I can share with everyone. I'm about finished with school so I will have more time to work on this beast. Since the last picture post, I have fabricated the downpipe and exhaust, painted the intake manifold and valve cover, made my my hybrid spark plug wires (more on that later), routed the fuel lines and installed a fuel pressure gauge, and although not pictured I wired up the VW TPS to the SDS system (finally got the wiring diagram). The last thing I did this past weekend was the fuel lines, starting from the engine and working my way back. Unfortunately, when I reached the tank I uncovered some bad news, the tank was badly rusted, and the lines in the rear of the car were really ratty looking. So I dropped out the tank and removed the section of bad fuel lines, which I would have had to do anyway. In a Rabbit the fuel filter in located under the hood, I was relocating the filter to the rear of the car where it is on later models. Have a new tank, fuel pump, and sending unit on order. Didn't get any pictures cause it got really messy back there and was working on a tight time budget. The spark plug wires were interesting, I used VR6 wires (well 4 of them anyway) because they were the right length to go through the valve cover, but the length had to be adjusted and the end that goes to the SDS coil pack is different than that of the VW coil pack. I used MSD wire connectors and holders as you can see in the pics. Making the downpipe and exhaust was simple. I really enjoy metal fabrication. I haven't welded in some time, so the first few welds didn't look that great but got better on latter welds. Downpipe and exhaust is 2.5" with a straight through Magnaflow muffler. Well enough talk, enjoy the pictures.







Exhaust:


Side exit exhaust:


Current bay shot minus the TPS wiring and charge pipe: