awesome. Keep plugging away.

The serpentine setup makes the PS pump puke fluid out under high RPM because it tilts the pump. Either run the pump with barely enough fluid to touch the bottom of the stick (and still have it blow out) or take another pump, cut the neck off the reservoir, and use a piece of radiator hose and a couple hose clamps to extend the neck.

I just did the radiator hose trick and this is the first time I've ever been on track (since HPDE1 in 2005) and not blown out PS fluid. I even over filled the reservoir on accident!

Ok. Finally a real status update. I've been some combination of lazy and just uninspired to work on this thing lately, so progress has been slow...or non-existant. However, tonight I finally have some photos (and questions for Alan).

Pics:

Ok, the SFC's came out without doing too much damage.

I got the main hoop located and holes in the floor so I can weld the top of it. Tapped the floor plates under it and the main hoop is really tight against the roof (you can slightly feel the bulge when you run your hand over the roof skin). Is "really tight" actually too tight?

Alan I'm hoping this is where you wanted it located...

I can't speak for Alan, but move the main hoop back if you can. Notch the frame rail to body gusset and slide it in there. You can probably move the main hoop back 4-5".

I wish I would've stressed that more what I had my cage built. It might seem trivial now, but it leaves a lot more room for a triple master cylinder pedal setup/etc down the road.

PS- if this is going to be an AI car, you might want to search for an old thread of mine about gutting the roof. I took 15lbs out of mine then welded what was left of the roof to the halo bar. It's bad sprung weight, high and outside.

This post has been edited by nape: May 15 2009, 07:01 AM

Might be a little rearward than I intended at the base - notch a door bar and see if you'll be able to fit it to the main hoop without notching the door frame. You can take a little out of the frame, but weld it back up when you're done. Also, don't weld the plate in yet, don't even tack - those plates will be in and out of the car many times before your ready to weld them in.

Too tight is just right

Also, the angle that the main hoop will end up at will depend on the trim and fitup of the Apillar tubes - get those fitted before the backstays.

This post has been edited by Blainefab: May 15 2009, 07:10 AM

Am I a half inch back from your target or "inches"? I looked at the photos I took of Dave Schotts car and used the other links you gave me and my best guess was right there. However, it can be moved if needed. Is that the notch in the roof you were suggesting that I use, or should the top be forward too? I know the A pillar bars are going to determine the final location, but I was wondering if I shouldn't be targeting that particular notch after all.

The Apillar tubes will determine where the top of the main hoop goes - fit them up next. Then, the middle door bar will determine where the base of the main hoop goes - I put door bar fab at the end of the build sequence, but since you have prebent door bars you'll have to position the main hoop to fit them. Fit the middle door bars between Apillar and main hoop, mark those locations and go back to the build sequence.

Progress!!! Thanks to Billy (Racerdad916), I finally got back to the garage and ripped the dash out (ok, we finished ripping the dash out) and started fitting tubing.

The front bar is just tacked at the top. I'm intending to push it out towards the circle you see on the floor plate. However, I have to see where the door bars land before doing the final fitting (as far as spacing from the wall). Alan, is this about where you wanted it? I looked at my pics of Dave Schott's car and I think I'm right where I should be (but tell me if I'm not).

Looks good, but you should not have tacked the plates in - you'll need to cut them out and grind the tacks smooth. Read the whole build sequence before going any further.

We tacked it down to let us hammer form the plate to the wall. I expected to have to cut/grind them out.

Crap! Your catching up with me!

Wow. I get one tube fitted and you're in danger? You better get moving...heck, I better get moving.

Besides getting some seam welding done with my new MIG, I haven't made much progress in the past month. Softball 2-3x per week, a new puppy, and a landscaping project have been keeping me busy. Now vacation next week.

Yeah, I gotta get on the stick. Work is hinting at another short layoff, so that might be an unfortunate opportunity.

Here we are in August and I've not accomplished anything since June. Racerdad916 and I put in another hot afternoon of fitting, adjusting and such and pretty much wasted all the time we spent in the shop. No real progress was made and I'm probably behind where I was when we started the day. I managed to cut the angle wrong on one of the back stays and that tube is now back up tubing for verticals for my door bars. We did cut the windshield out of the car so we have some room to work, that is probably the best thing I can say about this weekend.

I'm actually reaching the point of being torn about what to do with this thing. I spent most of the weekend considering just parting it all out, selling off my two shells and looking for a car like Gary K has advertised, or a Corvette, or going out and buying a new TDI Jetta and dumping the truck and the project car. I'm not sure if I'd do it or not, but I'm starting to think I'd be a lot happier some days if I didn't have this thing on jack stands in my garage (on the other hand, after buying 4 new VW's between 2000 and 2004, I swore I'd never do that again either). It's worth far more in pieces than it is assembled, but I don't think it's worth nearly enough, even in pieces to actually get rid of it.

I'm can't offer advice on whether you should keep this car or not, but friends don't let friends buy new VW's. It's a huge money pit. Yes, the diesels get great mileage, but a few electrical gremlins and some engine problems and all your fuel savings go down the drain in repairs.

I know, I bought 3 brand new 2000 VW's (2.0 liter "base" golf 5 speed, 1.8t Jetta 5 speed and a 2.8 liter VR6 GTI 5 speed) and a new 2004 (1.8t GTI 5 speed). Every single one of them was in the shop...a lot. I know the service guys really well. They had my first GTI for about 8 weeks sorting out a transmission issue, as well as about 100 other trips.

Keep building.

I get to this point as well. Geez, it seems like nothing works or fits or you find yourself having to tear it all down again in order to accomplish another target.

But each time I've been at this point and do work past it, I find that the car is 80% of 80% complete. Assemblies I've been fretting over and getting frustrated with bolt up and a huge chunk of the car is in place. When you see it begin to come together, that is the motivating part.

Billy (Racerdad) says the same thing, "We'll just keep plugging away".

Don't you dare get this car ready and then "do it again." That being said, seeing that kind of progress on the car makes me really wish I was up there helping! And before you can say it, I know the offer stands, don't worry, I'll get up there some time!