Anyone got a Project they want to share?

[Corrado_Guy]

It is amazing what you can do if you have the time and equipment. I wanted an AWD car so I went and bought one of these because I liked the body style...



Then I bought a pretty trashed 1992 Pass G60 Syncro...



I stripped the Passat down and got a bunch of this...















Before this I took a lot of measurements to figure out where everything sat in the Passat and then marked it up on the Jetta. Once that was done I cleaned up the floor of the Jetta for the next step.





As a note, the black sound deadener comes out really easy with a chisel & hammer when it is -15 C outside. The next step was to make sure the car was high enough to work on and sitting perfectly level....

[Corrado_Guy]

The step after this involves a lot of cutting and some of the parts are rather important and help with the structural integrity of the car so I welded braces inside the car to keep things straight when it was apart...







I made some jigs so I was sure that everything sat in the correct place when it was welded back together...



Then the first big cuts were made....







Once the old tunnel was out I did a lot of test fitting with the Passat tunnel in the Jetta and found it was too long for one and the firewall on the Passat sits further forward than the Jetta...





Step one with the tunnel was to cut the back of it off to get it to sit inside of the car....



I had to do a fair bit of cutting and shaping to get the front of the tunnel to sit properly which I used tin-snips and a body hammers to do but it worked out well..





Then it was time to address the rear of the tunnel, I cut a section out and had a buddy weld it back on and then test fit it in the car....





Now it was getting close to welding this back in, out came the measuring tools and I slowly shifted the tunnel back into place and welded it in...





These are the first welds I have ever done, I did a bit of practice on some scraps and used this project to learn how to weld. I have never done any metal fabrication before this nor have I welded. I didn't want to have other people do the welding on this because there would be a lot of it so I went out and bought a Millermatic MIG welder and using the settings on the lid and just went at it. The weld on the rear of the tunnel was done by a buddy using his TIG which is why it looks so nice but mine didn't turn out bad.







You can see above that the tunnel was welded in place from above and below so my introduction to welding started by welding normally and then on my back. The next step was the trunk floor, I had the slight problem because there was a spare tire and fuel tank sitting where my diff was going to sit so out it came....

[Corrado_Guy]

Once the sheet metal was out of the way I test-fit the rear suspension/diff and got my rear cross-member in place....



Here's the car with main rear suspension/axle fitted and everything welded in place....



I had a choice here, either I use the Passat rear floor and fuel tank or I run a fuel cell and make my own floor. The Passat tank hangs down too far and the passengers side frame rail must be a little thinner because this this is as far as I could get the tank up onto the car without hammering the tank/neck up between the frame rail which isn't safe...





So fuel cell it is, the fist step was to make something for the fuel cell to sit in....



Then I needed a floor so this was made next....















I also made a short-shifter, this is the end result of one the main shifter support....



The suspension support bracket is NLA so I had to make one of these....



Once the rear of the car was put back together it was time to test fit again, the rear section of the driveshaft had to be cut down, welded, and balanced but it all fits...



Here's the first time the car was back on all wheels as a Syncro, coil-overs in the rear and the stock A2 suspension up front...



Wired in the G60 swap, kind of sits close to the wiper linkage but it will work...





Once reason why some swap fail is because people don't do their homework, these are some of notes after going through the wiring diagrams from each car...



Here's one of the car with the coil-overs all around, no motor, and a Audi 4000 tilt/slide sunroof installed...



Did some porting on the head just to clean things up...



I also had the G60 block punched out two sizes and new pistons installed...



Put the motor back together and did another test fit...



Fit the rad for the intercooler...



Got the intercooler mounted....



I need exhaust so I cut down the factory cat and made a simple 'Y' pipe to replace the factory monstrosity....

[Corrado_Guy]

This is the actual exhaust system being fitted...







Once I got everything to fit properly I tacked it in place before removing it from the car and then welded it up...







I need to put fuel in the car and I didn't want to use the stock filler because I would have to cut through the inner wheelhouse and there is a safety belt right above this so this was my idea...

















So there is a fast-forward through part of the project, I am still working on the project but haven't had much time in the last year to do much. There is a huge amount of progress missing from this post because I concentrated more on the fabrication part but you get the idea.

I would like to point out to any of you thinking that you wish to do this sort of stuff that I am a geek by trade and work on computers and servers and have no training in this kind of stuff. I barely passed mechanics in school because I was barely there so you may surprise yourself what you can actually do if you try. There is a huge amount of information out on the Net just waiting for you to find it so start small and work your way up and you can probably do it. As you have probably noted this entire project to this point was done out in my driveway so it is not like you really need a garage either.

[AudiA4_20T]

EPIC build man. Really really awesome. I've been thinking about doing an Evo5 swap on a Mitsubishi Mirage one day. Same idea. Anyways, you'll find there are a ton of Audi modders that work in IT.