Floor Pan Swap - haldex to come...

[All_Euro]

Re: Floor Pan Swap - haldex to come...

Interesting build so far and not to be picky but are you using a mastercraft flux core welder on something you hope won't fall apart and kill you? Please tell me you are a welder by profession so that you at least know what you are doing.

Thanks. Sure am - no issues with the quality so far. I design houses for a living but did consider becoming a welder years ago

At the very least get some argon to weld with!

I have gas wire as well but there's no need, as of yet, to go that route.

[All_Euro]

Re: Floor Pan Swap - haldex to come...

DAY TWENTY ONE

Today was the same as yesterday really - stitched some of the new frame rails seams together. Might have to break down and buy a proper helmet though...

[All_Euro]

Re: Floor Pan Swap - haldex to come...

That's exactly my dream build... with a VRT

Sweet - you're part way there too.

Looks like you made it inside!!!! Or maybe not?

Well... with no floor in the car I'm kind of in a shelter - not sure if that counts though. Hopefully I can replace the TT shell with a garage next summer.

[onceover]

Re: Floor Pan Swap - haldex to come...

At the very least get some argon to weld with!

[Stonewall]

Re: Floor Pan Swap - haldex to come...

Interesting build so far and not to be picky but are you using a mastercraft flux core welder on something you hope won't fall apart and kill you? Please tell me you are a welder by profession so that you at least know what you are doing.

[GINCH]

Re: Floor Pan Swap - haldex to come...

Looks like you made it inside!!!! Or maybe not?

[Fizzo20]

Re: Floor Pan Swap - haldex to come...

Nice, I was seriously considering buying one and adding a quattro drivetrain instead of haldexing this car!

That's exactly my dream build... with a VRT

[All_Euro]

Re: Floor Pan Swap - haldex to come...

...Definitely still my favourite car that I've owned

Nice, I was seriously considering buying one and adding a quattro drivetrain instead of haldexing this car!

[All_Euro]

Re: Floor Pan Swap - haldex to come...

DAY TWENTY

Finished trimming and fitting both pieces of TT frame rail and tacked them into place. Then I moved the pan into position, as if I was going to install it, just to make sure things look ok - and they do but fitment will be nothing short of SNUG so next step will be fully welding the rail seams and then cleaning and priming any bare metal...

[Fizzo20]

Re: Floor Pan Swap - haldex to come...

Thanks, I've just been trying to accomplish something every day while the weather is reasonable... hopefully I be done before winter gets serious. Cool Jetta project on your end too - my first VW was a small bumper MK2 Jetta Carat. Loved it but always wanted a big bumper version.

Yeah this next week doesn't look too bad either, you still got time!
Thanks! Yeah my first car was a small bump jet coupe, but then the red one came up for sale and was is much better shape (and big bumper) so I scooped it. Definitely still my favourite car that I've owned

[All_Euro]

Re: Floor Pan Swap - haldex to come...

DAY NINETEEN

Finished removing the incompatible sections of frame rail on both sides... cleaned up the areas and trimmed the new pieces to fit. Will do touch ups tomorrow and hopefully weld the TT rails in - here are the test fit shots...

[All_Euro]

Re: Floor Pan Swap - haldex to come...

DAY EIGHTEEN

I was having trouble getting the TT pan to slide into position and after having a closer look I noticed the way the GLI and TT pans connect under the back seat are a little different. Thankfully I still had the appropriate Audi piece in good condition - here's the difference...




I've been avoiding cutting into the frame rails but I really don't see a better way to accommodate the new pan so after measuring, and remeasuring, each frame rail I marked a line at 4.5cm from the foot pan joint on the top of the frame rail and cut all four...




4.0-4.5cm keeps the new joint as far away as possible from the existing joint in the rail without hitting this internal brace in the TT rail...




No internal brace in the GLI rail but I didn't know that until it was open. So I got the top and sides free tonight and will endeavour to drill the bottom welds out and tack in the TT rail tomorrow...

[All_Euro]

Re: Floor Pan Swap - haldex to come...

Glad to see a break in the weather for you.

Me too - it was painful to watch my frozen project just sit there last week.

Making fast progress! Glad the weather smartened up!

It's coming... easy parts done... home stretch now

This is quite the undertaking, especially during this time of the year! Props to the bravery and amazing work. Looking forward to more progress.

Thanks, I've just been trying to accomplish something every day while the weather is reasonable... hopefully I be done before winter gets serious. Cool Jetta project on your end too - my first VW was a small bumper MK2 Jetta Carat. Loved it but always wanted a big bumper version.

[All_Euro]

Re: Floor Pan Swap - haldex to come...

DAY SEVENTEEN

This is where things slow down... the pan is a snug fit for sure and trimming without overdoing it takes time. A few pics up you can see the inner lower portion of fender by the back piece of frame rail - that needs to be trimmed to get the TT pan in place. I've got some of it removed and cleaned up but will have to shave into the upper portion of back corner to match the profile of the new pan... seems like about 5cm needs to come out - each side is a different length though.




I had taken rough measurements the other day and thought the GLI pan was 159cm compared to 139cm for the TT - this is the case so the difference between the two is 20cm. This is why I kept the GLI frame rails in tact when I took them out - should come in handy to bridge the gap...

[Fizzo20]

Re: Floor Pan Swap - haldex to come...

This is quite the undertaking, especially during this time of the year! Props to the bravery and amazing work. Looking forward to more progress.