So, after reading many build threads here I decided I would finally make my own. I'll probably make myself sound or look like an idiot frequently but, well, I am an idiot.
Anyway, about two years ago I was looking for something a little less boring than my Mazda3. At the time I was thinking a little faster than my Mazda3. Then I came across this.
I got carried away taking pictures of it but you get the idea. It was awesome. And not fast.
It has a 1.6L turbo diesel. I don't know a whole lot about VW's but I believe the engine is from a 1983 Jetta. It's loud and slow and very small and awesome for all those reasons. According to the PO it came from the south which would explain the lack of rust, at least for New England standards. I drove it around for a bit and really enjoyed it but there were a few things that bothered me. Number one was the cracked dash that was covered with a glued down piece of carpet. The windshield leaked and the interior was damp and smelly.
Finally, I got fed up and tore the dash out. That's where the "build" began. I'll try walk through what I've done so far but, with over a year of work, I'll probably miss something. I also hadn't really considered a build thread so I don't have a lot of pictures of the details.
The dash came out and I stripped the foam and vinyl. I had the goal of putting new vinyl on myself but that still hasn't happened and is definitely outside of my current skill set. Then the carpet came out. That's where I discovered this.
Rust. Which really shouldn't be a surprise. The holes had been filled with silicone or something and I just punched through the floor trying to remove sound deadening. And so began my adventure in learning to weld. I don't think this is the best beginner welding project but I went for it anyway. I bought floor pans and inner rocker pieces and started cutting the floor out.
Fitting floor pans and cutting out rusty inner rockers.
I welded in all the panels. It wasn't pretty which might be why I don't have many pictures but in the end I could place my entire weight on the floor without any issues. As a wise man once said, "Grinder and paint for the welder I ain't." I painted the entire floor with POR15 and undercoated the bottom. Then, I put sound mat in with hopes of keeping a little of the tractor noises coming from the engine bay out of the cab.
Those pictures look like they're sideways. I take pictures like everyone else my age apparently. That's where I end it for now. I've got a little more done since then but I need to dig up the pictures.