Custom Install in a MK3 Golf Wagon

[glidn]

A few issues i have to take into account.

1. It has a MK4 dashboard, so it's already almost 30mm wider either side.
2. Mk4 dashboard, has a different shape.
3. Mk4 skin is longer in length but shorter in height, mk3 door cards is shorter in length but longer in height.
4. Maintane an OEM look about it. Still have to fit 6 1/2" mids in the door and maybe even tweeter too.

will post pictures shortly.

[glidn]

here are the back doors done.

Stuck all the wiring down, so no shaky shaky or rattle rattle.

http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00535-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00536-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00539-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00538-1.jpg

[glidn]

Sub box work yet to do the glassing, been so damn wet and cold have not been able to do fibreglassing.
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00534-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00533-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00532-1.jpg

[glidn]

and finally the really hard bit, i have to make a combo front MK4ish panel and the rest with mk3 door skin, once complete it will then be housing a single or dual 6.5" speaker set and also mk4 door window switches and mirror switch, which will be able to be popped out as if it was 100% stock in usability.

as you can see, since the MK3 has a mk4 Dash board, i have virtually no room what so ever to work with, so i have had to go to strange resorts.

http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00540-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00542-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00543-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00544-1.jpg

[glidn]

and the final up date. what i originally intended to do.
Mould a Mk4 front and build it to the door
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00530-1.jpg

But this did not work so i had to resort into making a mould of the side of the dash and building that instead. So i have no idea how this is going to turn out. But will have to see how i go.
As you can see is how much of the door skin has already been cut away.

http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00546-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00547-1.jpg

And then finally The sub box is ready to be glassed.
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00548-1.jpg

[Soundofav6]

Thats some crzy install you have... another words you are retro fitting mk4 trim into a mk3 wagon..


You have pics of the mk4 dash you can share.
Nice work so far glading.

P.S. I took your advice and stood on my fiberglass .. and it had a hair line crack. :eek: hehehe ...

[99gti]

I can see Jazz blue, Mk4 dash and Mk3 door trims??? More pics of this car stat please :D

[glidn]

I would post pics of the car, but i feel i would have to check with the owner first.

But very nice spotting 99gti, jazz blue MK3 is very right. Kudo's to you.

As for MK4 dash, yeah, i will reveal cars stats later when it make more sense.

Soundofav6 - Only retro fitting front half of mk4 to mk3 door skin, and will end up having to build a custom pod for car and MK4 window switch on drivers side.

[99gti]

I would post pics of the car, but i feel i would have to check with the owner first.

But very nice spotting 99gti, jazz blue MK3 is very right. Kudo's to you.

As for MK4 dash, yeah, i will reveal cars stats later when it make more sense.

Soundofav6 - Only retro fitting front half of mk4 to mk3 door skin, and will end up having to build a custom pod for car and MK4 window switch on drivers side.


I am the Jazz blue whore! haha

:bowdown:

[glidn]

a little update from the weekend, and around 6 - 7 hours of fibreglassing.


Ok so here are some updated pics for this weekend. I tried originally make moulds of the factory MK4 door skin, but alas this will not work. So i decided to do this instead. Making a mould of the dash board itself, as shown in the next few photo's. then while i was at it on saturday, i glassed the rear of the sub. Still unsure if i'll be doing dual 8" or single 10".

Dashboard moulds:
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00555-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00556-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00552-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00553-1.jpg

As you can see by this above photo's i'm going to try and do the front corner of the door skin this way instead. I have no idea if this going to work but i guess i'll find out.

the start of the sub box:
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00557-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00559-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00561-1.jpg

by these above photo's you can see i have glassed the rear of the sub box foor the car.
2 things here, all those black dots and line you see. It will be either single 8, dual 8 or single 10 to go in there so i have the 3 lot of lines depending on how the sub box will be built. All the dots you see is potential mounting point i'm thinking of using.
Ultimately i want the sub box mount and you shoiuld not be able to see any of the screw mounting point what so ever. So hopefully i do achieve this.

something else i have been thinking about where you see the strange kink in the glass i cannot explain, because looking at it straight on you can not see that what so ever.
I'll be Liquid nailing most likely something like a 2x4 behind where that kink is. In addition i''ll be doing that on the other side. So i can mount the rear of the sub box from the inside too. Hopefully giving additional bracing.

Now the last thing you will notice it's build into the left rear corner of the boot to hopefully give it a couple of DB's boost, in the lower frequency to make the sub really shine.

http://www.vwwatercooled.com.au/forums/images/imported/2008/06/DSC00551-1.jpg
and lastly The Headunit i'm installing in the car:
Pioneer P80RSII

I still have no idea where i'll be mounting the tweeters for the front. I will try a few different places and go from there. Hopefully not on the A pillars, as the idea of this car is to have everything stealth as much as possible. Hence there will be a removable grill of some sorts for the sub/s too..

[glidn]

i will have to get a better picture of the radio, it was done with my cell phone.

[glidn]

Here is a quick update. I have started joining the front pieces like i explained a few post back, but at least with these photo's you have a better understanding.

Also if you look at these photo's you can see the door almost looks like it suppose to. But there is a little gap at the moment which i will glass back in again.
This is the Left Door
http://www.vwwatercooled.com.au/forums/images/imported/2008/07/DSC00566-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/07/DSC00567-2.jpg

The Gap For the Left Door - It almost fits like it was suppose to be there
http://www.vwwatercooled.com.au/forums/images/imported/2008/07/DSC00572-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/07/DSC00574-2.jpg

Now The Right door - Much the same but i'll have to space the right doors glass bit around 8-10mm as right now the big gap bothers my alot.
http://www.vwwatercooled.com.au/forums/images/imported/2008/07/DSC00575-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/07/DSC00576-1.jpg
The Gap for the Right door
http://www.vwwatercooled.com.au/forums/images/imported/2008/07/DSC00577-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/07/DSC00579-1.jpg


And finally i'm not to sure if any of you have really seen or heard of the E-Audio Amplifiers. None the less i thought i would post up some quick pics for you guys.
http://www.vwwatercooled.com.au/forums/images/imported/2008/07/DSC00562-2.jpg

Cert for the power
http://www.vwwatercooled.com.au/forums/images/imported/2008/07/DSC00564-1.jpg

[glidn]

Ok here is abit more of an update. I have spaced the right door piece out around 10-11mm, i feel i could have gone a little bit more but this will have to do.
http://www.vwwatercooled.com.au/forums/images/imported/2008/07/DSC00582-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/07/DSC00581-1.jpg

Also i have started on a door pod, but will update that a little bit later. As i have not taken photo's.

I orginally intended to use as much of the standard stuff as possible. But this is what happened since then. The Right side door (Drivers door) has extra bracing and electronic gadgets in now. So the factory panel does not clip on anyway. So what i have to do now is cut pieces out of the door till the original door skin clips back in place then start sealing the door up again.

These are 2 problems i have with this.
1. I'll have to cover up door same for both sides or it will look strange.
2. Mean there will not be a useable pocket any longer.

this really sucks.

Well if you guys have any idea's regarding the door pods post them up after i have posted the rear of the door pod.

thanks

[glidn]

wow i have not updated alot of this, will do this over the next couple days.
Been having horrible weather not fibreglassing worthy.

[glidn]

here are the front doors just about finished.
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00595-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00596-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00598-2.jpg

I have also learnt how to do plastic welding, mainly because no company over here wanted to do it for me.
Before
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00605-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00604-2.jpg

During
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00599-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00602-2.jpg

After the platic welding
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00602-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00601-2.jpg

Just about done, need one more coat of primer than to be painted.
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00603-2.jpg

[glidn]

I have since then made a few more sanding and painting layers.

First idea of the doorpods:
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00617-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00621-2.jpg

The First Subbox design:
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00640-2.jpg

Finally had good enough weather and have done the front left door pod and also the subbox - As seen here

http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00680-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00677-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00684-2.jpg

And finally working on the driverside door pod and MK4 window switch module to fit and clip in and out of the drivers side doorpod.
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00660-2.jpg

[KI11Z]

very cool project but wats up with the window switch relocation? :???:

[rayray086]

Sick fibreglass work :bigok:

[Mrk_Mickey]

Sick fibreglass work :bigok:

x2 on that one, Louis is going to freak!

[glidn]

KI11Z - the problem with this car it's a MK3 but is running all MK4 running gear dashboard and all MK4 wiring, so i have to build a mk4 Window switch into the car for the owner.

So everything i have done for window switch unit and also all the plastic welding is MK4 bits into mk3 bits. So if anything had to fail at any point simply un pop the mk4 switches and replace with new ones. Easy as that.

[KI11Z]

oh right, nice! coolies :)

[thestu]

awesome fiberglass job! i wish i knew how to do that sorta stuff!!

good job mate :)

[glidn]

thanks for the comments guys,

should have the right doorpod and amp rack built by the end of tomorrow night. So will post up the progress.
Will also be changing the face of the sub and speakers mounts black.
Right now it will be black and yellow contrast. That will look cool
Still have to do the grills i have 2 options i'm working on at the moment.

[HOLEIN1]

very impressive work mate, looks to be well thought out indeed... not too many realise how hard/time consuming it is to pull something like this off...

well done :)

[99gti]

Holy crap batman :batman:

This is freakin awesome!

[glidn]

Ok so another update again, man as long as i get the time i can finally have the system done in the next few days.

As promised here are some pics of the design before wrapping,
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00698-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00699-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00700-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00701-2.jpg


Then here are some pics of the Subbox clean and place in the boot but not mounted yet.
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00689-2.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00691-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00692-2.jpg

Just enough gap for the vinyl once mounted and it should not pressure the vinyl at all either.
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00690-1.jpg


And of course the the doorpod cleaned and mounted to the door and checking for gaps.
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00695-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/08/DSC00696-1.jpg

If you have a look you can see that slight gap between the doorpod and arm rest, i'm thinking i might build the door pod up to there from the rear to the front of the door pod.Also the front of the doorpod has gap between doorpod and doorskin that to will be built up and cleaned.
Also i might stick a glowing VW badge with perspex and LED's in there as the door lights
any thoughts on this idea?

[glidn]

I have also wrapped the drivers side doorpod, then Imprinted a Friends 9887 the R32 that i did actually.

Well just before i got started into glassing the other doorpod i decided to triple check everything as far as measurements go and location, shape and design are spot on. But after some measurements found the drivers side doorpod was 20mm to far back, so i have pulled the pod apart and will re do it today and glass it, So by tomorrow the opds will all be glassed.

Then i just need to add finishing putty and sand till it's smooth, then i can hopefully install all of the gear.

[dubbed]

Whoa you're a magician. This is going to look awesome!

[ranton-inc]

if you have an imprint capable headunit or module i strongly reccomend getting your car imprinted..

its amazing!

[glidn]

another update.
Amp rack built, will cover with material today, then give photo of finished product.
Also this is how far the doorpod and Subbox have progressed.
http://www.vwwatercooled.com.au/forums/images/imported/2008/09/DSC00706-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/09/DSC00707-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/09/DSC00708-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/09/DSC00710-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/09/DSC00711-1.jpg

Subbox
http://www.vwwatercooled.com.au/forums/images/imported/2008/09/DSC00709-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/09/DSC00712-1.jpg
and as you can see still some filling and sanding to do.
http://www.vwwatercooled.com.au/forums/images/imported/2008/09/DSC00713-1.jpg


also the subbox is now mounted, still have finished off the correct angle for one of the bolts. Then sub box will be ready and done, for the work i need to do.
Will also mount the speaker terminal on the one side of the box. Will do that hopefully sometime today.

If you go up a few post and have a look at the door pod mounted, you will see a gap between the doorpod and armrest. This gap has been bugging me so as of last night that gap no longer exists. I have built that gap up with fibreglass.
So hopefully today i can have the last and final bog and sanding happening,
Then i can use finishing putty. And hopefully then do the final sand and fit.

Once i get to this stage, then all that is left to do is assembly of the car and tuning.
this should be fun, this radio has 16 band parametric EQ per left and right channel. So i would have to think this is going to be a little of a headache.

But will see.

[thestu]

looking fantastic mate :D

[glidn]

Well I'll resurect this old thread.
Why you might ask?

Well ironically, this car has now become mine.
The car is a 1998 VW mk3 Wagon that had a VR6 24v motor installed. I have since removed it the day I got it.
I'm currently installing a 1.8T engine in this very car.

Well this is some of the wiring I removed
http://www.vwwatercooled.com.au/forums/images/imported/2012/07/IMG_0954-1.jpg

This is how the wagon currently looks
http://www.vwwatercooled.com.au/forums/images/imported/2012/07/IMG_0980-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2012/07/IMG_0985-1.jpg

This is what the mounted and covered sub box looks like - Not yet screwed in
http://www.vwwatercooled.com.au/forums/images/imported/2012/07/IMG_0983-1.jpg

Here is the donor car
http://www.vwwatercooled.com.au/forums/images/imported/2012/07/0cd16fa911-1.jpg

will link a build thread to this and start updating it that way.