The Next Chapter: The GTI Build Progress

Initial Shell Prep and Weight Reduction
Before sending the car off to be caged, we focused entirely on weight reduction. We stripped as much from the shell as possible to take advantage of our best opportunity at weight loss, primarily by removing now unnecessary factory brackets like the stock seat rails and sun roof supports. While the shell was out, we also cut the new Lexan windows and wrapped several of the body panels in our color of choice, Arancio Argos Red Orange.

Cockpit Ergonomics
On this build, we opted to push the driver and co-driver seats further back to optimize our weight distribution and safety. This change required more interior fabrication then we have done in the past, forcing us to assemble a new steering column, rework our power steering, utilize floor-mounted pedals, and reconfigure how the shifter and handbrake mount. At this point, the core fabrication work is completed, and we are nearing the point where we can finishing painting the inside of the shell.

Chassis Reinforcement
A major objective for this new chassis is building in the structural durability we lacked in the Jetta (we didn’t know better). Most of this was resolved with the cage and the number of additional tie in points to the front and rear suspension, but we still spent a significant amount of time reinforcing the front frame rails of the car (forward of the shock towers). Instead of just adding reinforcement plates on the inner faces of the frame rails, we opted this time to also add plates on the top and outside of the rails, hoping this adds enough additional strength to support the front cross member during big impacts.

Powertrain Refinement & Harness Thinning
With the engine out of the car, we took the opportunity to address reliability and performance layout issues learned from our past setups. We replaced the engine wiring harness, installed a turbo blanket for heat management, and prepped a new lightened flywheel and clutch assembly. To ensure simplicity and reduce electrical risks on stage, the factory body wiring harness and fuse block have also been thinned out to remove any unnecessary circuits.

Looking Ahead
Once the shell is painted, our next phase will move onto running the brake lines, fuel lines, and wiring harnesses. Although we are taking our time to ensure everything is well thought out and done correctly the first time, we are currently on track to finish in time for one or two of the fall rally trials with the Sports Car Club of New Hampshire.