My 1Z TDI Rabbit Truck Conversion

vw_nut · Nov 29, 2010

Here is my first start..................http://s168.photobucket.com/albums/u174/vwnut49/TDI Caddy/?action=view&current=video148.mp4

vw_nut · Dec 7, 2010

Well Today i worked on cleaning up the fuse box and mounting it in place, got all my wires all cleaned up and zip tied up, finishing up the dash and getting it ready to send off and get recovered, i think the mk4 console will work around the shifter gonna work on that.
I got my new scirroco 16v calipers today and i painted them and will mount them tonight and bleed them and the hydraulic clutch and get it ready to roll

rackaracka · Dec 7, 2010

Are you planning on a radiator fan setup?

vw_nut · Dec 7, 2010

Yes i have everything in the shop to do it just haven't got to it yet i have to pull the radiator back out to fit the bung for the fan switch sensor and ill finish it then plus i am working on the A/C lines they are to close to the radiator and im looking into making a 90 on the aluminum pipe instead of it comming straight out and making that big loop

rackaracka · Dec 7, 2010

This project looks fantastic! You are doing an awesome job! Thanks for taking the time to update this thread.

vw_nut · Dec 7, 2010

Your quite welcome, i was gonna hire a lot of the work out at first, then money got tight, i just decided that i would like to say that i did most of the work myself, i have really enjoyed it, kind of my scape goat , i may not have all the best ways but there mine and so far things have worked out just fine

Dimitri16V · Dec 7, 2010

did you replace the power steering rack bushings ? where did you get them from ?
Project looks good

vw_nut · Dec 7, 2010

All of my stuff came from world pac

vw_nut · Dec 9, 2010

here is the shifter installed

vw_nut · Dec 9, 2010

Here is how the fans are gonna go, i have to cut the holes and then there ready to install

Rgarza06 · Dec 9, 2010

damn that looks like i would of gave up at the engine bay lol good progress

vw_nut · Dec 10, 2010

Well for the umteeenth time i put the dash back in and did more fitting for the heater controls and to work on more support to keep the dash solid, so far everything is fitting together fairly well, just time consumming, everything is a little dusty from sitting but it will all clean up nicely, ill have to tear the dash back out at least a few more times yet, besides this dash is the test dash once i get all the cuts done i will then copy it and then send it off to be recovered

vw_nut · Dec 10, 2010

this is the duct work i made for the vents, im still up in the air with the center vents wheather to keep them or take them out,

dieselherb1 · Dec 11, 2010

One more time(I think) this is a Corrado dash? Did you use the complete Passat fusebox or MK1? I tried to pull a complete harness from a TDI Jetta at the salvage yard, what a mess. Can't believe I need the headlight-grill wiring in a MK1 swap? Wiring for all the doors and windows? Someone told me only four wires needed, what?

vw_nut · Dec 11, 2010

Herb
Yes this is a corrado dash, yes i used the passat fusebox and entire wiring harness, i took all the stuff out of the harness that i didnt need for my truck, the harness for the taillights i used
As far as 4 wires it depends if your gonna use the passat clluster and all, if your not then that sounds right, not sure what your trying to do

vw_nut · Dec 11, 2010

Today i worked on getting the fans mounted and the radiator mounted, i have to take it back out to get the bung for the sensor welded on

vw_nut · Dec 20, 2010

Well Today i took the truck over to a shop so we can finish up the hydraulic clutch pedal assembly, also having the bung made for the Air temp sensor for the intake, also im putting the battery under the truck in the back were gonna make a carrier back there, after that its to German Performance where Doug will make the exhaust and work on the wiring upfront in the engine bay, in the meantime im sanding the doors and fenders getting them ready to be primed and then painted, which will be the next step, i still have some dash things to tidy up but will wait till i get it back to finish that up...

dieselherb1 · Dec 23, 2010

Please take plenty of pics of the pedal swap. I've of several methods but I also have 2 Passat donor cars would like to use them. Thanks

vw_nut · Dec 25, 2010

Im using the mk1brake and clutch pedal

dieselherb1 · Dec 25, 2010

How can you use the MK1 clutch pedal with the hydraulic clutch cylinder? Passat accel pedal?

vw_nut · Dec 26, 2010

Im making a bracket that goes on the clutch pedal and I am using the passat accel pedal but having a bracket made in the truck

dieselherb1 · Dec 26, 2010

How much for the brackets I'll probably need them?

vw_nut · Dec 27, 2010

Herb the guy that is helping me builds street rods, I will have to ask him if he wants to make more

vw_nut · Dec 28, 2010

well tonight we got the throttle pedal all put it, the clutch is done, we had to renforce the clutch pedal i hope to have pics tomorrow but it all looks factory and fits very nicely im very happy with it , were working on the battery tray underneath and hope to have it done tomorrow or thurs

G60ING · Dec 29, 2010

cool, I'd love to see the pics because I have a couple friends with AHUs ready to install in mk1s and they always ask me for details.

vw_nut · Dec 29, 2010

Well Frank Ill get you some im busy with work and not sure what day this week ill get to go back up there

vw_nut · Dec 31, 2010

Today i picked up my truck, here are a few pics of the clutch and throttle as you can see we reinforced the clutch pedal just for strength, i used some of the passat bracket for the throttle but couldnt use much, no room

Well after getting the Truck back to the House I have decided to go a different way with the hydraulic clutch so its back to the shop and fix it

vw_nut · Dec 31, 2010

a little closer of the throttle

AndersenMotors · Jan 6, 2011

Awesome job! I just picked up a 77 champaign edition Rabbit with 34k kms on it and am going to do a tdi conversion. Thats why I joined this awesome site! This info is invaluable. I'll be going slightly newer, using a 04-05 setup with an auto box for cruising. Cant wait to see your finished product!

vw_nut · Jan 10, 2011

Well today i had a BIG SNOW day, we got 7' and i was snowed in, so I worked on finishing up the hydraulic clutch, i bled it and had to make a front brace so when you pushed in the clutch it didnt push the bracket down, it all works super, im real happy with it and the clutch works, i bled the brakes while i was at it and gonna have to buy a new master cylinder, so i'll order one tomorrow, i just hate to have to go through the pain of keeping the brake fluid off everything but gotta be done, i have to take it over to get the battery tray done and also the exhaust... then no more pushing around i can actually drive it in and out of the shop

My 1Z TDI Rabbit Truck Conversion

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