What to do while waiting to finish!

[John Phillips]

I'm waiting for my final parts, and a little antsy. Here's how I used some of my sawed-off Jetta metal. I'm teaching myself to MIG weld using the internet. So far it seems to me you have to learn how to set up the machine, then spend a lot of time welding scrap metal and learning how to keep from burning holes in it. As soon as I get a little better, I'm building a welding cart to haul around all the stuff you constantly need to use: MIG welder with hose and wires, gas bottle, grinder, helmet, face shield, pliers/cutter, extension cord. Then I'm gonna make a welding table: plywood on top of garbage cans isn't too cool. Anyway, for now I just kept chopping off little bits of Jetta door steel and welding them back on, plus using some scrap strap steel I had laying around. Great way to spend Father's Day!

[Cobra Steve]

Sure looks like fun.

[dukegrad98]

Sheet metal is one of the harder ways to learn; of course, if you master that, bigger iron will be really easy for you. I started from the middle, practicing on scrap 1/8" angle iron pieces. Then from there I learned to adjust settings and technique for thin sheet, and finally upped all the settings for thicker stuff like 1/2" plate. I'm a long way from being any kind of a master, but it's a good skill to have.

Of course, it's a small project. From the start of the "time to talk" thread until now you could have finished law school for a second time. Maybe you want to check in for a quick one-year LLM while they decide how to do a top for the car?

Cheers, John

[JKleiner]

Look out South Florida, Phillips is welding! I think this will most definitely put an end to your fondness for incorporating wood into your builds

John H., Even after stepping out of the game you just can't let it go can ya'?

Jeff

[dukegrad98]

Originally Posted by JKleiner

John H., Even after stepping out of the game you just can't let it go can ya'?

Hey, I added something constructive to this thread! And I have actively tempered my comments for the last several months after the project ended for me...nevermind the couple of years before that. And nevermind the approximately four grand I've still got tied up in a beater Jetta for a project that doesn't exist. That's my own fault for drinking the kool-aid, but that doesn't fix the empty space in my wallet or remove the car from Wayne's shop...

Given the way I was ultimately treated by the "other brother," he's lucky I've been both this friendly and this quiet. Hey, who needs to satisfy an early, dedicated, paying customer when you've got 20,000 close Facebook friends anyway?

Cheers, John

[manual_tranny]

That does look like a great Father's day! I've got to take a few days and get better at welding myself. What fun!

Offtopic: Was I right about the clutch interlock?

[John Phillips]

Whew, Lynn's gone and called to be sure I didn't start the house on fire (again). Nothing caught fire, so I think I'll continue to use the outdoors for my apprentice welding career. Gonna find some heavier gauge steel to practice on...too easy to burn holes in this thin stuff!

Michael, I haven't attacked the electrical situation yet...it's such a frustrating topic for me, so waiting til one of my guru friends has some time to spend. So far, I'm sure the solenoid isn't getting electricity, and that the clutch is bled and the hot line to the starter is good. More investigation to come soon...THANKS for your response to my email , I neglected to reply, but really appreciate the ideas. Will report the results!

[manual_tranny]

Originally Posted by John Phillips

Whew, Lynn's gone and called to be sure I didn't start the house on fire (again). Nothing caught fire, so I think I'll continue to use the outdoors for my apprentice welding career. Gonna find some heavier gauge steel to practice on...too easy to burn holes in this thin stuff!

Any day I don't burn my house down is a success in my book.

Originally Posted by John Philips

Michael, I haven't attacked the electrical situation yet...it's such a frustrating topic for me, so waiting til one of my guru friends has some time to spend. So far, I'm sure the solenoid isn't getting electricity, and that the clutch is bled and the hot line to the starter is good. More investigation to come soon...THANKS for your response to my email , I neglected to reply, but really appreciate the ideas. Will report the results!

I understand... I'm still learning about electrical systems as they've never been my favorite subject.

The clutch hydraulic line shouldn't cause any heartache getting the engine to turn over. Only that annoying in-line pedal-activated switch that you can barely see or access under the dash. Do you have VCDS? I loaned my cable out but I can get it back and send it to you. There are a few things that are surprisingly easy to check for in VCDS. Sometimes these switches can physically appear to be functioning when in fact they aren't sending the correct signals.

Some newer MKIV vehicles have two clutch switches... an interlock switch (prevents starting) and a separate cruise control deactivating switch. I have a 2003 GTI 24V VR6 that experienced poor performance and hesitation because the ECU wanted to know when I was shifting. When it didn't get the correct data, it refused to allow the cruise control to work and it produced a full 1 second delay between punching the throttle and getting power.

[D2W]

John check with your local welding supply houses for demo days. The big boys like Miller come in with a trailer and let you get "hands-on" with a lot of cool stuff. They will also give you pointers on what type of wire you should use for different projects (it makes a big difference), and how to properly set up your equipment for different types of materials. Short of taking an actual welding course its one way to learn quite a bit.

[John Phillips]

Thanks for the input guys, this welding deal is fun so far. Trying to locate scraps of thicker stuff today. D2W, good idea, I'll call around and see if any demos coming here soon.

Michael, I DID catch our house on fire ~10 years ago, when my Factory Five Roadster caught fire in our garage. Burned & destroyed the entire garage contents, including my wife's new S2000 and my FFR. We were out of the house 13 months while they rebuilt the whole place due to smoke damage. Turned out it was caused by FORD'S faulty-design alternator in that generation of 5.0 engines...I learned the guys in the auto electrics industry referred to it as the "fire-alternator". Thus my hesitancy about auto electrics I guess, and Lynn's fear of me starting fires in our house for sure!!

[manual_tranny]

Originally Posted by John Phillips

Thanks for the input guys, this welding deal is fun so far. Trying to locate scraps of thicker stuff today. D2W, good idea, I'll call around and see if any demos coming here soon.

Michael, I DID catch our house on fire ~10 years ago, when my Factory Five Roadster caught fire in our garage. Burned & destroyed the entire garage contents, including my wife's new S2000 and my FFR. We were out of the house 13 months while they rebuilt the whole place due to smoke damage. Turned out it was caused by FORD'S faulty-design alternator in that generation of 5.0 engines...I learned the guys in the auto electrics industry referred to it as the "fire-alternator". Thus my hesitancy about auto electrics I guess, and Lynn's fear of me starting fires in our house for sure!!

Wow.

I too had a scary fire experience. I was helping my step-dad and a couple other farmer/"mechanics" who were acting like damn fools.

They were installing rebuilt carburetor for an enormous boom truck from the late 60's/early 70's. It wasn't starting, so they got the bright idea to half-fill a spray paint can lid with gasoline, so they could pour the gasoline into the open carburetors as I started the truck from inside the cab. I was chosen to start the vehicle, and even though they were trying to be careful, they forgot to tell me the potential consequences of a backfire. I was 16 at the time, and I didn't know very much about engines.

Of course, a backfire happened, and I watched through the front windshield as a fairly good sized fireball engulfed my stepfather. He was wearing a polyester shirt and glasses. The glasses saved his eyes and the polyester shirt caused 3rd degree burns around his chest.

I had the presence of mind to yell "drop and roll" as Larry, Curly, and Moe tried to pat their fires out while running around trying to find water in a half-built shed. I wasn't much smarter. When I saw something still burning under the truck I lunged at it and put it out with my hand, only to find out that it was the plastic spray bottle cap they were using to pour gasoline into the carburetor. Now I'm a bit more careful with gasoline. The only gasoline motors I own are lawn tools and an RX7, which is really an oil burner anyway. :P

[Bill Shaw]

With a sawzall and a welder you can do anything :-)

[John Phillips]

I just feel so damn manly, this welding practice is great! Burned up some thicker scrap steel last night, more tonight...