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2004 VW Jetta GLI CarPC and more

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  • 2004 VW Jetta GLI CarPC and more

    I bought my charcoal grey 2004 VW Jetta GLI last year. It was completely stock with minor dings and dents. The interior however had a few panels recovered and it looks like crap. So, I decided to take out the interior, sound proof the car, and run cables for my new carpc.

    Before I get into the tear down here is some back ground pics.

    Step 1. New Paint Job.

    Paint Prep



    http://share.shutterfly.com/action/w...AcOHLRw2bOWj2Y

    Painted



    http://share.shutterfly.com/action/w...AcOHLRw2bOWj4g
    Last edited by cazzz; 06-15-2012, 12:51 PM.

  • #2
    Keeping with the exterior appearance I replaced the headlights and tails. Dectane.de all around.





    http://share.shutterfly.com/action/w...AcOHLRw2bOWj6o

    Changed the front and rear chrome VW emblems with black emblems.

    Added smoke running and turn signal lights all around. Led bulbs throughout.

    Step 3. Added a little performance with APR Stage 1.
    Last edited by cazzz; 06-16-2012, 03:04 AM.

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    • #3
      This is where I am at now. I have removed the interior from my car. I will be adding sound proofing materials, covering the upper pillars, headliner, sunroof cover, and door inserts.

      I plan on using foamed back material for the headliner and sunroof cover and will experiment with 3M vinyl for all the other surfaces.

      Interior pulled:





      http://share.shutterfly.com/action/w...AcOHLRw2bOWj8w

      Sound proofing was an important part of this project. I researched most if not all of the products available and did an analysis to determine cost per sq ft. Here is a run down of the materials.

      CLD, contrained layer dampner, commonly called sound proofing. Usually butyl rubber covered in a foil. This deadens the sound of the panels and only needs to cover 25% of the surface to be affective.

      MLV, mass loaded vinyl. I used the 1 lb per sq foot density and this material is for sound proofing as it blocks noise. Ideally you install this over full panels with no seams. I did find this difficult in some places so I used overlapping pieces. I did not glue the seams and taping the seams is nearly impossible as the tape does not stick very well.

      Under carpet cover, I used 1/4" high density foam covered in MLV.

      Closed cell foam, used to eliminate vibration and rattles from loose panels.

      Extruded Butyl Rope, used around the doors and speakers to eliminate air movement.

      If anyone is interested I can provide a cost comparison between these suppliers.

      sounddeadnershowdown.com
      dynamat.com
      fatmat.com
      secondskinaudio.com
      hushmat.com
      desgnengineering.com
      tmsoundproofing.com



      Last edited by cazzz; 06-16-2012, 03:25 AM.

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      • #4
        http://share.shutterfly.com/action/w...AcOHLRw2bOWj-4

        I have to repair a few wires that I accidently cut when removing the stock undercarpet material.

        I am also going to repair a tear in the drivers seat bolster. I will probably remove the material completely from the seat and take it to get it sewn.

        Next I need to run wires for my carpc install.
        Last edited by cazzz; 06-16-2012, 08:50 AM.

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        • #5
          The Plan:

          Stock monsoon head will be replaced with a 7" or 8" LCD touchscreen. The 7" fits the double din slot, the 8" however will take some fabrication and the fit will be tight.

          Mac Mini installed in the trunk.

          DC-DC power supply installed in the trunk.

          USB hub installed on or near the dash.

          Remote power switch for the Mac Mini installed in the center console

          Sewell Digital to Analog 5.1 DTS/AC-3 Decoder installed in the trunk for computer sound integration into the stock monsoon amp and stock speakers. I know they will be upgraded in do time. I am adding a small sub with this install however.

          The following wires will need to be run before reinstalling the interior.
          Power to the trunk. I am installing a marine grade fuse bus under the hood and in the trunk. These will provide grounded power distribution for all future wiring projects.

          #8 black ground hood to trunk
          #8 red power hood to trunk
          Power and ground for LCD panel trunk to dash
          HDMI, DVI and VGA cables trunk to dash. Covers all the bases for future upgrades.
          USB cable to USB hub trunk to dash


          The remaining cables are in the trunk area.

          Once these are run I can get my car back on the road and start bench testing the carpc.
          Last edited by cazzz; 06-16-2012, 06:34 PM.

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          • #6
            Components:

            Basic Mac Mini
            Carnetix P-2140 power supply
            Carnetix P5USB hub
            Griffen remote usb controller for volume control
            Sewell Digital to Analog 5.1 DTS/AC-3 Decoder for audio integration
            Lilliput 7" or Xenarc 8" touchscreen.
            Replacement antenna, includes wifi, gps, and cellular. (No FM)

            Next I will cover modifications to the Mac mini and list all of the connections.
            Last edited by cazzz; 06-16-2012, 04:22 AM.

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            • #7
              5 modiificatons to the Mac Mini

              1. Replace the 500GB HD with a 450GB SSD
              2. Replace the 4 GB of ram with 16 GB ram
              3. Remove the internal power supply and replace with a cable and connector mounted on the side of the case. The external power supply will be used in the house with a patch cable to the case connector. In the car, the DC power supply will plug into the dc connector on the side of the case.
              4. Disconnect the internal wifi antenna and replace with a pigtail cable to a connector on the side of the case. A small external antenna will be used in the house. In the car, the roof mounted antenna includes wifi.
              5. Modify the on/off button wiring. The power supply will control the on/off function of the mac mini based on ignition power. When the car is turned off the power supply will turn off the mac mini. I may use a remote on/off switch mounted in the center console. I plan to use a 2.5mm plug in the side of the case for the on/off switch connection(s)


              The following items will be connected to the mac mini USB ports.
              1. USB cable to the USB hub in the dash
              2. GPS dongle with external antenna connection
              3. AT&T 4G dongle
              4. Power supply

              USB hub
              1. LCD monitor for touch screen function
              2. Super Drive
              3. Volume Knob
              4. OBD II

              Other connections:
              Wifi Antenna
              Power
              On/off function
              TSOLink out to Sewell audio converter
              - This unit provides RCA out for 5.1 surround or 2.1 stereo
              Last edited by cazzz; 06-16-2012, 04:23 AM.

              Comment


              • #8
                LCD panel planning.

                I am attempting to fit an 8" Xenarc LCD panel in the dash.

                There is enough room by removing the double din radio and a dead panel above the radio.

                The radio cage will be modified to fit the panel.

                The challenge is to make a bezel that fits the opening and accepts the LCD panel.

                I have a buddy who works with carbon fiber and fiberglass. He will make an attempt.

                I also contacted Joe Shock to see what he can do. There are 4 local sheet metal fab shops that I will discuss this with as well.

                The LCD panel will be the last purchase.




                Last edited by cazzz; 06-16-2012, 03:58 AM.

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                • #9
                  I will be on vacation for 1 week.

                  Task list for my return.

                  Repair wiring bundle under passenger seat.

                  Purchase wire, cables, connectors, fuse blocks and fuses.

                  Disassemble the dash.

                  Run cables and wires.

                  Install new antenna and maybe a hidden FM antenna just in case.

                  Take drivers seat for repair.

                  Reassemble the interior.

                  Hopefully the car runs and everything works.

                  Disassemble the trunk.

                  Wire all power connections and fuses.

                  Purchase Mac Mini

                  order connectors for the antenna and on/off switch.

                  Install software and verify the mac mini is up and running.

                  Setup an ATX power supply to bench test the entire setup in the house where its nice and cool.

                  Modify Mac Mini as outlined above verifying operation after each mod.

                  Attach the PSU to Mac Mini and verify operation.

                  Purchase GPS and AT&T dongles verify operation.

                  Purchase audio interface verify operation.

                  Check the USB hub and volume control

                  Ready for installation.

                  By now I should have a bezel and decide on the easy route using a 7" Lilliput or the bezel works and I purchase the 8" Xenarc.

                  Back in a week.
                  Last edited by cazzz; 06-16-2012, 04:18 AM.

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                  • #10
                    Just returned from a cruise to the Bahamas. Much needed rest. It's time to get working on my car.

                    Play by play starts tomorrow.

                    Comment


                    • #11
                      Repaired the wiring, soldered and heat-shrink. Hopefully I didn't miss any.



                      Removed the sunroof glass panel.

                      Removed the sunroof headliner panel. Removed the material and foam.



                      Covered the headliner in black cloth. Need to finish the edges.



                      Went shopping:

                      West Marine, 8 ga red and black wires, 16 ga red and black wires, 2 fuse blocks, connectors, heat-shrink.

                      Sears: torque wrench

                      Online: 15 ft each, VGA cable, HDMI cable, USB cable, composite video cable, and connector for the wifi antenna FME to SMA.

                      Plan for tomorrow:

                      Finish the headliner.

                      Pull the back off of the drivers seat for seam repair.

                      Double check for more cut wires.

                      Run 8 ga red and black wires from the engine compartment to the trunk.

                      Run 16 ga red and black wire from trunk to radio cage for LCD power.
                      Last edited by cazzz; 06-24-2012, 08:10 AM.

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                      • #12
                        11am. Taking my time on the headliner.

                        Looks like that may be all day to finish it up.

                        1pm. Headliner is nearing completion. I found the regular contact cement works great along the edges.



                        1:48 headliner is done.



                        Thats about it for today. I will probably take the back off of the drivers seat so I can take it tomorrow to get sewn.

                        Last edited by cazzz; 06-24-2012, 01:25 PM.

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                        • #13
                          Remaining tasks

                          Disassemble the trunk.

                          Disassemble the dash.

                          Run cables and wires.

                          Install new antenna and maybe a hidden FM antenna just in case.

                          Take drivers seat for repair.

                          Reassemble the interior.

                          Hopefully the car runs and everything works.

                          Wire all power connections and fuses.

                          Purchase Mac Mini

                          order connectors for the antenna and on/off switch.

                          Install software and verify the mac mini is up and running.

                          Setup an ATX power supply to bench test the entire setup in the house where its nice and cool.

                          Modify Mac Mini as outlined above verifying operation after each mod.

                          Attach the PSU to Mac Mini and verify operation.

                          Purchase GPS and AT&T dongles verify operation.

                          Purchase audio interface verify operation.

                          Check the USB hub and volume control

                          Ready for installation.

                          By now I should have a bezel and decide on the easy route using a 7" Lilliput or the bezel works and I purchase the 8" Xenarc.

                          Comment


                          • #14
                            i love love love that model jetta, especially in that color (or the blue... i think its called blue lagoon). i almost got it once, but went with an rsx.

                            looks like you're doing a fantastic job. what did you use to stick the cloth to the headliner?
                            can't wait to see the screen instal...
                            STiPC, my 2006 Subaru STi worklog

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                            • #15
                              The fabric and adhesive is from Joann's Fabrics.

                              I ordered fabric samples from two companies but Joann's fabric was comparable.



                              The adhesive worked well. Its not coming off thats for sure.



                              I used contact cement around the edges and any where I couldn't easily spray the adhesive. It worked great. The setup time is longer but once it holds, it holds.

                              Last edited by cazzz; 06-25-2012, 02:46 PM.

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