1997 VW Jetta GLS Install

SiGmA_X · 10-22-2003, 12:24 AM

I just finished my 1997 Jetta’s install on Sunday. First, before we get into this, I want to thank Marc, Troy, and Nick for all their hours of help, and Marc and Troy’s dad for letting us take over his garage on the weekend.

First, what I put in: VIA EPIA M10000 with 512MB PC2700 and an 82GB IBM hard drive using a Linksys 802.11g wireless card to war drive and connect to my network for file syncing. My input and display is a Xenarc 700TS (VGA with Touch screen) and my GPS unit is a Rand McNally serial receiver, which works GREAT! The software I am running is CoPilot 2003 and Media Engine 1.77 (Using Confused’s changes, which can be found here). The computer is in an old P2 case I had lying around, and will be moved into something smaller in the near future – Making a custom Lucite case for it this weekend most likely.

The console was molded from the original console, using a layer of fiberglass and then sculpted with Bondo. We started out using all Bondo, but the Bondo wouldn’t adhere do the console material, so we laid a layer of fiberglass at about 2AM and then went to sleep. The fiberglass was set up perfectly at 9AM when we went back to work, and Marc started laying Bondo onto it. I think we used about 5 layers of Bondo, and a LOT of sanding, which made it turn out really nice. Primed and painted semi-gloss with two coats, and looked great. But we rushed the install and I chipped the Bondo when I installed it into the car, and the paint smeared a little bit – Means I have work for this weekend!

When we drilled the switch panel, it cracked badly so we applied some Bondo and sanded and painted it, but it came out ****ty, so I am ordering another one from VW (or getting one from a junk yard this weekend if I can find out there) and trying it again. Also, the large red-lit switches I bought look horrible, so I am getting some smaller ones that are blue, or chrome and a blue LED above it, not quite sure yet.

I took the GPS receiver apart and sanded off the “GPS” text that was on it, and primed and painted it flat black, looks much better now, and then I tucked the wire away around the edge of the window lining and into the trunk – It can’t be seen from outside the car, or inside either.

Now, for some pictures…

Media Engine, running VW skin:

Console and Headunit:

Console (Custom):

Switch panel:

Computer in Trunk:

GPS receiver:

And some more pictures, and any more that I get will be here: http://pchardwaremods.com/sigma/images/jetta/

And I’m sure I’m forgetting to tell something, so feel free to ask anything and post comments/suggestions/etc. Thanks!

osirisdon · 10-22-2003, 12:33 AM

two words!!!

BAD ***!!!!

SiGmA_X · 10-22-2003, 12:44 AM

Quote: Originally Posted by osirisdon

two words!!!

BAD ***!!!!

Thank you!

Oh, and I should add.. My sound system is the stock with a new HU (Have had it for about a year) but is being upgraded to Infinity speakers and JL subs and JBL amps..

Nanozic · 10-22-2003, 01:20 AM

That looks great! I will be doing a very similar setup pretty soon. I really like you screen setup. Any 'in-progress' pics of you building up the LCD consol? I am new to the whole fiberglass bondo thing so any pics and tips would be great.

SiGmA_X · 10-22-2003, 09:16 AM

I wanted to post the 'in progress' pictures, but they are on my friend’s camera. He should be getting them to me tonight, and I'll post them

As for tips.. We started with a layer of fiberglass (Don't ask me - I wasn't around to do it, my friend only had one respirator!) and then we started adding Bondo. You just mix the stuff - The Bondo and the hardener - and then start laying it on. I don’t think you will need fiberglass and Bondo most times, but the Bondo wouldn’t adhere to the console at all, it kept chipping off, so we used fiberglass under it and it worked great. If I were you, pick up a tub of Bondo and start playing with it first

This was my first time, but I had a *pro* with me to help, and this guy is really good

Sh0cker · 10-22-2003, 09:26 AM

nice setup...great idea putting lcd in cupholder compartment
too bad i have bigger screen ;-\ have to customize entire center console now

btw: how did you manage to take it out, did you remove brake handle?

SiGmA_X · 10-22-2003, 09:50 AM

Yup, took out the eBrake and everything. If you look on the sides of the eBrake console, there are 2 plastic hole covers. Pop them out (Reach up behind it) and there are 2 screws that secure it

Sh0cker · 10-22-2003, 05:49 PM

about that computer in the trunk:
i used to have it right there (pic below) but since i bought a new system (epia) I have it right behind lcd, in dashboard.
Maybe this going to be helpful.

samc · 10-22-2003, 06:43 PM

that would be cool, if you made a more custom fit siding and carpeted. I like the idea.

In my mk4 Jetta I have my carputer in an 7x7x3.25" acrylic box under my passanger seat. I picked a dark color so that even in daylight with the door close you can't see it.

SiGmA_X · 10-23-2003, 12:33 AM

I am going to make a small plexy case for it this weekend or next, depending on how my re-doing of the console goes.. I think I have a good 8-10 hours cut out for what I want to do, given 4 of that is spent painting (3 min or so to spray, 1 hour to dry) but I want to get it looking perfect

Once I get my subs and amps, my friend and I are custom doing my trunk, with paneling and everything, and that should look good