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VWvortex Forums Golf III & Jetta III DIY: Euro font end conversion (rebar/radsupport/bumper)..
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Still Lost DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta « » 2:12 AM 9-14-2003
Member

DISCALIMER: THIS IS ONLY THE MAJOR PART OF THE PROJECT WE WERE NOT ABLE TO FINISH PROPERLY DUE TO A BENT
FRAME (THE PROBLEMS WE HAD WERE FIXED USING UNORTHODOX MEANS )

Offline we used both the euro rebar and euro rad support

Member Since
7-21-2002 What you will need:
1463 posts Euro rebar
Euro radiator support
Cherry Hill/ Camdezy Nj Socket wrench
84 Rabbit and 99 A4 10mm socket
1.8tqm 13mm socket
16mm socket
Adjustable wrenches
Screwdrivers
Hacksaw blade
Means to recapture freon
Bucket for old coolant
Plastic bags
Zip ties

We started with a Jetta VR6

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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

1.) Take off grill> (done by pressing clips along backside of grill)

2.)Take off bumper> This is done by unscrewing the 3 10mm bolts on the top and then sliding the bumper off the 2 slide clips on the sides,
also disconnect all the light harnesses> heres what you should look like now:

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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

3.) Take out the headlights> unscrew the 4 bolts that hold them in and dissconnect the harness>

4.) Take off the rebar> remove the 8 13mm bolts on the front side>

5.) Now you will take off the radiator/core support> You will want to disconnect the hood latch assembly> take out the 2 10mm bolts on
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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

either side and then disconnect the cable

then take out the 2 10mm on each side of the support this are located on the top of the fenders

>You should now look like this:

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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

6.) Next you will start the dissasembly off the radiator (rad)/core assembly (this involves a few seperate steps)

a.) You will need to dissconnect the 2 ac lines that go to the ac condensor (this is why you need something to recapture the freon) this is done
by using an adjustable wrench and unscrewing the male ends from the line at the top right and bottom left of the ac condensor

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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

you should then use plastic bags and zip ties and cover all 4 openings b/c any dirt or dust particles that get in your ac system can burn it up

Repeat for other side

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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

b.) Take out the 10mm bolts at the bottom on either side of the radiator/core assembly

d.)You want to disconnect the harness that goes to the fans

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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

>At this point the radiator/fans/condensor assmelby will be disconnected except for the radiator hoses, so when you pull the hoses get the
assembly out of the way so it is easier to drain

e.) You will now need to disconnect the radiator hoses, this is where a bucket comes in handy, the top hose does not drain much but the
bottom hose will let out about 1 gallon. You disconnect the hoses by using a wrench to depress the clamp climps. When you take out the
radiator/fans assembly there will still be some coolant which you will need to drain out of it so tilt it over the bucket and it should all come out

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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

>You should now look like this:

7.) Now you have to take off the first subframe. This is done by using a jack to hold the 2nd subframe and taking out the 16mm bolt that
holds both the 1st and 2nd frame to the car. You will then put the bolt back in so it supports the 2nd subframe. (repeat for other side)

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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

8.) Now you will the fan assembly out of the rad/condenser assembly. Do this by taing out the 4 (2 on each side) 10mm bolts on each side.

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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

9.) Now take each fan out of the N/A shroud> do this by unbolting the fans which are held in by 6 (3 on each fan) 10mm bolts

once that is done you will take a screwdriver and


pop out little compression clips all around the 2 fans to get off 2 plastic shields (don't worry about breaking these b/c they will not be used
later)

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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

10.) Now take the radiator/condenser assembly and cut off the 2 little legs on the bottom of each side ( i used a hacksaw blade, tin-snips, and
a file) E CAREFUL NOT TO PUNTURE THE RADIATOR

11.) You will also need to remove the top bump-stops on either side of the radiator

12.) Now you can install the fans in the euro rad support, do this by using the same 6 10mm bolts (3 for each fan) and bolt them into the
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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

designated area in the euro rad support (MAKE SURE THE BELT IS CONNECTED TO EACH FAN)

13.) Now you need to out a small part of the euro rad support to fit one of the ac lines coming from the condensor> your best bet is to trim
and test fit till you get it right

14.) Now you will bolt the radiator/condensor assembly into the euro rad support> do this by using the 4 bolts from eariler (taking the fan
shroud off the radiator) and bolt them from the back of the support into the radiator/condensor

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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

15.) You will now bolt this up to the car (using only 1 bolt on each fender wall instead of 2 like the N/A support)

This took me approx. 3 1/2 hours to get to this point and it shouldn't take much longer to finish up enjoy

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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

Now this is as far as I can take you, from here the euro rebar should bolt right up to 4 studs in the euro rad-support and then to the frame
studs. We were not so fortunate b/c one of our parts was wrong.

MAKE SURE TO RECONNECT EVERYTHING!!!

I hope this helps shed light onto the euro conversion, this was the hardest part the rest is cake. I will post pics of the finished car when it
comes out of the paint shop with its new textured-top euro front and rear bumpers

Modified by Still Lost at 8:18 AM 9-14-2003

Modified by Still Lost at 11:41 PM 2-6-2004

I'm Retired...I Invented Dice as a Kid

VRBTCHCAR Re: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta (Still Lost) « » 2:31 AM 9-14-2003
Member

Pretty informative thread


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Still Lost Re: DIY: Euro font end conversion (VRBTCHCAR) « » 2:32 AM 9-14-2003
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Offline
IM not done yet i just cant see one screen (should run out and get red bull)
Member Since
7-21-2002
1463 posts
I'm Retired...I Invented Dice as a Kid
Cherry Hill/ Camdezy Nj
84 Rabbit and 99 A4
1.8tqm

avw4me Re: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta (Still Lost) « » 5:36 AM 9-14-2003
Member

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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

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Good DIY thread.
Member Since
8-4-2000
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'95 Golf 2.0T
Kailua HI
'84 Rabbit Gti der ratty Peanut

EuroVR6Mk3 Re: DIY: Euro font end conversion (avw4me) « » 6:11 AM 9-14-2003
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thanks for the nice Tech . but i hope you didnt just release the freon into the air
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Still Lost Re: DIY: Euro font end conversion (EuroVR6Mk3) « » 10:40 AM 9-14-2003
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Offline
I didn't release the freon into the air, I had it taken out before we started, thats why I said it has to be captured
Member Since
7-21-2002
1463 posts
I'm Retired...I Invented Dice as a Kid
Cherry Hill/ Camdezy Nj
84 Rabbit and 99 A4
1.8tqm

Blown Wide Open Re: DIY: Euro font end conversion (Still Lost) « » 10:53 AM 9-14-2003
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VWvortex Forums: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta

Member Since
2-5-2001 Nice thread. I already did mine...but nice thread anyway.
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JPawn1 Re: DIY: Euro font end conversion (Blown Wide Open) « » 12:09 PM 9-14-2003
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dude...sooooo much cutting has to be done! Well at least the lining up of screws and bolts on mine was nowhere near ideal. Good write-up.
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Still Lost Re: DIY: Euro font end conversion (JPawn1) « » 1:14 PM 9-14-2003
Member

from what I hear the oem parts have no type of quality control, I didn't have any problems in what I wrote up. Once I had to put the rebar
and rad-support back on I ran into major problems but we had to cut/bend/drill to get it to fit good. But this I felt was the most technical area
Offline so i wrote it up

Member Since
7-21-2002 Trust me after this was done I needed a few
1463 posts

Cherry Hill/ Camdezy Nj


84 Rabbit and 99 A4
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Letsgopens13 Re: DIY: Euro font end conversion (Still Lost) « » 1:19 PM 9-14-2003
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Member Since
Yea Mike thanks again for all the work you put into my Jetta. This was the project from hell (took a week and a half). But for most people it
10-23-2002
should only take you a few hours. We just ran into some strange complications. I still don't understand why everything didn't line up, but it all
2626 posts
came together in the end so all's well that ends well.
Cherry Hill NJ
96 Jetta VR6 Can't wait til she comes back from the body shop.

-Nick
/// Dirty Jersey Dubs
FS: Bunch of mkiii stuff
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__enos__ Re: DIY: Euro font end conversion (Still Lost) « » 10:07 AM 11-13-2003
Member

When doing this DIY, do you bolt the first subframe back on at any point, or does it stay off to allocate room for the euro rad support and
rebar?
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10-25-2003
537 posts
.-:[_enos_]
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VReihenmotor6 Re: DIY: Euro font end conversion (__enos__) « » 10:21 AM 11-13-2003
Member

the furthest forward subframe (it only holds the bottom of the radiator)
goes the way of the dodo
the second one (that holds your engine up) stays
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12-12-2001 Nine Eight Tuning
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custom work, fabrication, bumper shaving, fender rolling, plastic & fiberglass fabrication and repair
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a VR and a few bikes F.S. custom Specialized Enduro/SX trail freeride bike

VReihenmotor6 Re: DIY: Euro font end conversion (rebar/radsupport/bumper)..sortta (Still Lost) « » 10:26 AM 11-13-2003
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Member Since
Quote, originally posted by Still Lost »
12-12-2001
15.) You will now bolt this up to the car (using only 1 bolt on each fender wall instead of 2 like the N/A support)
11676 posts

Dirty Jerz
a VR and a few bikes

I recomend using a 2x4 or wider peice of wood, with a jack to support the entire lower part of the euro rad support while doing this, and keep
the jack there till the rebar is bolted to the rad support and the frame rails
the upper "corner tabs" are quite weak and shouldn't be put thru this type of stress if it can be helped

Nine Eight Tuning


custom work, fabrication, bumper shaving, fender rolling, plastic & fiberglass fabrication and repair

F.S. custom Specialized Enduro/SX trail freeride bike

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