1980 B1 Passat Project

[Peter Jones]

The entire cooling system was pretty horrific, I kept finding worsre and worse stuff.

Here's some.

This is a spark plug that was used to block one of the lines.

[Peter Jones]

and a few engine bay shots of it going back together.











After all of this I got all the lights working too.

Next is to finish up restoring the engine fan and get it back in there.

[Jarred]

great work Pete! light at the end of the tunnel must be getting brighter!

[Peter Jones]

Cooling system all sorted now and it's back on its wheels.

Seems to drive OK, issues with the cluster and dash blower.

I think I'd best put a MK3 booster in there, the 18mm m/c isn't going to cut it. Otherwise though the brakes seem to work.

Pete

[Jace]

Loving this rebuild. As with all your builds you're doing a damn good job making an old car newer.

Is that a Uniflow air filter? Standard Solex carb. (same inlet size as Golfs)?

Great job. Keep it up.
But I suppose you don't really need anybody cheering you on to get a job finished.

[Peter Jones]

Is that a Uniflow air filter? Standard Solex carb. (same inlet size as Golfs)?

That's a Ramflo filter sitting atop a Weber DCD carb.

Thanks for the kind words

Pete

[Peter Jones]

Righto, knocked over the booster conversion today.

I'm not going to write up a "How to mod a MK3 booster for one of only 3 remaining B1 facelift Passats thread" You can read about it here instead.

The usual suspect.



Master cylinder off, and looks like it's long overdue, the booster is full of brake fluid!







Heaps came out when I drained it.

[Peter Jones]

It's worth pointing out here that Passats are a bit different here and this model in particular.

The transverse rod that actuates the brakes runs inside the firewall here's a few pics of the mechanism.









Much the same end as the MK1 Golf booster really.

[Peter Jones]

Firewall cleared off.

I trial fitted the MK3 (Seat Cordoba) booster about now and it fitted up fine despite being a bit bigger in diameter.



Here's a Seat Cordoba booster ready to be modified.



The Passat booster has an adapting collar on it which needs to be opened up a bit to sit over the neck of the MK3 booster.





OK classic PJ style MK1 booster mod now.

Chop off the ball end.



Turn a M10 x 1.5 thread down the shaft.



Of course you measure the old booster's clevis height and set up the new booster the same.

Before you know it, you've got a modern booster for your B1 Passat.

[Peter Jones]

Installation is the opposite of removal

New booster just bolted straight in.



Now the Cordoba m/c only has 2 ports so I'm using a couple of T pieces along with a pair of the much sought after 16v Scirocco portioning valves for the rears.

Leaves me with a couple of gaps to fill in the plumbing so I made a couple of short lines up.

This is a really neat flaring tool I picked up from eBay, Awesome quality and a perfect flare every time.



Cheapo bender to form the pipe up a bit.



And all together again.



The fluid reservoir is a bit tall, I can't quite get the level sensing cap on there but it clears the bonnet OK with a MK1 reservoir cap on it.

[roccodingo]

Looking good Pete, love how the brake relay rod is inside the car, just to make it even more of a headache..

[Preen59]

Way to go, Pete. Nice, clean and tidy job.

[Jarred]

Good work Pete! top notch as usual!

[DubSteve]

Once again Pete fantastic work mate, good to see its almost finished

[Peter Jones]

Got two new front seatbelts and fitted them today.

Fitted up a brake switch off the pedal too, there's a hole already there for the switch.

Next is the instrument cluster.