I decided to use an interior shop called Love's Trim. He's a VW specialist and does excellent work, much better than any of the local shops I've checked out. The only wrinkle in this plan - he's located in Georgia! This weekend I made arrangements to meet a guy named Jack in Hagerstown, Maryland on his route from CT to GA. He was making the trip for his interior, so I gave him some cash to haul my stuff as well!
I was so glad to get this stuff out of my way. I had un-boxed most of the interior over the last few weeks in preparation, and I didn't even have room to work!
I borrowed a friend's motorcycle trailer to keep everything dry on the trip down.
I wasn't sure what to expect, but managed to achieve 10.5 MPG all the way down and back.
Fro rode along. We left at 7:30pm on Black Friday.
We met Jack in a Walmart parking lot at about 1:15am. Not sketchy at all.
Jack was rocking a MK4 Golf pulling a Uhaul trailer. The photo is a little dark, but this thing was PACKED. He had 8 interiors in there!
Back to work. I'm walking the line between "detail oriented" and "clinically insane" on this fan shroud. I decided to add a few strips on the bottom of the flat area, and of course I couldn't leave the corners sharp!
Drilled and clamped with Clecos:
Plug welded through the 1/8" Cleco holes:
I have to add a clearance radius around the radiator inlet and outlet hoses, but I need to get a new radiator first. I'm not going to re-use this one, it's pretty old and has evidence of leakage.
I started shaving the radiator support. I'm going to use the original steel "North American" spec rad support, which has a lot of extra holes.
20ga steel filler:
Ground. I'm about halfway done filling the holes, then I'm going to re-shape the top section.