I was interested in working out the unladen weight of the car when finished. The original VW Instruction Manual gives a list of the dimensions and weights of the Fastback and the Variant as built. I extrapolated from these values to calculate the extra weight of the doors and then added a bit more to allow for the sunroof.
The following table sets out in kilograms the standard weights and (in italics) the anticipated final weights when completed.
|
Fastback | Variant | |||
| 2 door | 4 door | 3 door | 5 door | Sunroof | |
| unladen | 1080 | 1100 | 1120 | 1140 | 1160 |
| permissible load | 450 | 430 | 545 | 525 | 505 |
| permissible total weight | 1530 | 1530 | 1665 | 1665 | 1665 |
| permissible front axle load | 680 | 680 | 680 | 680 | 680 |
| permissible rear axle load | 870 | 870 | 1010 | 1010 | 1010 |
I have increased the weights for the 5-door in the same proportion as for the Fastback, then have added another 20kg for the sunroof. I put the mechanism on the bathroom scales to check that! The handbook gives no clues on the unladen axle weights so, unless I put the finished car on a weighbridge, I cannot say what the weight distribution will be when completed. Further confusion arises from the numbers VW give not adding up!
Note that, because I am not altering the suspension, the maximum permissible front and rear axle loads and total weight will remain the same. The carrying capacity will thus be reduced slightly from the standard Variant, but I can still carry about half a tonne so I don’t see a problem!
Looking at the weights in this table gives a strong hint that the normally quoted tyre pressures must be wrong. Working on the reasonable presumption that the tyre pressures must be directly proportional to the weight on the wheel, and given that the rear tyre pressure fully loaded should be 35psi, then the front tyres at full load should be 27.5psi, not the 18psi given in the handbook. The pressures for half-load would be 22psi front and 28psi rear. For a long time now I have run my front tyres at 24psi with the rears at 33psi and it transforms the handling; the steering is more precise, it goes where you point it, and it becomes a joy to drive.
Interestingly, the VW Instruction Manual states that the maximum permissible trailer weight with brakes is 900kg and without brakes is 500kg for all models. UK regulations permit a trailer up to 750kg to be un-braked and I have towed my old Fastback on a (braked) car trailer behind the original Variant before now!
Tyre pressure discussion updated 23 May 2025.