Ok then, so here we go again.
As some of you may know, I've got a bit of a habit of engine swapping mk2s.
Over the last 21 years, I've had (until now) 10 mk2s, only 4 ended up keeping their original engines.
Now my blue one, I'll never sell (unless someone offers me really stupid money for it), but it's not really in keeping with the original GTI mantra any more.
So as prices are on the rise, I thought now is the best time to get a nice standard one before I'm priced out completely.
Fortunately, Paulina (my wife) thinks a very similar way to me so we started looking.
We didn't have much money, so it would have to be a resto/project.
After several weeks of being outbid and seeing mk2s go for staggering amounts more than I thought they would, a little gem was offered up to us.
After seeing the photos, it was clear the full exterior would need paint, as someone had keyed every panel, but the interior was mint, several nice options on it and it looked like it could get snapped up by a breaker. So a deal was done and we sent up our tame car transporter to collect.
(https://live.staticflickr.com/65535/50897796402_f7b34d3687_h.jpg) (https://flic.kr/p/2kxEvBQ)Untitled (https://flic.kr/p/2kxEvBQ) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
BTW, Jason is excellent, really cares about classic cars and is reasonable on rates too, so if you need anything moved, give him a shout.
Didn't take long to coax the old girl off the back and start to have a good look around.
(https://live.staticflickr.com/65535/50896965058_178d98cc80_h.jpg) (https://flic.kr/p/2kxAfuj)Untitled (https://flic.kr/p/2kxAfuj) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/50897797847_32a0a2d014_h.jpg) (https://flic.kr/p/2kxEw3K)Untitled (https://flic.kr/p/2kxEw3K) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/50897797892_0252e5615f_h.jpg) (https://flic.kr/p/2kxEw4w)Untitled (https://flic.kr/p/2kxEw4w) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Put the jump leads on and she fired up, no worries!
(https://live.staticflickr.com/65535/50897680216_5037512328_h.jpg) (https://flic.kr/p/2kxDV5C)Untitled (https://flic.kr/p/2kxDV5C) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
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Engine sounded sweet enough, but lots of rust everywhere, so it'll be coming out as part of the resto.
Will be refreshing to put this one back in again though...
(https://live.staticflickr.com/65535/50897797877_22304f9670_h.jpg) (https://flic.kr/p/2kxEw4g)Untitled (https://flic.kr/p/2kxEw4g) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Best part was the interior
(https://live.staticflickr.com/65535/50897797882_00c46f060e_h.jpg) (https://flic.kr/p/2kxEw4m)Untitled (https://flic.kr/p/2kxEw4m) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Leather steering wheel, electric windows, electric mirrors, adjustable headlights(!), but the best part was the previous owners taste in music...
(https://live.staticflickr.com/65535/50897681751_2111574c15_h.jpg) (https://flic.kr/p/2kxDVx6)Untitled (https://flic.kr/p/2kxDVx6) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/50896966463_e9c71d865a_h.jpg) (https://flic.kr/p/2kxAfUx)Untitled (https://flic.kr/p/2kxAfUx) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
https://www.flickr.com/photos/152481044@N07/50897797817/in/album-72157718117532981/
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Think I'm going to like this one...
Does the title need tweaking.....'Red Rescue Lockdown Rebuild Son's first car'
:D
Is this going to be completely standard...no aircon?
Neither of my kids are into cars like me. Elder son never cleans his car and wants a Caddy Camper. Younger happy with his Fiesta. Both have copious amounts of spare time playing #mindnumbingMinecraft !
I can't understand them. Gimmie a screwdriver/spanner and I can enjoy hours of relaxation working on the car!
Very nice and following with interest. Nice tape collection included as well - bonus.
Prices do seem on the rise. My garage kit gets delivered tomorrow and then I can finally start on my one!
Cheers!
The only mods I'm allowing myself are suspension and stereo.
I'm thinking Eibach springs, possibly koni shocks, a stereo that will interface with my phone and speakers that will fit in the standard locations. For some reason it came without PAS, which is wierd, considering the amount of other options that were ticked and how many GTIs were coming out with PAS at the time. But I'll probably correct that, just to make life easier for Paulina if nothing else. You could call it a mod too, I'm calling it a correction ;D
As for the boys first car, well, I don't think he'll be able to drive it, I severely doubt he'll be able to find an instructor that has a manual car in 17 years time, so it'll be an auto only licence for him.
God only knows what would happen if he got hold of the blue one! :o
Ok, so it's about time I updated this one.
Wasted no time in pulling the car apart.
(https://live.staticflickr.com/65535/51114987866_fc6808e0b8_k.jpg) (https://flic.kr/p/2kSRF5f)Untitled (https://flic.kr/p/2kSRF5f) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
First off, found that at some point in the past, it had been home to a furry rodent of some variety, but he seems to have long gone.
Kind of odd, as there was no obvious entry point for him.
(https://live.staticflickr.com/65535/51114895793_a8f0e9de3b_k.jpg) (https://flic.kr/p/2kSRcGM)Untitled (https://flic.kr/p/2kSRcGM) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
But to be honest, I was just happy there was no body or chewed wiring.
Speaking of wiring, I found three (!) immobilisers/alarms that were also rattling around in there, some of the wiring involved was downright dangerous!
(https://live.staticflickr.com/65535/51115779900_8fcc7ecc37_k.jpg) (https://flic.kr/p/2kSVJw1)Untitled (https://flic.kr/p/2kSVJw1) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
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But on the whole, the inside of the car was pretty good with minimal rust
(https://live.staticflickr.com/65535/51114739859_c1856f50b5_k.jpg) (https://flic.kr/p/2kSQpmg)Untitled (https://flic.kr/p/2kSQpmg) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
There is always some though.
Found the typical filler neck one, fortunately managed to source a new one, which will find its way on soon.
(https://live.staticflickr.com/65535/51114987441_8343e75afe_k.jpg) (https://flic.kr/p/2kSREWV)Untitled (https://flic.kr/p/2kSREWV) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51114423302_44b5f3233e_k.jpg) (https://flic.kr/p/2kSNMfo)Untitled (https://flic.kr/p/2kSNMfo) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Also, popped the engine out and found both the chassis leg tops were well past saving, so on went the new panels.
(https://live.staticflickr.com/65535/51114999751_00b1b23f7f_h.jpg) (https://flic.kr/p/2kSRJBa)Untitled (https://flic.kr/p/2kSRJBa) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51115780195_a925361d8f_k.jpg) (https://flic.kr/p/2kSVJB6)Untitled (https://flic.kr/p/2kSVJB6) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51114739994_03109aacc2_k.jpg) (https://flic.kr/p/2kSQpoA)Untitled (https://flic.kr/p/2kSQpoA) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51114739884_75bcba536c_k.jpg) (https://flic.kr/p/2kSQpmG)Untitled (https://flic.kr/p/2kSQpmG) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Once all the rust is taken care of, I'll go over the whole of the engine bay with the wire wheel, take off any surface rust and then rust proof/underseal where is needed before the whole thing goes off for paint.
At this rate, there's a good chance this one will be cleaner than the blue one!
lovely job! top work Dave
Quick work. there
If (when i mean) I have a car painted again this is the way i'll be doing it - send it off as a shell once the issues have been fixed. Rather than do what I am doing now and pulling it all apart and fixing issues. Hopefully it will work out cheaper as well!
That's what I'm hoping too, I've never pulled a car apart to this extent in one go before.
The furthest I want was the blue one and that had to have the engine stay in.
I think you're doing the right thing from my experience - you know the warts and all and the person painting it can give you realistic quote as they can see it all. I would recommend, but think you're ok on this front and have done it, is wire wheeling back any suspect areas so the bodyshop can see and deal with.
I've re-stripped down my Corrado after painting last year as my rear arches were starting to rust and wasn't happy in other areas - underside really but that wasn't part of the respray. If I had done as you have done I wouldn't be in this situ. After wire wheeling I found suspect metal and filler. I don't think they treated the metal and I don't have the budget for another load of paint so have fixed it myself as have learnt to weld this year. Fortuatnely it was behind the bumper line and away from the body and can be covered in epoxy and stone chip but i have still ground off the arch lip to be sure. I will be able to paint as made a good job on the front arch lip with no visible paint line (bodyshop used cheap screws that rusted in situ and transfered their rust to the wings). The joys.
The great thing with the mk2/mk3 is the black plastic arch covers can hide the sins, or at least you can do your best if like me and make a solid repair and not affect the overall appearence and also you can get repair panels - starting to go off my corrado this year - if it's not careful it may end up with its running gear in my mk2 haha!
Haha! I've done that before actually, bought a written off VR and chassis swapped it, even down to the interior and dash, took me ages!
Ok, may be time for an update.
We have been working weekends for what seems like forever, chasing the rust, but I think we finally have it beat!
Had to remove the back panel, as it was just past it and easier to replace the whole thing
(https://live.staticflickr.com/65535/51231101738_71e0f46fc0_b.jpg) (https://flic.kr/p/2m47MFy)Untitled (https://flic.kr/p/2m47MFy) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Also, the back of the rear wing had to come off.
Next, I moved to the front, to clean up the inner arches
Not bad, just need to get on it with the raptor now
(https://live.staticflickr.com/65535/51231103648_da8fb69fd2_b.jpg) (https://flic.kr/p/2m47Nfu)Untitled (https://flic.kr/p/2m47Nfu) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
While I was on at the front, Sean sorted the filler neck and the rear arch
(https://live.staticflickr.com/65535/51230184452_5a0baf7516_b.jpg) (https://flic.kr/p/2m4361h)Untitled (https://flic.kr/p/2m4361h) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
That will all get cleaned down and a dose of Raptor too.
Then once all the hard to reach bits were complete, the rear panel and tow eye went back on
(https://live.staticflickr.com/65535/51230892381_e8d326bb46_b.jpg) (https://flic.kr/p/2m46HrX)Untitled (https://flic.kr/p/2m46HrX) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
And with that, the (majority of the) welding was done!
So we moved on to body work, never done it before, but the idea is to do the prep as best possible, then hand off to a proper body shop to perfect and paint.
You may have spotted an odd red patch on the drivers door, turned out it was some horrible paint, that never actually set.
It was a right pita to remove and had to go all the way back to bare metal to get shot of it.
Odd thing was, there was no repair under it, no idea why it went on!
(https://live.staticflickr.com/65535/51230183332_e8bf3d2fa6_b.jpg) (https://flic.kr/p/2m435EY)Untitled (https://flic.kr/p/2m435EY) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Whoever keyed the car, done a bloody good job, every inch was either metal or primer.
Someone must have been VERY angry!
We didn't have any masking paper to hand (turning up soon), so had to leave the windows in for the time being.
But got on as best we could and it currently looks like this.
(https://live.staticflickr.com/65535/51231958640_a13033fb4f_b.jpg) (https://flic.kr/p/2m4cbpJ)Untitled (https://flic.kr/p/2m4cbpJ) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51230184427_260a06d3b0_b.jpg) (https://flic.kr/p/2m435ZR)Untitled (https://flic.kr/p/2m435ZR) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
This is a feeble excuse for not getting on with the R32 aircon 😂
Lookin good though.
Nice Project!! It's is one of the dream ones I wise I could part take in... but need a shed to pull it a part and just some more basic knowledge on the cars.
Looking forward to following your journey here!
/D
Boom! epic little project mate :) and some great progress
Cheers guys!
Yes, I've kind of neglected the blue ones air con project. Something I'm currently regretting!!
Got a couple days off coming up soon, plan is to pick up some spares (PAS kit) and crack on with the sanding.
Be nice if by this time next week I had the whole thing in primer.
Ok, so over the past few weeks, I've been pressing on.
First up, I got some masking paper, so I took out the windows and pressed on with the sanding/primer stage.
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The tailgate is done, so I've sourced another one.
I've also prepped the new wings, sanding and priming the outside, while using bed liner on the inside, to help protect from stone chips.
(https://live.staticflickr.com/65535/51291999200_97f9c8ded8_b.jpg) (https://flic.kr/p/2m9uUnN)Untitled (https://flic.kr/p/2m9uUnN) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
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Whoever keyed this car must have really meant it, it's pretty much all the way down to the metal the both sides of the car!
(https://live.staticflickr.com/65535/51290246382_05606ce06b_b.jpg) (https://flic.kr/p/2m9kVjN)Untitled (https://flic.kr/p/2m9kVjN) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
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But after a load of sanding, it's finally all gone!
(https://live.staticflickr.com/65535/51291708154_04f2b7f739_b.jpg) (https://flic.kr/p/2m9tpRL)Untitled (https://flic.kr/p/2m9tpRL) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
I'd say the car is more of a Grey Rescue now!
Along with the back end
(https://live.staticflickr.com/65535/51290246117_fea663979b_b.jpg) (https://flic.kr/p/2m9kVfe)Untitled (https://flic.kr/p/2m9kVfe) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
and the bay.
(https://live.staticflickr.com/65535/51291999530_0d9cb6882c_b.jpg) (https://flic.kr/p/2m9uUtu)Untitled (https://flic.kr/p/2m9uUtu) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Finally, I'd run out of primer, so I moved on to the wheel arches with the bed liner and gave them all a good couple of coats.
(https://live.staticflickr.com/65535/51292075885_921e264840_b.jpg) (https://flic.kr/p/2m9viaX)Untitled (https://flic.kr/p/2m9viaX) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
When the car gets painted, they will go body colour, as per factory.
Very good. Are they original wings or pattern? I need some and wondering about pattern part fit etc. I'm currently welding my mk3 16v but the mk2 is up next for similar treatment to yours. I will aim to do a thread like yours as love other peoples.
Cheers! They're pattern wings from heritage.
They seem to fit pretty well, I know some people complain about fitment, but both these ones and the ones on my blue car are from Heritage and I can't see any issues.
Wow - this progressed on quite quickly. I feel like I’m slacking now! Keep it up!
Ok, so after a few weeks of waiting, the car has finally gone off to paint!
(https://live.staticflickr.com/65535/51344962328_59e0b24060_b.jpg) (https://flic.kr/p/2mebmtb)Untitled (https://flic.kr/p/2mebmtb) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51344962343_671f4f5f2d_b.jpg) (https://flic.kr/p/2mebmtr)Untitled (https://flic.kr/p/2mebmtr) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
So now the next stage begins, while the car is away, I'll dig out the engine and get it stripped down.
I'll also look into electroplating for the nuts and bolts, so I'll buy a kit soon.
Bet you're pleased, staying red presumably... how long 'till it's back?
Looking forward to your engine work, plenty of pics. I hope!
Been sniffing around my own engine / gearbox, though not starting anything in earnest until the rest of the car is closer to being sorted - be looking for plenty of pointers.
Yeah, the bodywork isn't something I particularly enjoy!
I'm much more at home with mechanicals.
It's staying red, though the painter recommended using laquer.
I wasn't keen at first, though I'm coming around to not having to polish it every other week.
Didn't get as far with the engine stripdown as I'd have hoped this weekend, but I did get a few shots, I'll get them up later.
You know, it's little wonder I like MK2's... even a near bare shell sitting on steel rims (granted they're possibly my favourite steels on any car) looks good.
Know what you mean, something clean about them
Yeah, the bodywork isn't something I particularly enjoy!
I'm much more at home with mechanicals.
It's staying red, though the painter recommended using laquer.
I wasn't keen at first, though I'm coming around to not having to polish it every other week.
Didn't get as far with the engine stripdown as I'd have hoped this weekend, but I did get a few shots, I'll get them up later.
I can confirm after many many red cars that lacquer is a better idea.
Yeah, the bodywork isn't something I particularly enjoy!
I'm much more at home with mechanicals.
It's staying red, though the painter recommended using laquer.
I wasn't keen at first, though I'm coming around to not having to polish it every other week.
Didn't get as far with the engine stripdown as I'd have hoped this weekend, but I did get a few shots, I'll get them up later.
I can confirm after many many red cars that lacquer is a better idea.
:)) I thought you liked polishing things Sam! :))
So little update, found the 8v engine, next to my spare 8v engine, a V6 and two G60 motors!
(https://live.staticflickr.com/65535/51352240057_449d5eb035_b.jpg) (https://flic.kr/p/2mePDTg)Untitled (https://flic.kr/p/2mePDTg) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Didn't take too long to pull the gearbox off and get it across the yard to the workshop
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Managed to start stripping the engine down, typical 8V motor, all the exhaust manifold nuts were rusted and rounded as soon as the socket touched them! But a load of WD, a little heat and only a minor amount of swearing, it all came off.
(https://live.staticflickr.com/65535/51352240452_ce26621e5a_b.jpg) (https://flic.kr/p/2mePE15)Untitled (https://flic.kr/p/2mePE15) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
All things considered, it's a very honest engine. Everything looks original and not bodged/messed with.
(https://live.staticflickr.com/65535/51353206523_37a39fce9a_b.jpg) (https://flic.kr/p/2meUBbt)Untitled (https://flic.kr/p/2meUBbt) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Next time, the head will come off and we'll inspect the bores to decide how deep this resto goes.
If all good, it'll just be a head rebuild, skim and reassembly. But if necessary, I'll rehone it, install fresh piston rings and big end bearings.
Time was I'd have looked at pics. like those and my eyes would've glazed over, now I can nearly identify everything in sight.
Probably bread and butter to you, but stuff like this is invaluable when you're starting out.
not been on the forum for some time, great to see this progressing!
Cheers!
So all my plans for this weekend included being outside and they were all rained off, so back in the workshop I went!
Started off by inspecting the engine, I wanted to make a decision on what needed to be done.
As much as I'd like to send it all to a machine shop, I just don't have the budget for it and half the time it's not necessary.
So I started off by doing a leakdown test on each cylinder, first three were in the green, but the fourth had a nasty leak past the valves, this is probably due to coke build up. Either way, the head is being sent off for a rebuild and a skim.
Once that was established, I moved on to taking the head off to inspect the block.
(https://live.staticflickr.com/65535/51365956814_9f70ede77e_b.jpg) (https://flic.kr/p/2mg2Xp5)Untitled (https://flic.kr/p/2mg2Xp5) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
It all looked very original, not messed with or bodged.
Quick clean up with the scotch pad and it I could have aproper look at it.
(https://live.staticflickr.com/65535/51365444068_bba0027fe9_b.jpg) (https://flic.kr/p/2mfZjYC)Untitled (https://flic.kr/p/2mfZjYC) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
All the pistons looked ok, there was still evidence of honing marks down the bores and next to no play in the pistons at the top.
Nevertheless, needed to make sure, so spun it over, dropped the sump and oil pump off, marked up the conrods and started removing pistons. All the journals looked good and there was just typical wear on the bearings you'd expect on a 200k mile engine.
(https://live.staticflickr.com/65535/51364309519_d12ea8d23b_b.jpg) (https://flic.kr/p/2mfTvHr)Untitled (https://flic.kr/p/2mfTvHr) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Popped of the 1st ring on each piston and put them back in the bores for measurement.
Unfortunately they were 0.1mm out of tolerance, so we measured the bore sizes (very fiddly and didn't get a shot), but all were well within the tolerance.
(https://live.staticflickr.com/65535/51363793723_a15be7cafc_b.jpg) (https://flic.kr/p/2mfQSop)Untitled (https://flic.kr/p/2mfQSop) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
So the plan is to give the bores a light hone, fresh original piston rings, new conrod bearings and she should be good for thousands more miles.
Very happy with that outcome. All that was left was to lube up the bores and then seal the engine up as best possible.
Now I just have to decide on the best course of action for painting the block
(https://live.staticflickr.com/65535/51363793703_5a1a38c752_b.jpg) (https://flic.kr/p/2mfQSo4)Untitled (https://flic.kr/p/2mfQSo4) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Also, for the first time ever, I decided to give the standard manifold and downpipe a bit of love.
Usually they just get binned in favour of a four branch or a turbo, but this time I resisted the urge!
(https://live.staticflickr.com/65535/51366812811_2ebfe4e8ee_b.jpg) (https://flic.kr/p/2mg7kRD)Untitled (https://flic.kr/p/2mg7kRD) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Not bad condition, just a bit of surface rust and the standard heatshield is about ready to fall off.
Quick trip into the shot blasting cabinet and it was looking a bit more like it
(https://live.staticflickr.com/65535/51366812801_87c0be4c46_b.jpg) (https://flic.kr/p/2mg7kRt)Untitled (https://flic.kr/p/2mg7kRt) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Four costs of extremely high temperature paint later and it was like this
(https://live.staticflickr.com/65535/51367545219_6b74324fcd_b.jpg) (https://flic.kr/p/2mgb6zn)Untitled (https://flic.kr/p/2mgb6zn) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Hopefully, once it's fully cured, it'll go black, like the tin!
Also, I binned off the rotten heat shield, but wanted to protect the engine.
Now not strictly oe, but considering they're probably all dead or ridiculously expensive for what they are, I opted for heat wrap instead.
(https://live.staticflickr.com/65535/51366050872_7b3d1b08f7_b.jpg) (https://flic.kr/p/2mg3rmL)Untitled (https://flic.kr/p/2mg3rmL) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Great pics / progress... sort of near where you are with the block, so will be keeping a close eye on this, keep the camera handy!
(Did you look for the mystery 'rivet'?)
Oh crap! I completely forgot!
I forgot the rivet again!!
I've been on holiday for the last week, so I haven't had huge amounts of time or money to spend on the project.
That being said, the sand blaster was there and so was some worse for wear parts.
Won't bore you with them all, but here's a selection of before, during and after pics...
(https://live.staticflickr.com/65535/51394410142_790c66155c_b.jpg) (https://flic.kr/p/2mixMzG)Untitled (https://flic.kr/p/2mixMzG) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51395905579_98cb8beb7a_b.jpg) (https://flic.kr/p/2miFs86)Untitled (https://flic.kr/p/2miFs86) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51396190135_0f6e80baa4_b.jpg) (https://flic.kr/p/2miGUHe)Untitled (https://flic.kr/p/2miGUHe) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51395178436_c3d30eb450_b.jpg) (https://flic.kr/p/2miBHY9)Untitled (https://flic.kr/p/2miBHY9) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51396190230_03e19c9569_b.jpg) (https://flic.kr/p/2miGUJS)Untitled (https://flic.kr/p/2miGUJS) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51395437428_c513f12299_b.jpg) (https://flic.kr/p/2miD3Xw)Untitled (https://flic.kr/p/2miD3Xw) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51395903634_07a62f4e02_b.jpg) (https://flic.kr/p/2miFrxy)Untitled (https://flic.kr/p/2miFrxy) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51396185085_e996f75a4f_b.jpg) (https://flic.kr/p/2miGTda)Untitled (https://flic.kr/p/2miGTda) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Really happy with the results, I just have so much more to do!!
Sandblasting's the doggies do-da's... very envious!
I bought a cabinet a couple of years back now, cost about £150 2nd hand and it completely destroys the compressed air supply, but it does a good job!
Sorry for anyone with slow internet connection, this is a big update!
Bit more blasting and cleaning was done, the water pump housing was especially bad!
(https://live.staticflickr.com/65535/51504925015_879e232a49_b.jpg) (https://flic.kr/p/2mtjcNx)Untitled (https://flic.kr/p/2mtjcNx) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51504925215_44410aa33e_b.jpg) (https://flic.kr/p/2mtjcRZ)Untitled (https://flic.kr/p/2mtjcRZ) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51503196447_1d02996891_b.jpg) (https://flic.kr/p/2mtakXD)Untitled (https://flic.kr/p/2mtakXD) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51504000781_6f3f79c606_b.jpg) (https://flic.kr/p/2mtet4t)Untitled (https://flic.kr/p/2mtet4t) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51503195597_41a84f1e9f_b.jpg) (https://flic.kr/p/2mtakGZ)Untitled (https://flic.kr/p/2mtakGZ) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
I replaced the pump itself, wanted to make sure it had a metal impeller.
(https://live.staticflickr.com/65535/51504710994_5a319d3d31_b.jpg) (https://flic.kr/p/2mti7bw)Untitled (https://flic.kr/p/2mti7bw) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51504226948_e34b433ffc_b.jpg) (https://flic.kr/p/2mtfChU)Untitled (https://flic.kr/p/2mtfChU) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Thermostat was well past it though!
(https://live.staticflickr.com/65535/51504224183_8e9c327488_b.jpg) (https://flic.kr/p/2mtfBte)Untitled (https://flic.kr/p/2mtfBte) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Next I turned my attention to the block, couple hours of prep and a couple coats of engine enamel later...
(https://live.staticflickr.com/65535/51504925910_3c5304ef36_b.jpg) (https://flic.kr/p/2mtjd4Y)Untitled (https://flic.kr/p/2mtjd4Y) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51504712204_67863112d5_b.jpg) (https://flic.kr/p/2mti7xo)Untitled (https://flic.kr/p/2mti7xo) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Also took my injectors to work where we have an ultrasonic cleaner!
Before:
(https://live.staticflickr.com/65535/51504001281_91860ac417_b.jpg) (https://flic.kr/p/2mtetd6)Untitled (https://flic.kr/p/2mtetd6) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51504225343_8770b21414_b.jpg) (https://flic.kr/p/2mtfBPe)Untitled (https://flic.kr/p/2mtfBPe) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
And after
(https://live.staticflickr.com/65535/51504225398_89de78c0e2_b.jpg) (https://flic.kr/p/2mtfBQb)Untitled (https://flic.kr/p/2mtfBQb) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Finally, last night, I had an update from the painter!
(https://live.staticflickr.com/65535/51504925185_2f7cd6fce4_b.jpg) (https://flic.kr/p/2mtjcRt)Untitled (https://flic.kr/p/2mtjcRt) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51503196887_021306d396_b.jpg) (https://flic.kr/p/2mtam6e)Untitled (https://flic.kr/p/2mtam6e) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51504709509_b0ddbb93e8_b.jpg) (https://flic.kr/p/2mti6JV)Untitled (https://flic.kr/p/2mti6JV) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51504709619_3a15646005_b.jpg) (https://flic.kr/p/2mti6LP)Untitled (https://flic.kr/p/2mti6LP) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51504709624_434b971781_b.jpg) (https://flic.kr/p/2mti6LU)Untitled (https://flic.kr/p/2mti6LU) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51503195742_1b481c5c89_b.jpg) (https://flic.kr/p/2mtakKu)Untitled (https://flic.kr/p/2mtakKu) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51503998671_c642ffaf2a_b.jpg) (https://flic.kr/p/2mtesr6)Untitled (https://flic.kr/p/2mtesr6) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51503999366_b26566a83c_b.jpg) (https://flic.kr/p/2mtesD5)Untitled (https://flic.kr/p/2mtesD5) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51504225438_29dba5de5a_b.jpg) (https://flic.kr/p/2mtfBQS)Untitled (https://flic.kr/p/2mtfBQS) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Looking good
Noticed you appear to have abandoned original heat shield on down pipe for exhaust wrap? My heat shield has disintegrated and thinking of doing same but not sure if this will mitigate heat soak on steering rubbers etc?
Noticed you appear to have abandoned original heat shield on down pipe for exhaust wrap? My heat shield has disintegrated and thinking of doing same but not sure if this will mitigate heat soak on steering rubbers etc?
Yes, like yours mine was about to fall off.
So I've removed it and put the heat wrap to protect the rubber boots.
I'm trying to keep the car as original as possible, but couldn't do much about that.
Tornado red? Looks a bit dark
I know this isn't an original feature but it is an early 90s addition. You have the same alarm as me mounted in the same position, or did have. Is it going back in?
Great work.
Tornado red? Looks a bit dark
If you watch the video I posted on facebook, that looks mars red, so it evens out!
I know this isn't an original feature but it is an early 90s addition. You have the same alarm as me mounted in the same position, or did have. Is it going back in?
Great work.
Thanks.
No, it was very, very badly lashed in, also I didn't have any fobs for it.
So it (and the other two immobilisers) went in the bin.
Getting close now, bet you're well pleased with progress so far, and the paint looks outstanding.
Saw this on eBay (https://www.ebay.co.uk/itm/333494841555) - looks a neat solution... amongst others, they do a MK2 version also.
(https://i.ebayimg.com/images/g/kpcAAOSwpqhcqkhr/s-l1600.jpg)
Damn you Mbps rich lot!
Thanks and yeah, I've actually got next week off work, so hopefully I can really crack on with it!
Oddly enough, I think my friend makes those.
Might tap him up for a couple.
Messaged him about one... put a good word in for me!
New paint is looking great good luck with the rest of the build, not that you'll need it with your experience!
So I had last week booked off work, just happened to be the week the car came back!
(https://live.staticflickr.com/65535/51539984971_f8f363ca2a_b.jpg) (https://flic.kr/p/2mwpTUx)Untitled (https://flic.kr/p/2mwpTUx) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51540231803_e7bffd124a_b.jpg) (https://flic.kr/p/2mwrahg)Untitled (https://flic.kr/p/2mwrahg) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Wasted no time in getting it in the workshop and starting the tinkering.
(https://live.staticflickr.com/65535/51539984991_e54225d9f6_b.jpg) (https://flic.kr/p/2mwpTUT)Untitled (https://flic.kr/p/2mwpTUT) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
It looks as fantastic in real life as it does in the photos.
(https://live.staticflickr.com/65535/51539985016_094345bd32_b.jpg) (https://flic.kr/p/2mwpTVj)Untitled (https://flic.kr/p/2mwpTVj) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
While it was mint on the outside, it had been about 3 months without any windows and was thoroughly minging inside because of it.
So the first thing I wanted to do was get the windows back in, so I can clean up and begin the interior refit.
First off, the rear decal had to go back in, took about an hour to get it right.
(https://live.staticflickr.com/65535/51540708394_c6fbf3b87a_b.jpg) (https://flic.kr/p/2mwtAXm)Untitled (https://flic.kr/p/2mwtAXm) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
To get to where the windows were stored, I had to get all the interior carpets/insulation out the way, so I changed on to cleaning detail and spent hours with the soapy water, brushes and paper towel, came up ok though.
(https://live.staticflickr.com/65535/51539199717_ef7f547e7c_b.jpg) (https://flic.kr/p/2mwkStF)Untitled (https://flic.kr/p/2mwkStF) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Managed to save the original sound deadening and after giving the carpet a quick hoover, it went back in too.
(https://live.staticflickr.com/65535/51539199602_3cce406dea_b.jpg) (https://flic.kr/p/2mwkSrG)Untitled (https://flic.kr/p/2mwkSrG) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Along with the rear door cards and seats.
(https://live.staticflickr.com/65535/51540708494_6c98bf25d7_b.jpg) (https://flic.kr/p/2mwtAZ5)Untitled (https://flic.kr/p/2mwtAZ5) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51540918480_9de665d28b_b.jpg) (https://flic.kr/p/2mwuFpw)Untitled (https://flic.kr/p/2mwuFpw) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
A mate is getting a wet vax hoover, so I'll be going back over the interior parts at a later date.
But as I'm climbing all over the car to rebuild it, I'm not going all out on the interior cleaning just yet.
But it did allow me to get all the windows back in, starting to feel more like a car now
(https://live.staticflickr.com/65535/51540918170_8f12e18e9d_b.jpg) (https://flic.kr/p/2mwuFjb)Untitled (https://flic.kr/p/2mwuFjb) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Split rear bench too, nice option. Not seen many in the flesh.
Split rear bench too, nice option. Not seen many in the flesh.
Yeah, this has loads of little touches, like that and headlight height adjustment.
But it had no PAS and the oddest thing, the speakers are wired up to be fronts on the dash and rears in the front doors, nothing in the parcel shelf at all!
Superb! Lots and lots of pics please...
Superb! Lots and lots of pics please...
Well, if you insist...
Wasn't going to post this as it's not as exciting ,but here goes.
As I've been putting things back together, everything has been cleaned and were possible refurbished.
So the heater box has come apart to inspect the flaps.
(https://live.staticflickr.com/65535/51558048980_0f31a89b6a_b.jpg) (https://flic.kr/p/2my1tGY)Untitled (https://flic.kr/p/2my1tGY) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
I think they were well past it!
(https://live.staticflickr.com/65535/51557815424_23ef74c0ec_b.jpg) (https://flic.kr/p/2mxZhh9)Untitled (https://flic.kr/p/2mxZhh9) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Bit of silver tape first
(https://live.staticflickr.com/65535/51558049050_dd50d24aca_b.jpg) (https://flic.kr/p/2my1tJb)Untitled (https://flic.kr/p/2my1tJb) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Then on with the sound deadening (all I had to hand)
(https://live.staticflickr.com/65535/51557127811_1143fc75c0_b.jpg) (https://flic.kr/p/2mxVKSK)Untitled (https://flic.kr/p/2mxVKSK) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
I used the cloth tape to help the seal against the plastic, should help to stop any whistling too.
Finally, I re-wrapped the entire loom and started fitting it back in the car.
(https://live.staticflickr.com/65535/51556334502_11c23287b4_b.jpg) (https://flic.kr/p/2mxRG41)Untitled (https://flic.kr/p/2mxRG41) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Non-PAS on a late car seems unusual, I know it wasn't until the later run out model that it became standard spec for a GTI but by the 90s you'd think it was expected. Especially given some of the extras that were added. Will you be retro fitting PAS? I think I would be tempted to, especially as you're at the stage you are now rather than not do it and regret it later.
And I know you're going for an OEM rebuild here but since you've already gone with non-factory spec loom wrap ;-) I would be looking at fitting Mk3 PAS and updating the pulleys for serpentine belts. Nothing wrong with a resto-mod to bring a car up to modern day usable spec.
Non PAS isn't that bad on the move, I actually went for Non PAS originally as I preferred a heavier drive but after having cars with PAS for many years and then going back to trying it with non it was very different but not overly heavy until you were going slow and parking it, bonus is less weight.
My second car ever was a VW Polo Coupe and they didn't even have brake servos!
Dare I ask what's happening with the front subframe? Apologies I might have missed something.
Love the red paint.....read ENVIOUS :D
Thanks guys :)
It will be getting PAS added at this stage, I've got the kit ready to go.
I'm not worried about it, but Paulina will be driving it a fair bit and really wanted it.
I know it was imported from Germany at some point, most likely a squaddie had it over there and brought it back.
Which could explain some of the random option choices, as Germany had some things as standard.
I'm waiting till the payday, then the subframe, wishbones, hubs, rear beam and slam panel will be going off for blasting and powder coating ;)
Was going to get that handled last week, but ran out of cash!
And Tim, the loom is as close to oem as I can get, :P
All the plastic loom covers have been cleaned and the dead, crusty tape has been swapped out for Tessa's finest.
Ok, this weekend didn't quite go as smoothly as planned.
The dash was in and out about a dozen times, as I kept forgetting bits of loom that had to be added and the steering column was playing me about. Someone has put an aftermarket lock/barrel on there at some point and it's not straight, couldn't see that without the dash though and it was kicking the stalks off. Took me ages to get that right.
But finally, it went back in and I started buttoning things back up.
(https://live.staticflickr.com/65535/51573806254_0681b80c9b_b.jpg) (https://flic.kr/p/2mzpeN7)Untitled (https://flic.kr/p/2mzpeN7) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
As I was wiring, I moved on to a job I've had to do to pretty much every mk2 i've ever had.
The dreaded tailgate wiring! Nearly every wire had to be repaired.
(https://live.staticflickr.com/65535/51574052030_ab03794024_b.jpg) (https://flic.kr/p/2mzquRC)Untitled (https://flic.kr/p/2mzquRC) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Once that was done, I tripped over the ECU, so I thought I'd better put that back in.
I blasted and repainted the cage and cleaned up the ECU and ignition module thingie.
(https://live.staticflickr.com/65535/51574061490_c67c285dea_b.jpg) (https://flic.kr/p/2mzqxEJ)Untitled (https://flic.kr/p/2mzqxEJ) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
And popped it back in the scuttle
(https://live.staticflickr.com/65535/51573370283_eec29e5cee_b.jpg) (https://flic.kr/p/2mzn1cn)Untitled (https://flic.kr/p/2mzn1cn) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Still got a bit of tidying to do in there.
Lastly, I finally remembered to bring my Solution Finish to the workshop and applied it to the spoiler after giving it a proper wash.
I've no idea how someone managed to get mud up there!
(https://live.staticflickr.com/65535/51573130396_3ed120c498_b.jpg) (https://flic.kr/p/2mzkLTo)Untitled (https://flic.kr/p/2mzkLTo) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
and fitted it
(https://live.staticflickr.com/65535/51572322792_c80d3eae2b_b.jpg) (https://flic.kr/p/2mzgCPb)Untitled (https://flic.kr/p/2mzgCPb) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
In the 25 years I've had my Golf I haven't had an issue with the tailgate wires! However in our 08 Octy Scout they failed in the same place as your's have.
The car is looking great....just like mine.....only better!..great work.
Looking good! Bizarre seeing you doing these jobs, we're sort of going in tandem though I'll likely be stopping when it comes to the actual engine.
Thanks, I think you're a little further on than me though.
I'm going to start pulling things off again soon!
Ok, so this is something that I've been wanting to do for a while and I've finally got around to having a go.
(https://live.staticflickr.com/65535/51601381576_7b84900cae_b.jpg) (https://flic.kr/p/2mBQyYG)Untitled (https://flic.kr/p/2mBQyYG) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
No, it's not producing drugs! It's electroplating the bolts.
(https://live.staticflickr.com/65535/51600557797_f182301170_b.jpg) (https://flic.kr/p/2mBLm6B)Untitled (https://flic.kr/p/2mBLm6B) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
As you know, 99% of the bolts on a mk2 are made up primarily of rust at this point.
While I can blast them off, they'll rust in about 20 minutes and any paint will just crack off when you tighten them.
So I bit the bullet, bought a kit, read the manual, re-read the manual and then just watched a couple of youtube videos on it!
Must say, I'm very pleased with the results, they're not perfect, but there is plenty more bolts to experiment on.
(https://live.staticflickr.com/65535/51602038739_405fd41df4_b.jpg) (https://flic.kr/p/2mBTWk6)Untitled (https://flic.kr/p/2mBTWk6) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51600557792_0d81ea2c49_b.jpg) (https://flic.kr/p/2mBLm6w)Untitled (https://flic.kr/p/2mBLm6w) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51602038774_5eb1109386_b.jpg) (https://flic.kr/p/2mBTWkG)Untitled (https://flic.kr/p/2mBTWkG) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Learnings so far:
The power supply with the kit is a bit crap, so I've ordered a bench power supply with I and V control.
Wire brushing the bolts after blasting will provide much better results, so a wire wheel for the bench grinder is on order too.
Just a quick shot of before, after blasting and plated
(https://live.staticflickr.com/65535/51601381641_0688ec9c6c_b.jpg) (https://flic.kr/p/2mBQyZP)Untitled (https://flic.kr/p/2mBQyZP) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
I told you to wire brush them :-). Also just two bolts at a time until you are getting consistent good results.
Haha! Had a feeling that was you on FB.
Yeah, to be honest, we only went for 6 bolts to test both the rail and the power supply that came with the kit, as it turns out, it's not really strong enough. Yesterday was all about getting a feel for the kit and having a bit of a play.
If I'm honest, I'm surprised we got them as good as we did!
One, thing, do you know anywhere that has conversion tables for working out the surface area of bolts?
I'm sure someone must have a site somewhere for it.
If not, I'll knock up a spreadsheet with a calculation on it.
2 * Pi R squared + Pi D * L. But after you have done a few you will look at them and say, this 1.5 inches square. Then when you have your power pack you will set a current then check the voltage and a quick visual, adjust, then set the timer.
Edit, I've just recently posted some of my plating on my build thread.
That does look really good, did you plate your calipers too?
I paid for calipers, engine end plate, engine mounts, gearbox steady arm and inner CV shield to be plated. I couldn't generate the required current from my lab power pack.
Everything else including the CV joints I've done in a 10lt DIY tank. I'm particularly pleased with the rear shocks. The plated components came out very well. Will post when I get to fitting.
Never did get around to doing this, looks like I missed a trick!
(The Irn Bru's probably got your insides looking even cleaner.)
Never did get around to doing this, looks like I missed a trick!
(The Irn Bru's probably got your insides looking even cleaner.)
We bought a case of it by accident, now I'm addicted to the stuff!
Never did get around to doing this, looks like I missed a trick!
(The Irn Bru's probably got your insides looking even cleaner.)
We bought a case of it by accident, now I'm addicted to the stuff!
OOooo - I love a bit of Irn Bru. Irn Bru and a Twix was my little sugar boost to get me through when I used to work nights. It's still a standard 'pick me up - get me through' thing in my family now.
Amazing work on the bolts and bits ;D
So yesterday was a much better day for plating.
Took all the learnings ad advice from last week, bought a wire wheel for the bench grinder and a lab power supply with up to 5A delivery current.
(https://live.staticflickr.com/65535/51627944875_c43072cbb7_h.jpg) (https://flic.kr/p/2mEbHjB)Untitled (https://flic.kr/p/2mEbHjB) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Also, ran out of Irn Bru, so switched back to coke
(https://live.staticflickr.com/65535/51627735704_35b5ef25e1_h.jpg) (https://flic.kr/p/2mEaD9d)Untitled (https://flic.kr/p/2mEaD9d) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
It's made a huge difference! The plating is now much more consistent and infinitely more controllable with the PSU.
(https://live.staticflickr.com/65535/51627307658_3045312d02_h.jpg) (https://flic.kr/p/2mE8rU7)Untitled (https://flic.kr/p/2mE8rU7) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Managed to get all this done yesterday
(https://live.staticflickr.com/65535/51627735699_412264faa6_h.jpg) (https://flic.kr/p/2mEaD98)Untitled (https://flic.kr/p/2mEaD98) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
On another note, I'd done a little research and bought a Headliner-World headliner on ebay.
(https://live.staticflickr.com/65535/51627307678_32da6f3235_h.jpg) (https://flic.kr/p/2mE8rUs)Untitled (https://flic.kr/p/2mE8rUs) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
The fit is spot on, all holes are in the right places and the a/b/c pillars all line up too
(https://live.staticflickr.com/65535/51627307673_d44581b2d9_h.jpg) (https://flic.kr/p/2mE8rUn)Untitled (https://flic.kr/p/2mE8rUn) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51627086286_1c1ceeaa20_h.jpg) (https://flic.kr/p/2mE7j6m)Untitled (https://flic.kr/p/2mE7j6m) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
I've still got the inner sunroof and blinds etc to cover.
But I'll do that at a later date, when I can focus on just that, not dipping in and out between plating.
Headliner wasn't cheap but it definitely looks to be worth every penny. it's great that it's getting to be there's not much left you can't source new for a MK2.
You make it sound easy, bet it was anything but, though not at difficult as explaining away the C & B's on you picnic table! :o
Headliner wasn't cheap but it definitely looks to be worth every penny. it's great that it's getting to be there's not much left you can't source new for a MK2.
You make it sound easy, bet it was anything but, though not at difficult as explaining away the C & B's on you picnic table! :o
Haha! Yes, that was a 'Birthday Card' one of my mates drew for the other a few weeks ago!
Ok, a little more plating porn, as I was at the workshop today.
I cracked on and dropped the suspension off, painted the wheel arches and plated anything I could get my hands on!!
(https://live.staticflickr.com/65535/51630255332_f671b8cff4_h.jpg) (https://flic.kr/p/2mEoy95)Untitled (https://flic.kr/p/2mEoy95) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51631930520_31401da33f_h.jpg) (https://flic.kr/p/2mEx97C)Untitled (https://flic.kr/p/2mEx97C) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Then I noticed the wheel nuts...
(https://live.staticflickr.com/65535/51631728109_e5e738c44c_h.jpg) (https://flic.kr/p/2mEw6WM)Untitled (https://flic.kr/p/2mEw6WM) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51630255197_588cdcbf53_h.jpg) (https://flic.kr/p/2mEoy6K)Untitled (https://flic.kr/p/2mEoy6K) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
And the sh1t shield bolts
(https://live.staticflickr.com/65535/51631305798_d4e2ffa31e_h.jpg) (https://flic.kr/p/2mEtWpy)Untitled (https://flic.kr/p/2mEtWpy) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
I plated loads today, basically setting everything up, leaving them to plate for 30 minutes, while I tinkered about with other bits and repeat.
That container from the other post is basically full now.
An electrolytic rust conversion tank would take the pressure of your wire wheel, it must be busy, and give even better plating results. It will slow you down though, that’s been quite a busy tank.
I did think about the rust conversion tank after seeing Tims brake disc efforts a while ago.
But everything goes into the sand blaster before it goes to the wire wheel, that helps loads.
I tried a couple of bolts without the blasting, it took ages, didn't look at good and I just ended up blasting them again!
What does your blasting machine look like? I ask because mine is like a chunky spray gun that spreads grit everywhere. I only use it as a last option.
Re blasting.
I took some Beetle stub axles in for blasting then had to use a tap to clean the threads.
They must have shot blasted them and the thread needed cleaning out. Sand is less distructive/abrasive tho.
Preparation is important before you take a component for blasting i masked machined surfaces, taped male threads and put old bolts in female threads. I put the old bush back in my rear axle so that the hole wasn’t blasted and painted.
Edit, like this:
(https://i.imgur.com/iksalw4.jpg)
I bought one of these second hand:
https://www.uktoolbox.com/products/sealey-tools-shot-blasting-cabinet-double-access-695-x-580-x-625mm.html?F1=0&ID=510898&utm_source=GoogleBase&utm_media=Product+Search&gclid=Cj0KCQjwlOmLBhCHARIsAGiJg7lBMXY3tWmBEzQziS9fUuVWdpgevUOCHpD9aKPHNePGcpLCAlIq15gaAu8vEALw_wcB
It works well, though it will demolish your compressed air supply!
It's perfect for most small things, bigger things like hubs take an absolute age to do, but that's more to do with the media and the small nozzle.
In this photo, the middle one is blasted without any other treatment, it was just as bad, if not worse than the rusty one.
(https://live.staticflickr.com/65535/51601381641_0688ec9c6c_b.jpg) (https://flic.kr/p/2mBQyZP)Untitled (https://flic.kr/p/2mBQyZP) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
A cabinet like that would contain the mess. Strictly for small bits though.
That's a good call on the rear beam.
Mine will be going in next month, so I'll have to do the same thing
I cleaned up the bush location and put the old bush back in so no grit nor paint got in there.
(https://i.imgur.com/AEcE6wK.jpg)
Great work, really impressive.
Headlining is giving me food for thought. Which colour did you go for - is that black or grey? Either way, looks great!
Thanks, I went for black in the end, little bit darker than the standard material, but still works very well with the black A/B/C pillars.
Thanks! Agree it looks really good. Was it a two person job to fit it?
Very much so!
I got it so far in, but then when I was trying to get the clips in, I couldn't hold it up and get enough clips in to hold the weight while I got more. Fortunately a couple of mates were nearby to help while I secured it.
If you're on your own, this is what I did for the 205, though it has hinged rear windows that come out so you may have to think of a workaround if doing it on a 3 door MK2.
205 has slighly different attachment points, but the principle's the same.
Do it in stages, lifting then tieing the cord loops so as to take up the slack.
(https://lirp.cdn-website.com/1af6dd8a/dms3rep/multi/opt/5-3eabc0f0-960w.jpg)
(https://lirp.cdn-website.com/1af6dd8a/dms3rep/multi/opt/3-6d55a767-960w.jpg)
(https://lirp.cdn-website.com/1af6dd8a/dms3rep/multi/opt/4-50617959-960w.jpg)
(https://lirp.cdn-website.com/1af6dd8a/dms3rep/multi/opt/2-9b10d885-960w.jpg)
(https://lirp.cdn-website.com/1af6dd8a/dms3rep/multi/opt/1-0f9faa7c-960w.jpg)
Very much so!
I got it so far in, but then when I was trying to get the clips in, I couldn't hold it up and get enough clips in to hold the weight while I got more. Fortunately a couple of mates were nearby to help while I secured it.
I've done headlining in and out a few times on various cars now, with seats in and headrests all the way up you get a good resting spot then can lift it into place. I imagine it's harder in an empty car.
I have done them on my own, but have had help also. With 2 people it can be easier, but also very streesful if the other person isn't on your wavewlength and doesn't understand the fragile nature of the product.
Thanks for the info guys, appreciated. Monkey, apologies for the digression, seeing how good yours looks has given me some impetus! (That and seeing my headliner hanging down in the rear view mirror on every trip)
Good shout with the string, didn't think about that, just chucked it in, climbed in behind and got stuck!
So I got to spend another day on the car yesterday.
A part that has been letting the car down since the paint is the drivetrain.
It was always the plan to wait till after the paint, as it would be overspray city, and I was not wrong.
Though, admittedly, I did tell the painter not to worry!
Either way, it all came off and I started stripping it down.
Pulled off the subframe and inspected, with the bolts to one site, for the inevitable plating they were going to get!
(https://live.staticflickr.com/65535/51644573306_d2abd541c9_b.jpg) (https://flic.kr/p/2mFDWnG)Untitled (https://flic.kr/p/2mFDWnG) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
The hubs are going to need a fair amount of work
(https://live.staticflickr.com/65535/51645427390_72fe69184e_b.jpg) (https://flic.kr/p/2mFJjgh)Untitled (https://flic.kr/p/2mFJjgh) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
I'll pull the bushes out the wish bones and they'll go again, pretty happy as they look to be original.
(https://live.staticflickr.com/65535/51645427360_ab7ea1e94d_b.jpg) (https://flic.kr/p/2mFJjfL)Untitled (https://flic.kr/p/2mFJjfL) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Stripped down the subframe, fortunately, no killer rust.
(https://live.staticflickr.com/65535/51645427320_40db3b3b16_b.jpg) (https://flic.kr/p/2mFJjf5)Untitled (https://flic.kr/p/2mFJjf5) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Also, managed to whip the rear beam off, staggeringly, all the brake pipe nuts came undone, not a single rounded one!!
(https://live.staticflickr.com/65535/51643747097_00fa01017c_b.jpg) (https://flic.kr/p/2mFzGLH)Untitled (https://flic.kr/p/2mFzGLH) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
And finally, the finished subframe bolts!
(https://live.staticflickr.com/65535/51644573176_a8024b569a_b.jpg) (https://flic.kr/p/2mFDWks)Untitled (https://flic.kr/p/2mFDWks) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
My sub frame and rear axle were in much worse state. A decent blaster will have those cleaned and looking new in no time.
Yeah, I've given everything a good tap with a hammer and chisel, nothing is falling off, so I'm hopeful!
So with birthdays and family get togethers, I only managed to squeeze in a couple of hours this weekend.
We needed the room back, so I've had to take my plating lab down.
Before that, I pulled a couple more bits off the rear beam and run them through the usual process.
From what I can tell, this car hasn't been serviced for a VERY long time, but someone had gone to the trouble of pre-rounding off some of the caliper carrier bolts, so that was fun.
(https://live.staticflickr.com/65535/51661897561_7c1d047a2b_b.jpg) (https://flic.kr/p/2mHbJgK)Untitled (https://flic.kr/p/2mHbJgK) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Then I noticed this little bracket.
(https://live.staticflickr.com/65535/51661897601_a7914c5a37_b.jpg) (https://flic.kr/p/2mHbJhr)Untitled (https://flic.kr/p/2mHbJhr) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51661090922_01b68f014c_b.jpg) (https://flic.kr/p/2mH7Aub)Untitled (https://flic.kr/p/2mH7Aub) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Well, it would have been rude not to!
(https://live.staticflickr.com/65535/51661086737_d6a5a48a44_b.jpg) (https://flic.kr/p/2mH7zf2)Untitled (https://flic.kr/p/2mH7zf2) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51662574744_efa0074119_b.jpg) (https://flic.kr/p/2mHfczj)Untitled (https://flic.kr/p/2mHfczj) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Not mint, but the plating should put a pin in the rust for the next few years, might actually give it a coat of paint too yet, undecided at the moment.
Out of the bolts that came off the rear beam, the only non rounded (savable) ones were the slider pins, though they had seen better days
(https://live.staticflickr.com/65535/51661086742_a751a058f3_b.jpg) (https://flic.kr/p/2mH7zf7)Untitled (https://flic.kr/p/2mH7zf7) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
And with that, the last plating batch (for now) was done and the kit put away
(https://live.staticflickr.com/65535/51661892876_e1ffc3e8f4_b.jpg) (https://flic.kr/p/2mHbGSY)Untitled (https://flic.kr/p/2mHbGSY) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Next time, I'll be focusing on prepping the kit that's going for powder coating...
I've plated then painted loads of components. especially if they were painted from the factory. It's double protection better than just plate or paint.
Not the most of exciting of updates.
I had intended to get the kit on, after spending loads on the original fitting kits for the sill covers.
However, I now have a window at the blasters and coaters, but I have to get everything there next Saturday.
No problem, I thought, I'll whip the bushes out the beam and arms and get on with the kit.
How wrong was I?! Took me bloody ages to get all the bushes and bearings out!
Turns out the rear beam bushes were nearly new and therefore a nightmare to get out.
Took me the entire day and a crushed little finger, but I finally had a big pile of rusty crap, all ready for treatment.
(https://live.staticflickr.com/65535/51679826506_f22a1b2b72_b.jpg) (https://flic.kr/p/2mJLBVu)Untitled (https://flic.kr/p/2mJLBVu) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Can you spot the oddity in this pile?
(https://live.staticflickr.com/65535/51679023987_9bf331d46a_b.jpg) (https://flic.kr/p/2mJGvmX)Untitled (https://flic.kr/p/2mJGvmX) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51679023972_01bd49861c_b.jpg) (https://flic.kr/p/2mJGvmG)Untitled (https://flic.kr/p/2mJGvmG) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Big steps now, getting close... looking forward to the engine work, might motivate me to do some also.
The slam panel on the bottom looks different somehow, is it a Jetta one?
Big steps now, getting close... looking forward to the engine work, might motivate me to do some also.
The slam panel on the bottom looks different somehow, is it a Jetta one?
Close, but it is a golf one.
The odd part is there are two slam panels, I've thrown my spare one into the pile, so I can put a fresh one on my blue golf.
In the photo below, you can see it's not the best and I've chopped it about, as I've been trialling my A/C setup.
(https://live.staticflickr.com/65535/50498582287_856a175ddb_b.jpg) (https://flic.kr/p/2jWoraR)Untitled (https://flic.kr/p/2jWoraR) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
I'm going to get the spare one coated and ready to swap over.
Though, I expect it'll just sit in the container for another year or so!
Well the rusty pile of crap has now been upgraded to just a pile of crap! :))
(https://live.staticflickr.com/65535/51704304191_d90a8eeca1_h.jpg) (https://flic.kr/p/2mLW5hx)Untitled (https://flic.kr/p/2mLW5hx) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
I dropped it off the coaters, where it will have the zinc coating first, followed by the black powder coat.
Looking forward to getting it all back!
I think the idea of applying zinc to that after blasting is good. Powder coating is something I would avoid if the car is a keeper. Just paint it.
I've noticed that when some rusty components have been blasted then powder-coated you can see the rust bitten patches underneath, I guess the zinc coating could smooth that out ?
I doubt the zinc will make up the metal lost to rust. The problem with powder coat is rust can spread undetected under the coat. Zinc should slowdown that spread of rust.
When I looked into plating previously copper was suggested as a build coat. It’s soft so the high spots can be sanded back leaving material in the dimples.
Which makes sense when you think it’s used as a base coat to chrome. Copper is also very easy to plate with, you just need some old pipes.
Could always zinc over it then paint or powder…. If you want to be a perfectionist.
Ok, so I've now picked up the powder coating and its looking lovely!
(https://live.staticflickr.com/65535/51721824755_f230484c27_b.jpg) (https://flic.kr/p/2mNtSxe)Untitled (https://flic.kr/p/2mNtSxe) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51721824745_f090c9a046_b.jpg) (https://flic.kr/p/2mNtSx4)Untitled (https://flic.kr/p/2mNtSx4) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51720948961_0b3774cf57_b.jpg) (https://flic.kr/p/2mNpock)Untitled (https://flic.kr/p/2mNpock) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51720948991_9475ac20fc_b.jpg) (https://flic.kr/p/2mNpocR)Untitled (https://flic.kr/p/2mNpocR) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Not sure how much more progress I'll make for a while, I'm now skint after all that, the head work that I'm soon to pick up and the latest addition to the fleet...
(https://live.staticflickr.com/65535/51721824695_c310d0333e_b.jpg) (https://flic.kr/p/2mNtSwc)Untitled (https://flic.kr/p/2mNtSwc) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Yes, I've gone to the dark side for my daily.
But I do a lot of miles and I've worked out it'll save me 2k per year on fuel alone!
Looking good on both fronts.
I guess the savings can go to the VW fund!
That's pretty much the exact plan, this golf is costing much more than originally planned for!
So I only spend a couple of hours on the car this weekend.
Dug the arch liners out of storage and gave them a bloody good clean, then put them on with the shiny zinc plated bolts.
While I was in the wheel arch, I put the black plastic arches back on. I wanted to use some black plastic trim clips I'd bought.
(https://live.staticflickr.com/65535/51727178234_0ebb840352_b.jpg) (https://flic.kr/p/2mNXiWA)Untitled (https://flic.kr/p/2mNXiWA) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
But the lip of the arch was just too thin to take them and I didn't want to go drilling it out and ruining the lip, so they went on with rivets, which will be painted black in due course.
(https://live.staticflickr.com/65535/51725717732_1223988b6b_b.jpg) (https://flic.kr/p/2mNPPMw)Untitled (https://flic.kr/p/2mNPPMw) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Starting to look a little more like a GTI now. I do love the red/black contrast.
(https://live.staticflickr.com/65535/51726525616_efdb463c7a_b.jpg) (https://flic.kr/p/2mNTXWy)Untitled (https://flic.kr/p/2mNTXWy) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Shame you didn't make it to the pub Friday, there was a good healthy debate about EVs. We'll have to continue in February.
Yeah, I'm genuinely gutted I couldn't make that, the Golf has a fresh MOT and everything!
Ok, I'm not going to lie, I've been having major issues getting enthusiasm to work on the car in the recent month or so.
I've been down twice now, got out the car, thought f**k that and went back home in the warm!
But last week, the head came back from Retro Resus after having new guides/seals all machining work and vapour blasting.
I must say, it looks fantastic for it.
(https://live.staticflickr.com/65535/51757611809_586a4728bf_b.jpg) (https://flic.kr/p/2mRDhMp)Untitled (https://flic.kr/p/2mRDhMp) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51756961256_4e79b797e0_b.jpg) (https://flic.kr/p/2mRzXoY)Untitled (https://flic.kr/p/2mRzXoY) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51757611844_81e011ce7f_b.jpg) (https://flic.kr/p/2mRDhN1)Untitled (https://flic.kr/p/2mRDhN1) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
So that (and the £450 hole in my wallet) spurred me on to getting out and getting on with the project.
Some of you might remember, I'd left the block without the pistons, post inspection.
So I cracked on and re-honed the bores, put the new rings in, confirmed everything was in spec and put the pistons back in with new big end bearings
(https://live.staticflickr.com/65535/51756135612_84c8474464_b.jpg) (https://flic.kr/p/2mRvHXJ)Untitled (https://flic.kr/p/2mRvHXJ) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Next went on the new oil pump and brand new sump (for £13, I couldn't refuse!).
(https://live.staticflickr.com/65535/51757832385_9205caab64_b.jpg) (https://flic.kr/p/2mREqmr)Untitled (https://flic.kr/p/2mREqmr) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Then finally the head and things are starting to look much better for the little 8v motor.
(https://live.staticflickr.com/65535/51756961401_be451deca0_b.jpg) (https://flic.kr/p/2mRzXrt)Untitled (https://flic.kr/p/2mRzXrt) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51756135627_04fb61448d_b.jpg) (https://flic.kr/p/2mRvHXZ)Untitled (https://flic.kr/p/2mRvHXZ) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Nice, is that a new sump?
Next went on the new oil pump and brand new sump (for £13, I couldn't refuse!).
Nice, is that a new sump?
I can tell someone just looks at the photos! :))
But thanks :D
Looks to me like you should tidy that garage. There could be another Golf hiding in there.
scs
There is so much crap in there!!
Funny you should say about the golf, there is actually a Rallye under that silver cover!
Very envious of the work going into this. It will become too nice to use! What are your plans for it when its complete?
Thanks!
I've not got plans per se, I just thought it would be nice to have a mint standard one as my blue one is now highly modified.
It does mean me and the better half can both drive mk2s to the National Meet!
But I expect I'll use it a little in the summer for work/days out.
It's got over 200k on the clocks, so I don't need to worry about mileage any more.
I have booked to go to the national meet also, hopefully camping if i can convince my girlfriend to drive either my mk2 or t5. I will come and say hi if i recognise you by car. Think my tickets have rolled over for 2 years!
Yeah, I've had my track passes for 2 years now too. Not giving them up, love that meet!
Yeah, feel free to pop over, I'll either be near the red one (providing it's finished!) or driving about in the Blue one.
So I managed to get a few hours in on the golf this week.
I started off by pressing the bushes into the crossmember, that was bloody fun, ended up borrowing a mates press and still it took two of us! But once it was on, I popped it back together with the radiator support and put it back on the car for safe keeping.
(https://live.staticflickr.com/65535/51790145313_ca3641cb1c_h.jpg) (https://flic.kr/p/2mUw2RT)Untitled (https://flic.kr/p/2mUw2RT) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
While I had the press, I moved on to the wishbones, a press makes life so much easier!
I was going to keep everything standard, but had these in stock and need to save as much money as possible.
(https://live.staticflickr.com/65535/51790399314_2d20ac641a_h.jpg) (https://flic.kr/p/2mUxknd)Untitled (https://flic.kr/p/2mUxknd) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
When I had the tank straps blasted, unfortunately one of them came back looking like a tea strainer!
So I bought a new set that came galvanised, they had to go black. I stuck some primer on and let it dry while I went about other things.
(https://live.staticflickr.com/65535/51790765200_6cc320af03_h.jpg) (https://flic.kr/p/2mUzd8A)Untitled (https://flic.kr/p/2mUzd8A) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
One thing I hadn't got blasted was the rocker cover.
One, because I wanted to be sure the gauze would be properly protected and two because I put it in a different box and forgot about it!
Either way, I wasn't convinced the powder coating would be up to the heat and decided to use the engine enamel I'd used on the block.
(https://live.staticflickr.com/65535/51790020566_0bbf715888_h.jpg) (https://flic.kr/p/2mUvoM5)Untitled (https://flic.kr/p/2mUvoM5) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Once the blasting was done, I stuck some black on the straps and went in search of a paint brush.
(https://live.staticflickr.com/65535/51790399179_553f86afd5_h.jpg) (https://flic.kr/p/2mUxkjT)Untitled (https://flic.kr/p/2mUxkjT) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
This was the shot straight after painting, I thought it looked pretty presentable
(https://live.staticflickr.com/65535/51790765120_a7b74c5030_h.jpg) (https://flic.kr/p/2mUzd7d)Untitled (https://flic.kr/p/2mUzd7d) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Looked even better after it had an hour to settle
(https://live.staticflickr.com/65535/51790768245_8221574c25_h.jpg) (https://flic.kr/p/2mUze36)Untitled (https://flic.kr/p/2mUze36) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Lastly, I started stripping down the PAS setup off my blue golfs original engine.
It has definitely seen better days, but the pump felt ok and I knew it would run again.
(https://live.staticflickr.com/65535/51789082017_9600eb4d50_h.jpg) (https://flic.kr/p/2mUqzMc)Untitled (https://flic.kr/p/2mUqzMc) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
After a few hours in the blasting cabinet and a lick of paint, it's back to it's former glory.
Though one of the bolts sheared off in the pump and had to be drilled and re-tapped, so that was fun!
(https://live.staticflickr.com/65535/51790020851_cc53ed9ced_h.jpg) (https://flic.kr/p/2mUvoRZ)Untitled (https://flic.kr/p/2mUvoRZ) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Plumbers silicone assembly grease if you have trouble with any more rubber bits. Think I got my X member bushes by hand, definitely didn't use the press.
Don't get the grease on any painted surfaces though.
Plumbers silicone assembly grease if you have trouble with any more rubber bits. Think I got my X member bushes by hand, definitely didn't use the press.
Don't get the grease on any painted surfaces though.
Impressive! I was swearing at mine for ages!
One of the biggest problems I had was I had to be very careful of the coated crossmember, so I couldn't just wail on it or chuck it in the vice.
I think I put them in the oven to soften them. Then they eased in with the grease.
I think I put them in the oven to soften them. Then they eased in with the grease.
Wish I’d have thought of that! I was just using brute force and ignorance!
Ok, a relatively unimpressive update, but it's progress all the same.
Something I didn't get photos of was the arches and liners for the passenger side went on, along with the final fit of the wings.
It's quite tight down that side of the car, working on it is a pain in the ass, so I've been putting it off till now.
I was doing that in between painting the rest of the PAS stuff, which is now finished, but I can't put it back together again, as I need to get the plating stuff back out for the bolts!
(https://live.staticflickr.com/65535/51842591410_3035d70f1f_b.jpg) (https://flic.kr/p/2mZ9QfW)Untitled (https://flic.kr/p/2mZ9QfW) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
So in the box they go, as I build my collection of bolts up for the next plating session!
(https://live.staticflickr.com/65535/51840914757_c2522c917e_b.jpg) (https://flic.kr/p/2mZ1eR8)Untitled (https://flic.kr/p/2mZ1eR8) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Something that annoyed me about the car is the previous owner removed the wiper and washer, but didn't bother with the blanks...probably why I had to replace the rotten tailgate!
Either way, after a little fiddling, I managed to get everything back in, as VW intended.
(https://live.staticflickr.com/65535/51840914807_a3f6d58d3f_b.jpg) (https://flic.kr/p/2mZ1eRZ)Untitled (https://flic.kr/p/2mZ1eRZ) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
The boot lock and door handles were absolutely butchered and weren't working when I got the car.
I'd actually been using a cable tie poking out the wiper hole to open the boot. That finally got to me enough to do something about it.
I bought a new boot lock off of heritage, which I combined with as many oe parts as possible to get the lock set working again.
Something else I spent time on while I was there was to re-blade all the locks on the car to match the oe ignition lock, so it'll be a one key wonder! :D
(https://live.staticflickr.com/65535/51840914847_7609dd124e_b.jpg) (https://flic.kr/p/2mZ1eSF)Untitled (https://flic.kr/p/2mZ1eSF) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
And finally, a random engine pic to give me motivation to get on with it again!
(https://live.staticflickr.com/65535/51842591430_aa281fa512_b.jpg) (https://flic.kr/p/2mZ9Qgh)Untitled (https://flic.kr/p/2mZ9Qgh) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Looks like a decent space you have to work from. Do you rent a unit?
Is the black lip on the boot painted or a sticker? Mine is beginning to lift and looks a bit scruffy
Yeah, it's actually an old peat barn that they put a door on for us. Been in there about 14 years now.
The black lip is a vinyl sticker.
Not expensive, but took bloody ages to get it right, sprayed a load of soapy water on so we could move it about to dial it in.
Also, you need to take the rear window out to fit it properly and then give it some time to set before refitting.
I actually mention it on P4 and have a shot of it with just the sticker on and no window
Looks ideal. I have just wired a 3 phase ramp in a unit for a mate. Hoping I can make use of that when needed.
Good to know about the vinyl. I did wonder about redoing mine. I don't like fiddly jobs so I may see about having it painted in satin black or just leave it off altogether 🤔
We've actually got three phase too. We use it for the air compressor and some of the bigger toys.
Hopefully this year, they'll extend the unit for us and we can get a ramp in there too, I'm getting too old to be working on my back under cars!!
It's a bit fiddly, but as long as there are two of you there and you're methodical, it's not too bad.
We put loads of soapy water on first, moved it into place and one of held a section while the other used the heat gun to really stick it down.
Hi hijacking the thread try a product called solutions it is a dye if the trim is in good order
Hi hijacking the thread try a product called solutions it is a dye if the trim is in good order
Do you mean Solution Finish? Great stuff, I use it on all my black plastics.
Another couple of hours spent on the project this weekend.
The ARB bushes arrived, so it finally enabled me to rebuild the subframe with the shiny zinc coated bolts.
(https://live.staticflickr.com/65535/51850458454_9af86ff4eb_b.jpg) (https://flic.kr/p/2mZR9RC)Untitled (https://flic.kr/p/2mZR9RC) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Then on went the rack and the ARB drop links, I do love rebuilding with fresh parts!
(https://live.staticflickr.com/65535/51849167147_4462aa91c4_b.jpg) (https://flic.kr/p/2mZJwZH)Untitled (https://flic.kr/p/2mZJwZH) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
And then put it back on the car. Probably won't be the final fit, but I figured it was the safest place to store it all.
(https://live.staticflickr.com/65535/51850458414_8d7c6df396_b.jpg) (https://flic.kr/p/2mZR9QW)Untitled (https://flic.kr/p/2mZR9QW) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Then I directed my attention to the front brakes.
Turns out the bleed nipple was sheared on one of the calipers. So removing that was fun.
I spent the best part of an hour, lost an easy out and ended up having to weld a nut to what was left of the nipple and wind it out with a breaker bar!
Still they're both stripped now, ready for blasting. I'll probably end up painting them black, but want to try and zinc coat them for a little added protection too. But that'll all be at the end of the month, when I have a little time off coming up.
Still they're both stripped now, ready for blasting. I'll probably end up painting them black, but want to try and zinc coat them for a little added protection too. But that'll all be at the end of the month, when I have a little time off coming up.
You won't be able to generate the current or present enough zinc to DIY plate calipers. That is definitely a job for a plating shop.
Still they're both stripped now, ready for blasting. I'll probably end up painting them black, but want to try and zinc coat them for a little added protection too. But that'll all be at the end of the month, when I have a little time off coming up.
You won't be able to generate the current or present enough zinc to DIY plate calipers. That is definitely a job for a plating shop.
I did think that, but could I not compensate for lack of current by leaving them in longer?
No, MK2 rear brake caliper carriers were too much for my setup. The largest items I successfully plated were MK2 CV joints. They were right on the limit but being symmetrical I got an even current and zinc coverage. As soon as a component is irregularly shaped it is difficult to get even current and zinc into all of the corners.
These spring seats were on the limit too and took a few attempts:
(https://i.imgur.com/wiAIrs1.jpg)
Another couple of hours spent on the project this weekend.
The ARB bushes arrived, so it finally enabled me to rebuild the subframe with the shiny zinc coated bolts.
(https://live.staticflickr.com/65535/51850458454_9af86ff4eb_b.jpg) (https://flic.kr/p/2mZR9RC)Untitled (https://flic.kr/p/2mZR9RC) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Then on went the rack and the ARB drop links, I do love rebuilding with fresh parts!
(https://live.staticflickr.com/65535/51849167147_4462aa91c4_b.jpg) (https://flic.kr/p/2mZJwZH)Untitled (https://flic.kr/p/2mZJwZH) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
And then put it back on the car. Probably won't be the final fit, but I figured it was the safest place to store it all.
(https://live.staticflickr.com/65535/51850458414_8d7c6df396_b.jpg) (https://flic.kr/p/2mZR9QW)Untitled (https://flic.kr/p/2mZR9QW) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Then I directed my attention to the front brakes.
Turns out the bleed nipple was sheared on one of the calipers. So removing that was fun.
I spent the best part of an hour, lost an easy out and ended up having to weld a nut to what was left of the nipple and wind it out with a breaker bar!
Still they're both stripped now, ready for blasting. I'll probably end up painting them black, but want to try and zinc coat them for a little added protection too. But that'll all be at the end of the month, when I have a little time off coming up.
Great job on the subframe. That's another job I really should add to my list. Is the rack refurbished? I'm about to gamble on a 2nd hand pas rack 🤞🏻
Afraid not, with the costs getting out of control, I'm having to take a gamble.
I know the breaker and he said it was a good one, I've checked for play and turned it from lock to lock, everything feels smooth, so fingers crossed!
I seem to be at a stage where anything I want to fit, needs more bolts. So I spent the majority of the weekend tidying the unit, so I can set up the plating rig again.
One thing I kept tripping over was the slam panel, so on it went.
(https://live.staticflickr.com/65535/51874269114_5cad60ebef_h.jpg) (https://flic.kr/p/2n2XbWf)Untitled (https://flic.kr/p/2n2XbWf) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Wasn't expecting it to look quite that good, makes me want to get the thing finished even more now.
That looks great Dave. What did you use to get the washer bottle so clean? I've disolved a dishwsher tablet in hot water and left it overnight to soak.
Starting to come together now … getting the I have a standard car feelings yet?
nice pictures :-) would you make a pic of this golf ball lever in full ?
i wonder how close the thingiverse version (https://www.thingiverse.com/thing:4304024) is.
what is this solution finish, which you use for your plastic parts ?
i used good old stinky shoe cream, got similar results, but needed a lot.
some screws i even got in stainless. for the rest of them:
is there a guide about this electrolysis thing ?
is your back side emblem missing ? i broke the pins on mine.
do you have a source ?
i guess it could be 3d-printed too,
but this would take time and i mainly use openscad
where i code parts more, than i design them..
..long story short: some parts i like more than others.
one maybe could ask the guy, who did the front side emblem (https://www.thingiverse.com/thing:358536).
it came out very nice and was pretty close to the original.
the inner edges maybe a notch to round.
Hi solutions finish is a black dye that you apply with a cloth it comes in a small bottle which is more than enough to coat the black plastic on the car I even put it on the tailgate trim. Most of the items you are looking for are available on ebay a lot of sellers will post abroad. The golf ball is very similar to a standard ball but is matt in colour and the dimples appear a little deeper.
scs
@Damien.wrl yeah, it's starting to sink in, but I've still got the blue one!
@mk24ever, do you mean the standard gear knob? The STL looks very similar, but not quite there.
I believe you can still get new ones, I did buy one a few years ago, if I can find it, I'll stick that on.
I did think about stainless screws, but I've kind of got addicted to the zinc plating now!
Speaking of which, I set the kit up again this weekend and got to it with the driveshaft bolts and the exhaust hanger.
(https://live.staticflickr.com/65535/51877429936_b5070e850c_b.jpg) (https://flic.kr/p/2n3eoxb)Untitled (https://flic.kr/p/2n3eoxb) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51878070720_48fd0261e7_b.jpg) (https://flic.kr/p/2n3hF2b)Untitled (https://flic.kr/p/2n3hF2b) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Made a fair difference to the strut tops too, I know they should be in yellow passivate, but I really like the silver.
(https://live.staticflickr.com/65535/51877745834_9743af1907_b.jpg) (https://flic.kr/p/2n3g1rG)Untitled (https://flic.kr/p/2n3g1rG) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Biggest thing I've plated yet is the bonnet catch, that worked well and went straight on the car
(https://live.staticflickr.com/65535/51877429961_d525c917cf_b.jpg) (https://flic.kr/p/2n3eoxB)Untitled (https://flic.kr/p/2n3eoxB) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
@monkey:
@pwardy said i should not use stainless (https://www.vwgolfmk2.co.uk/clubforum/index.php?topic=517.msg9091#msg9091),
cause of the washers not being attached to the screws,
but since rusting screws can cause a lot of damage,
i can live with that. plus i can adapt the washer size
with my lathe, but was not necessary.
edit: i got it wrong. this is not what
@pwardy said (see his edit (https://www.vwgolfmk2.co.uk/clubforum/index.php?topic=517.msg9091#msg9091)).
if we are on it:
i dismissed frames with considerably fewer rust problems.
why are you guys putting so much effort in fixing frames ?
wouldn't it be easier to transform a cl with a good one ?
We fix them because they're all old now.
Over here, it's much harder to find good ones regardless of cl or gti, they all hide rust somewhere.
The rust that comes about isn't as easy to see on initial inspection and with the prices of them shooting up you just have to take your chances. The one I bought was completely sight unseen, they were going for so much money, when mine came up at a reasonable price, I couldn't afford to take time. I called and placed a deposit within 15 minutes of the advert going up. Apparently after that, he had 4 or 5 people call offering more than asking price for it.
sad.
at some point i would have possibly bought a gti, too,
but for bigger trips, i like my economic 55 ps mk2,
so i would not like to put more horsepower into it.
how much fuel does your gti need ?
i also wonder how it sound like, from the drivers perspective.
regarding stainless i had the screws, attaching the fenders, in mind (https://www.vwgolfmk2.co.uk/clubforum/index.php?topic=517.msg9110#msg9110),
but, as it appears, such should not be used with heavy loads
(see edit of my post, reply 140, above).
i'm so glad, i posted about "some screws" in reply 137.
I've actually had about 10 GTIs now, I've got an addiction to them!
I've found in both 8v and 16v GTIs, when driven normally I'll see around 6.7 l/100km.
Interestingly, my 3.2 gets similar consumption.
I love the sound of a standard GTI, my last 16v had a complete standard system on it.
Also, the arch liners would be good to have in stainless, but I had all the normal ones in good condition and they all came up really well with the zinc plating.
this is not much more than my 55ps needs.
i probably should have wanted a gti..
the 8v does not sound as sore as the 16v
and there is no crackling, true ?
how does this 6v 3.2 sound ?
That looks great Dave. What did you use to get the washer bottle so clean? I've disolved a dishwsher tablet in hot water and left it overnight to soak.
Sorry Andy, missed your question. I was just lucky, all it needed was a decent rinse out and a wipe down on the outside.
@mk24ever I had a 1.6 Driver for a few years and my first 8v gti was much better on fuel.
Not sure what you mean by crackling, but the 8 and 16v do sound quite similar, perhaps the 8v is a little deeper.
The 3.2 is something else entirely though. I love the noise of it!
Click below to see the video of it...
(https://live.staticflickr.com/1809/29131927838_e59f2f5156_b.jpg) (https://flic.kr/p/LohKcU)Untitled (https://flic.kr/p/LohKcU) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
is the actual engine a 112 ps one ?
do you know the reason, why your previous 8v gti was better on fuel ?
how desirable are the g60 and g60 limited machines ?
regarding 16v, i watched this (https://youtube.com/watch?v=xg210FS0DpE) test drive
and there was some crackling when he throttled back. why is such ?
for engine sounds, i have now started this (https://www.vwgolfmk2.co.uk/clubforum/index.php?topic=1325.0) separate thread.
Yes 112
The 8v is probably good on fuel compared to a smaller engine is the injection is more efficient and the larger engine means it's not as stressed to travel at normal speeds.
G60 and G60 Limited are very desirable (especially the Limited)
That video said he's got a 421 manifold, so that's probably why it crackled a bit.
Good vid, looks like a fun car.
So I had a few days off last week and managed to crack into the rear beam refurb.
Started off with some brakes that looked very sorry form themselves.
(https://live.staticflickr.com/65535/51930765647_ea53da2786_b.jpg) (https://flic.kr/p/2n7WKop)Untitled (https://flic.kr/p/2n7WKop) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
But after a lot of cleaning, some paint and a couple of rebuild kits, they look much more respectable
(https://live.staticflickr.com/65535/51932078104_9fb04f421b_b.jpg) (https://flic.kr/p/2n84twY)Untitled (https://flic.kr/p/2n84twY) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51931748126_448c57bb43_b.jpg) (https://flic.kr/p/2n82MrG)Untitled (https://flic.kr/p/2n82MrG) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Unfortunately, someone had forgotten to buy new flexi brake lines and slider pin boots, so the build stopped there!
So instead, I went on with the fuel tank, I've been tripping over it for a year now and had had enough.
No photos, but the pump came out and was replaced with a new pierburg unit.
Then in finally went back into the car, with the new straps.
I'm very pleased with the fit, the straps all went back on and the tank fitted exactly as it should.
Which is a relief, as we'd fitted a new neck bracket for it!!
(https://live.staticflickr.com/65535/51931748151_3b991d3efe_b.jpg) (https://flic.kr/p/2n82Ms8)Untitled (https://flic.kr/p/2n82Ms8) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51930765637_2a0f530e7e_b.jpg) (https://flic.kr/p/2n7WKoe)Untitled (https://flic.kr/p/2n7WKoe) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
All coming together very quickly now... it was a great motivator when the previously near bare shell suddenly started to look like a car again.
Those are two jobs that look straightforward to the viewer but are anything but, specially doing them on your own.
Did you print the plastic bungs?
Wouldn't like to meet your cat on a dark night, must be the size of a dog judging by all the empty Dreamies cartons!
All coming together very quickly now... it was a great motivator when the previously near bare shell suddenly started to look like a car again.
Those are two jobs that look straightforward to the viewer but are anything but, specially doing them on your own.
Did you print the plastic bungs?
Wouldn't like to meet your cat on a dark night, must be the size of a dog judging by all the empty Dreamies cartons!
Haha! We used to have a couple of cats, but unfortunately lost the workshop cat last year. Though my house cat is still getting through them like there's no tomorrow!!
As for the bungs, I printed them off and they both split when I tried tapping them in!
I'll probably print another couple off at 99%, just to see if that's better.
I was lucky to have a hand with the tank, I've done one by myself before and it was no fun at all!
So, in the week, I took the plunge and bought the suspension that has been on my watchlist on ebay for about a year!
I figured with everything going up in price, I'd kick myself if I ended up paying more - actually just checked and it's gone up by £20!
Also, while I was there, I bought new top mounts and spring caps/rubbers for everything too.
(https://live.staticflickr.com/65535/51980395505_71311ed97f_b.jpg) (https://flic.kr/p/2nck7BB)Untitled (https://flic.kr/p/2nck7BB) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Don't think it was a moment too soon either!
(https://live.staticflickr.com/65535/51978831832_30b898aa2f_b.jpg) (https://flic.kr/p/2ncc6MJ)Untitled (https://flic.kr/p/2ncc6MJ) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Unfortunately, I didn't notice the delivery date on the front spring caps, so they'll be here from Greece in a couple of weeks time!
Still, the rears went on a treat
(https://live.staticflickr.com/65535/51979836001_63a1cf4e73_b.jpg) (https://flic.kr/p/2nchfhZ)Untitled (https://flic.kr/p/2nchfhZ) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
After getting them on, I looked at the rear beam and even though I haven't got the flexi lines (on order), I could still bend up the hard lines and get them somewhere near. Meaning I could get the rear beam on for a bit of a landmark moment
(https://live.staticflickr.com/65535/51980395600_fd3f506927_b.jpg) (https://flic.kr/p/2nck7Df)Untitled (https://flic.kr/p/2nck7Df) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/51978831732_de2590200c_b.jpg) (https://flic.kr/p/2ncc6L1)Untitled (https://flic.kr/p/2ncc6L1) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Very pleased with how it's coming together, though it did remind me I need to strip the fuel pump assembly!
I get paid in a couple of weeks, so I'll look at getting the front back together, then it's just gearbox/engine/everything else!!
This is going to be such a nice car, like new! Are they eibach springs you have gone for? Hope your fuel pump comes apart OK 🤞🏻 have you seen the price of new housings!
I know it eventually gets hidden and next to nobody will ever see most of that again but so worth this effort, if only for your own satisfaction.
Thanks guys.
Yes, I'm planning to be very careful when removing it, hoping not to have to fork out nearly £500 for a new one!
Have you considered using a mk3 tank? They seem to be a common upgrade
This is going to be such a nice car, like new! Are they eibach springs you have gone for? Hope your fuel pump comes apart OK 🤞🏻 have you seen the price of new housings!
I thought the new housings were K Jet only?
I didn't think Digifant pump tanks were available new. They cost a fortune used and in a mess.
My mistake, you are correct about them being for 16v 🙂
Either way, I need to be extremely careful when removing/refreshing the pump.
Have you considered using a mk3 tank? They seem to be a common upgrade
I've got my blue golf that has all the modifications on it, so I'm trying to steer clear of them on this one.
The only mods I'm doing is suspension and stereo.
I've also refreshed the in tank pump for a Pierburg item, so hopefully, that should be good for another 30 years.
I found that I had to drill out every mounting stud and bolt on my pump tank. The pump retaining screws had to have a slot cut in them then used a flat blade driver.
Best of luck.
Oh joy. Guess I'll plan a whole day for that one then!
You need a vice to isolate the plastic from the torque of the drill. Clamp the item to be drilled while supporting the plastic then straight down the middle of all of them.
Had to do this twice recently, my own tank and one I bought as a spare.
Thanks, I'll have a good go at that this weekend hopefully.
Did you find any decent screws to go back in?
The pump screws and fuel pipes were genuine VAG bought over 20 years ago. The rubber mounts and the stud retaining clips and rubbers were imported from Greece while we were still in the EU. Metric screws and nuts and pipe clips were sourced off eBay.
Could be much trickier to get the bits now.
Please can you share a side profile of Red Rescue so I can see how it sits?
If I recall you have fitted this suspension kit?
Eibach/Bilstien (https://www.ebay.co.uk/itm/332524790827)
I'm wondering whether to do a suspension refresh.
TIA
Andy
HI Andy,
Yeah, that's the kit I've fitted, but the car is still on axle stands at the moment!
I hope to get the front hubs rebuilt and back on this weekend.
If all goes well, I'll drop it back on wheels then, though that won't give you a good steer as there will be no engine in it!
If you're on facebook, look through the mk2 oc on there, I put a post up a couple weeks back and a few other people posted up theirs with the kit on.
So, managed to get back out to the workshop Saturday with a load of goodies for the golf
(https://live.staticflickr.com/65535/52089090511_ef260afd26_b.jpg) (https://flic.kr/p/2nmWcRr)Untitled (https://flic.kr/p/2nmWcRr) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
My main goal was to get all the hubs etc built back up, so I started off by dropping the steering rack back off, to attach the track rods, boots and the super fiddly breather pipe that runs between them!
(https://live.staticflickr.com/65535/52089090571_8e6fd64e70_b.jpg) (https://flic.kr/p/2nmWcSt)Untitled (https://flic.kr/p/2nmWcSt) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Really liking the whole black and silver thing going on
(https://live.staticflickr.com/65535/52089337659_32d4e57943_b.jpg) (https://flic.kr/p/2nmXtjB)Untitled (https://flic.kr/p/2nmXtjB) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Unfortunately, the new wheel hub flanges I'd bought were early ones and too small for my hubs.
After a little cursing and a lot of googling, I found out that anywhere that listed mine were out of stock with no eta for replacements.
So we decided to refurbish my old ones (which came up pretty nicely) and press the bearings in.
(https://live.staticflickr.com/65535/52089592230_5b5e4f4a14_b.jpg) (https://flic.kr/p/2nmYLZL)Untitled (https://flic.kr/p/2nmYLZL) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
It was at this point I realised I'd gotten distracted last time and forgot to build up the front calipers!
So they went back together and were finally fitted to the car
(https://live.staticflickr.com/65535/52089113528_b739d28e08_b.jpg) (https://flic.kr/p/2nmWjGh)Untitled (https://flic.kr/p/2nmWjGh) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
And to top it all off, the boy arrived for an inspection of the steering...
(https://live.staticflickr.com/65535/52089337674_d0f671fc2f_b.jpg) (https://flic.kr/p/2nmXtjS)Untitled (https://flic.kr/p/2nmXtjS) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
I think it passed!
Nice to see some progress. I think you should recreate that final photo when you boy has passed his driving test.
That's a brilliant idea! If the car is still with us, I'll definitely be doing that one.
Back with the regular updates, even if this one is a bit of a boring one.
I spent the best part of the day doing just the front brake lines.
The ones that were installed were definitely not oe, they looked like they had been thrown in to get though an MOT and someone was on the clock!
So with nothing to copy, I was left to my own devices to check what was on the random mk2s around the unit.
Think they came out pretty well.
(https://live.staticflickr.com/65535/52108625482_cd38bbcf30_b.jpg) (https://flic.kr/p/2noEjVh)Untitled (https://flic.kr/p/2noEjVh) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/52108625522_872fb674eb_b.jpg) (https://flic.kr/p/2noEjVY)Untitled (https://flic.kr/p/2noEjVY) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Don't pay too much attention to the servo, it's a stand in while I refurbish my one!
(https://live.staticflickr.com/65535/52109684308_355abd2d5f_b.jpg) (https://flic.kr/p/2noKKEU)Untitled (https://flic.kr/p/2noKKEU) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Hopefully, I'll get back out over the week for a little more work.
The National Meet is getting closer and the list of jobs isn't shrinking fast enough!
So, I had a pretty busy weekend!
Paulina and Tony went to see her parents in Poland, allowing me to properly crack on with the car.
Took a half day on Thursday and started said cracking on.
First up was the starter motor. It functioned just fine, just a little dirty.
So all it needed was a strip down and inspection before being blasted and painted.
(https://live.staticflickr.com/65535/52126067361_c10f23c7fc_b.jpg) (https://flic.kr/p/2nqcHMk)Untitled (https://flic.kr/p/2nqcHMk) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/52126098493_80b13c82b8_b.jpg) (https://flic.kr/p/2nqcT36)Untitled (https://flic.kr/p/2nqcT36) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Also, had a message from Gas N Gears, letting me know my box would be ready by Wednesday.
So I took all Friday off to head over to south Wales and collect it.
And an absolutely fantastic job was done too!
Literally everything that can be has been changed for new oe parts, then the whole thing was blasted and coated.
(https://live.staticflickr.com/65535/52125050682_18841810ef_b.jpg) (https://flic.kr/p/2nq7vyo)Untitled (https://flic.kr/p/2nq7vyo) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
This spurred me on to get the engine built back up and put in the bay.
However, I had shot myself in the foot:
When plating all the bolts, I simply put them all into a container for safe keeping...
(https://live.staticflickr.com/65535/51627735699_244aff0e40_b.jpg) (https://flic.kr/p/2mEaD98)Untitled (https://flic.kr/p/2mEaD98) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
As it had been almost a year since pulling them all off the engine, I did spend a fair amount of time scratching my head about what bolts went where!
But before too long, we were looking pretty good...
(https://live.staticflickr.com/65535/52126571775_1281852275_b.jpg) (https://flic.kr/p/2nqfiJ8)Untitled (https://flic.kr/p/2nqfiJ8) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Then out came the trusty engine crane
(https://live.staticflickr.com/65535/52125051347_e9448d726c_b.jpg) (https://flic.kr/p/2nq7vKR)Untitled (https://flic.kr/p/2nq7vKR) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
And after watching a YouTube video about fitting an 020 clutch, I put the box back on and finally in the bay!
(https://live.staticflickr.com/65535/52125051397_2f110ee7b7_b.jpg) (https://flic.kr/p/2nq7vLH)Untitled (https://flic.kr/p/2nq7vLH) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Then on Sunday, I went to tinkering about with various parts, I rebuilt the driveshafts
(https://live.staticflickr.com/65535/52126098638_3d189ed869_b.jpg) (https://flic.kr/p/2nqcT5A)Untitled (https://flic.kr/p/2nqcT5A) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
And then turned my attention to the shifter linkage.
Turns out there were basically no bushes left in there.
(https://live.staticflickr.com/65535/52125051382_4ebcf87809_b.jpg) (https://flic.kr/p/2nq7vLs)Untitled (https://flic.kr/p/2nq7vLs) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
With a fair it of swearing later, I got the bushes fitted, only to find there was one bush missing out the kit!
So this is as far as I can go for now...
(https://live.staticflickr.com/65535/52125051262_d8fa9b34a8_b.jpg) (https://flic.kr/p/2nq7vJo)Untitled (https://flic.kr/p/2nq7vJo) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Also, it occurred to me this has to be on the road for next months meet!
Great progress Dave and some nice Jubilee pics of it too ☺
Nice work on the starter motor, wish I had done the same instead of buying new.
Gas n gears seem to have the best reputation for vw boxes. I hope to swap my final drive in the future so will definitely be calling on Mart's services.
Hoping you don't run out of time for 23-24 July!
Wish we could get red dipstick tubes you won’t be able to unsee it now , …. Looks amazing , well done
I painted mine red. Now the dipstick looks pink.
(https://i.imgur.com/19xvGdT.jpg)
Nice work on the starter motor, wish I had done the same instead of buying new.
Gas n gears seem to have the best reputation for vw boxes. I hope to swap my final drive in the future so will definitely be calling on Mart's services.
Hoping you don't run out of time for 23-24 July!
Yeah, about that, I've worked out I've essentially got three weekends left if I want to MOT it and get some shakedown miles on it.
It's going to be cutting it fine!
Wish we could get red dipstick tubes you won’t be able to unsee it now , …. Looks amazing , well done
Might paint the handle orange!
As for the progress, haven't got as much done as I'd hoped, I also forgot to take photos!
But the linkage is back on and setup.
The downpipe went on, then I sheared the last (and hardest to get at) bolt!
So it and the manifold had to come back off so it could be replaced, before being refitted... again.
But once that was done, I put the inlet manifold on, before turning my attention back to the fuel pump.
I stripped everything down, cleaned it up and went to refit my nice new Bosch pump, before realising it was for a 16v!
I also refurbished the handbrake tubes, so they're ready to go back on next time.
Ok, new update, lots of parts arrived, all new coolant pipes (took ages to buy the right ones), new alternator, new PAS and coolant reservoirs, radiator and loads of other parts that are very quickly bankrupting me!
A job I'd been putting off finally got covered, the fuel pump.
(https://live.staticflickr.com/65535/52158208613_91a3996506_b.jpg) (https://flic.kr/p/2nt3sfR)Untitled (https://flic.kr/p/2nt3sfR) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/52158208633_2a4cfec9c4_b.jpg) (https://flic.kr/p/2nt3sgc)Untitled (https://flic.kr/p/2nt3sgc) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
As usual for the under tank pump, the fittings were made primarily of dirt and rust!
But a decent amount of cleaning, some very careful work with the angle grinder, paint and stainless fittings later, we were ready for a refit.
(https://live.staticflickr.com/65535/52158440064_0480582baf_b.jpg) (https://flic.kr/p/2nt4D4o)Untitled (https://flic.kr/p/2nt4D4o) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Other things that were not photo'd was the completion of the brake lines (horrible job) and the installation of the new handbrake lines, including refurbishing the handbrake tubes.
Then I moved back into the engine bay, fitted the following:
Exhaust Heat Shield
Spark Plugs
Dizzy/Rotor Arm/Leads
Alternator
PAS bottle
Fuel Rail
Coolant Hoses
and probably a dozen other things I've forgotten about!
But at least it's starting to look like it may actually make the National Meet.
(https://live.staticflickr.com/65535/52158208623_d48fe2df91_b.jpg) (https://flic.kr/p/2nt3sg2)Untitled (https://flic.kr/p/2nt3sg2) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Been a busy couple of weeks, forgot to take photos of everything.
Stuff I did get was the radiator:
(https://live.staticflickr.com/65535/52192881157_13b348e860_b.jpg) (https://flic.kr/p/2nw7ack)Untitled (https://flic.kr/p/2nw7ack) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Not in the greatest of conditions, but a new Valeo unit and Lee spent a lot of time on the cowling gave us this:
(https://live.staticflickr.com/65535/52192881192_04f1f93c40_b.jpg) (https://flic.kr/p/2nw7acW)Untitled (https://flic.kr/p/2nw7acW) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
I'll try and upload the video later, but actually managed to get it running!
Few stupid issues, like dodgy hall sender, brand new thermostat leaking and an injector failed.
But to fault find, I ended swapping the ECU/Coil/Fuel Rail/Wiring and a host of other things.
Once it was running, I bled the brake/PAS/coolant system and put the wheels of choice on.
(https://live.staticflickr.com/65535/52194149684_02df21933d_b.jpg) (https://flic.kr/p/2nwdEhu)Untitled (https://flic.kr/p/2nwdEhu) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
By now, it was looking a damn site more like a golf, but there was still a load of works like wipers/interior/light checks etc.
I even ended up throwing a bucket of water over it for the first time in at least 7 years, scrubbed up well.
(https://live.staticflickr.com/65535/52194380095_a39fb0fefc_b.jpg) (https://flic.kr/p/2nweQM6)Untitled (https://flic.kr/p/2nweQM6) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Let's just hope the MOT man agrees
It's been a very busy couple of weeks for me, so busy I've been forgetting to take photos again.
It started off with the MOT, thought I was going to fail straight out the gate:
Turns out it was first registered in the country in July 92, so the system expected to see a catalytic converter on it and promptly failed it on emissions!
After a chat with the MOT guy (who agreed with me fortunately) he manually inputted the car and engine into the system and it went straight through.
Strengthens my theory that this car started off in Germany though.
After that, I had a load of little things, like timing (now I have a light), idle adjustment, and most of the interior!
Basically, if it wouldn't fail an MOT, I'd left it till after.
Did get a couple of shots of the cars together when I picked it up though.
(https://live.staticflickr.com/65535/52223247842_227c29d5b2_b.jpg) (https://flic.kr/p/2nyMN9S)Untitled (https://flic.kr/p/2nyMN9S) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/52224250146_e88ab9f37b_b.jpg) (https://flic.kr/p/2nySW6Y)Untitled (https://flic.kr/p/2nySW6Y) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
Just noticed the difference in brake discs!
Forgot to get an interior shot, but finished up the engine bay, for now
(https://live.staticflickr.com/65535/52224250371_2e532f55c6_b.jpg) (https://flic.kr/p/2nySWaR)Untitled (https://flic.kr/p/2nySWaR) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
I'm still looking for a few bits and pieces, but after looking back through a few of the original shots of it, I'd say it's definitely been rescued.
(https://live.staticflickr.com/65535/52224250201_297ff0489f_b.jpg) (https://flic.kr/p/2nySW7V)Untitled (https://flic.kr/p/2nySW7V) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
That looks so good … my fave colour …superb job
Looking good.
That reg date is a bit of a mystery, any thoughts on why it's not on a J plate?
That's looking gr8 Dave.
Just read this entire thread in one go.
Looking great.
I so wish I had the spare time to finish my Red one, its not like I dont already have 90% of all the parts needed and all the tools.
Thanks for the comments guys.
If I run the number plate, it dates it as a 91 car, but the V5 (that I checked when I got home) says June 92.
Bit of a bizarre one.
Ok, so the budget is all but gone, but ever since the National Meet, I have been hankering after a set of RAs.
After seeing other cars with them on, I knew that the BBS wheels I had on them had to go.
After keeping an eye out for a couple weeks, and then falling over at the price of fully refurbed ones, this set came up for reasonable money.
(https://live.staticflickr.com/65535/52302281077_6dc38bb80f_b.jpg) (https://flic.kr/p/2nFLRYR)Untitled (https://flic.kr/p/2nFLRYR) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
While they were all curbed the whole way round (yes, seriously!) they were all straight, no cracks and all had center caps.
(https://live.staticflickr.com/65535/52303731860_b307043a0d_b.jpg) (https://flic.kr/p/2nFUifm)Untitled (https://flic.kr/p/2nFUifm) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
So a whole day with a file and some sand paper later, I gave them a quick spray to make them much more presentable.
(https://live.staticflickr.com/65535/52303534044_9f0362511a_b.jpg) (https://flic.kr/p/2nFThrJ)Untitled (https://flic.kr/p/2nFThrJ) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
They are FAR from perfect, but they'll happily do until next year when I'll get them off for a proper refurb.
Got the stickers on order and the tyres booked for Saturday. :)
Can't go wrong with ra's in my opinion. They will finish the car off nicely. Fair play for the DIY refurb on them, I can't even bring myself to clean my ras 🤣
Cheers mate. I'm not looking forward to cleaning them either, used to have a set of RMs and they were such a pain in the ass to maintain!
when it comes to keeping wheels clean (and hiding crappy brakes) P-slots for the win :)) Shame 15s are so hard to come by
I had a mk2 on P Slots once, only 14s but they look great.
Think you really need 15s for a big bumper though.
Estorils get my vote - low maintenance. But deffo not diamond cut ;D
While not oem, the compomotives are super easy to clean!
(https://live.staticflickr.com/65535/48949381237_9f23f7835c_b.jpg) (https://flic.kr/p/2hzunEV)Untitled (https://flic.kr/p/2hzunEV) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
...and "brake dust" grey helps keep them looking smarter for longer too ;D
Over last week, I ordered the replacement stickers for the centre caps and got them on ready.
(https://live.staticflickr.com/65535/52316504058_779c56f2df_b.jpg) (https://flic.kr/p/2nH2KYE)Untitled (https://flic.kr/p/2nH2KYE) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/52316631785_d023996142_b.jpg) (https://flic.kr/p/2nH3pWR)Untitled (https://flic.kr/p/2nH3pWR) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
On Saturday, I took the wheels to my local tyre fitter to get them shoed up and on the car.
All of the guys working there came over to have a look at the old girl, at one point, I had three of them working on her!
Definitely think RAs were the right way to go though
(https://live.staticflickr.com/65535/52316631950_dccefbdcd8_b.jpg) (https://flic.kr/p/2nH3pZG)Untitled (https://flic.kr/p/2nH3pZG) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
(https://live.staticflickr.com/65535/52316631930_958f53c80e_b.jpg) (https://flic.kr/p/2nH3pZm)Untitled (https://flic.kr/p/2nH3pZm) by Dave Ackerman (https://www.flickr.com/photos/152481044@N07/), on Flickr
They do look nice Dave.
What have you used to protect the underside of the Golf? I've just bought some Lanoguard. If it's good enough for sheep! However you don't see many of them wading through salt water puddles do you? I'll see whether it stands-up to the hype/jet wash treatment as per You Tube vids.
I had previously tried Bilt Hambler which has worn off but I suspect I should have regularly re-applied.
Oddly enough, that's on my to do list.
I covered the welding in Hammerites under car protection stuff, but I'd like to go over the whole thing now it's mobile enough I can get it to a car lift.
Seen someone recommend Lanoguard, looks like good stuff.
Looks perfect mate the RA's really finish it off 👌🏻
Nice …