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Topic: Mk 2 16v restoration  (Read 6745 times) previous topic - next topic

Mk 2 16v restoration

Hi. Restoring a 87 16v I used to own in the early 90's and have traced and bought back. Pulled it apart. Looms out and all. . Rolling shell is in the body shop for a full windows-out respray. Engine is in workshop for minimum re-bore, new pistons, and exhaust valve guides, but otherwise looks good.  Gearbox looks good enough to go back in as-is. When the painted shell comes back the wheels and hangers will come off and all will be shot blasted and powder coated.  Off the interior will go to the trimmers.  Umming and ahhing over suspension. maybe just gas uprated struts. Got some 15 inch BBS cross spokes. Now ive got to remember how it goes back together - yikes. Wish me luck. 
16V GTI under restoration
Learning a lot  as I go along

Re: Mk 2 16v restoration

Reply #2 –
Hi Nige.

Keeping a photo record and will publish.
Just one owner all that time between me and , well, me, , although she had in her own and her daughter's name.
I tracked it down when I saw it driving locally and she was good enough to sell it to me when she gave up driving.  She then pranged it while we a]were negotiating, so it was written off by insurers on economy grounds, but I  bought it anyway to restore it as a project.
Just the budget slowing me down getting it back on the road. Hopefully end of September maybe, or definitely the Spring in full restored glory.
Eddie
16V GTI under restoration
Learning a lot  as I go along

Re: Mk 2 16v restoration

Reply #4 –
Look forward to seeing the pictures, sounds like a lot of work gone into her.
National Meet - 18-20 July 2025 @ Curborough Sprint Course

Re: Mk 2 16v restoration

Reply #5 –
Right, this is how it began:

I used to drive Golf GTis and once owned this 16v car.  I drove many happy miles in it, from around 30k.  An inheritance later prompted me to trade it in for a brand new VR6, which I then owned for 12 years. If I'm honest, the VR6, whilst being fast and smooth, felt soft and mushy in comparison, and I always preferred the feel and setup setup on the 16v.   Children dictated my choice of car after 2003, - currently an S-max, (which is actually a fine car).

As the years went on I started looking for a hobby car.  Seeing my old 16v still around in town a few times made me think of perhaps owning that car again. I started carrying a pre-typed note, and I even asked a few friends that remembered it to look out for the owner, and to let them know that I was Interested if it was ever for sale.  One day a friend rang me to say that he had seen it parking and had a chat with the owner (we'll call her Joan) on my behalf.  Joan had bought the car from my VW dealer for her daughter when I traded it in. Her daughter and her son-in law had driven it for a couple of years, then Joan  had  driven it ever since then.   Joan loved the car, and didn't want to sell it yet. She said she had been made many offers to buy the car, but she recognised my name from all of the old service history documents she had for the car, and so left her contact details for me.
 
I rang Joanand had a long chat about the car.  We compared notes on our respective times with the car, and liked each other immediately.  She said she'd be sure to let me know if she was thinking of selling. She warned me that the car had an agreed valuation on It with her insurers, so she wasn't going to give it up for a song!!  Not having a lot of money to spend, it seemed a bit of a remote chance to me. 

One sunny Sunday morning in October, I again saw the car and took some photographs (feeling a bit if a stalker!).   I saw that it has some of the classic golf  rust and damaged areas, but not many or extensive decay.  It looked a bit tired inside and out, with an aftermarket stainless exhaust that seemed slightly too big for it. But it seemed to be a structurally good and basically sound car.  But it was out of my league if it was expensive, though.

https://photos.app.goo.gl/vYAxEmc1SoQCUbY5A

https://photos.app.goo.gl/R4JusQoGRrxnaqmU7
16V GTI under restoration
Learning a lot  as I go along

Re: Mk 2 16v restoration

Reply #6 –
On the following  Tuesday I had a call from Joan in a very upset state.  She said that on the Sunday she had finally decided that she was going to ring me this week and offer me the car for sale.  She had driven it into town and parked (where I had seen the car and photo'd it).  Then she had driven to a supermarket where her feet had slipped off the pedals and she had hit a steel bollard stoving in the front of the car and spilling all the coolant onto the road.   Her insurers were coming to assess the car.
She seemed to be apologising to me for crashing what she clearly thought ought to be my car!  I told her I was still interested in buying the car if the price suited the condition, which cheered her greatly.

The insurance assessor wrote the car off due to light structural damage to the passenger side front chassis rail, combined with the need for  all of the front panels and bonnet to be replaced and painted.   They offered Joan the agreed value.  I had briefly looked at the car, and thought writing it off was a bit severe. I asked Joan to get a price to buy the car back from the.insurers, which she did. I paid what they asked via Joan and the car was mine.

https://photos.app.goo.gl/EoFEBSWxaT5FB223A
16V GTI under restoration
Learning a lot  as I go along

Re: Mk 2 16v restoration

Reply #7 –
Next weekend it started first go. I towed the car home and started to strip it down to see what was what, with my heart slightly in my mouth. 

First Impressions
The point of impact had bent all of the front panels and grilles, damaging the radiator, fan, and shroud.
The passenger side chassis rail was bent up in the middle, and seemed to have sustained  a fair bit of denting and paint damage before, perhaps from rough treatment when getting engine or gearbox out in the past.
The intrusion had touched on the front engine subframe, but the subframe looked intact and straight.
The bonnet was mangled but the rear anchors had held and the scuttle and screen were untouched.
The front outer wings were already a bit rusty and had been bent a bit, both historically and by this incident, but the inner wings seemed to have only been lightly distorted and were solid with no corrosion.
The front lights were all intact except both indicator lenses.
The gearshift felt very poor which made me worry the engine had moved, but there was heat damage to the plastic parts of the gear linkage behind the engine which I hoped was the true cause.
Otherwise:. The rear arches looked okay, but had been repaired a few times, so this was a likely problem area.
The sills, suspension and underside otherwise looked great. Very good for a 30 year-old car. 
The rear slam panel had been repaired more than once.
Inside:. The drivers seat foam is disintegrating, especially the door side lateral foam.  The seat tilt mechanism first work and the vinyl sides are torn where the tilt cables run. 
The head lining is sagging at the back. Probably a sign of the sunroof seal failing. 
The dash lights don't work.
The rear parcel shelf doesn't have speaker holes in it ( "uncommon" !),  but the hinges are broken.
An aftermarket radio proved so hard to remove I had to bend the cage and cut some wires, so this will need replacing.
Some extra dials had been fitted to the central console.  voltage, oil pressure, oil temperature.
At least two different aftermarket alarm/immobiliser  systems had been fitted, neither of which were operational.
Within the engine compartment, the engine had a lot of oil on the cambelt end.  It is hard to see if this is from spills when filling, but the extent of it looks like a cam cover gasket problem.  Joan said it didn't use much oil, but then she drove very few miles.
The cam belt felt loose, and I couldn't find any record of a belt change.

https://photos.app.goo.gl/pSeFMV4fPnEjzzS48
16V GTI under restoration
Learning a lot  as I go along

Re: Mk 2 16v restoration

Reply #8 –
I was still toying with having the front fixed and then doing a on-road restoration as funds allowed.
Not wanting to risk any engine damage, I thought I'd change the cam belt.  This means removing /replacing the water pump, but is easy with the front panels  of the car removed.  I started to do this, but one Allen key bolt into the water pump bracket that is inserted from the cambelt end of the engine just wouldn't budge and access was hard to do much about it. 
Not wanting to strip the Allen fitting, I abandoned the job. The engine had to come out and an impact driver used on it. 

This was the last small issue that made up my mind on a strip-down restoration - at least of the front end.  

Out she comes and lets see what's really to do. 

https://photos.app.goo.gl/mygnMP5vB8K7xdJ59
16V GTI under restoration
Learning a lot  as I go along

Re: Mk 2 16v restoration

Reply #9 –
I started to pull off and label all of the wiring and sone bulky /heavy ancillary engine parts., Labelling things as I went.   Fuel injection, plenum chambers, washer bottles and the like.   What it was clear enough, I removed the engine.  This was very tight, and I could understand how damage could easily be caused to the rails by attempting such things with the front panels of the car still on.
Once the engine was out, time to finish the bonnet strip.  I needed the chassis to roll, still, at it is being repaired and and painted a few miles away. So I had to leave rear engine subframe, steering rack, and driveshafts (you can't move the car without driveshafts in place or the wheel bearings get  damaged).
Brake servos and pedal connections and wiring looms were made easier by a complete dash removal, Including steering wheel.  This exposure might also make sorting and removing/replacing all the aftermarket wiring easier too.  But it doesn't look too tidy with the dashboard out.
The looms were difficult to get out and were labelled extensively.  I worry about my skills putting this back in, with all its clips and connections,  but all in good time!
So now the engine bay is clear, time to think about  cleaning the chassis up.  Trouble is, it will clean so much better with all the plastic body trim and lights etc removed, as who knows what's lurking?

https://photos.app.goo.gl/nAVMLiX4YRBrYB9T9

https://photos.app.goo.gl/yiqujxxiq6Y2Z9rm8

Another half day taking off trim and handles.
Dang! Last job before cleaning!   Removing a seized bolt in the rear spoiler. Rear window shattered.   Special one with three holes for the spoiler.  Ah well.
On to the wash pan. Jacked up one side.  Wheels off.  Seriously aggressive cleaning chemicals. Spray on.  Wait, steam clean off. Repeat and repeat.  Clumps of mud coming out of rear wheel arches.   Not rusty at top (maybe low mileage and garaging  meant it dried and stayed dry). But wheel arch rims have suffered a bit, especially bottom corners.
Wheels inside rims take some serious acid to clean too.
Result:  couple of new problem areas, but normal wheel arch stuff.  One area front of sill drivers side might need a small weld repair, or might clean up   Bit if rear balance attention needed.  But amazing underneath and sub frames.  Really good condition for 30 years old. 
Wheels back on to do the bodywork.
All amazing. Leaving the roof rail gutter and side rubber trims and the sticky stripes to the body shop. They look tricky.
Some wax still on the chassis has to wait until it is dry. But otherwise ready for the body shop. 

https://photos.app.goo.gl/nRFgnkJHvRqhunhm7

Here you can see the damage to the passenger chassis rail that made it an uneconomic repair for the insurance company, but easily fixed by a competent body specialist.

https://photos.app.goo.gl/dL8Vc6VUeZFBaMmi8

https://photos.app.goo.gl/S4SQ5HDNbnPFQeK87

Found a few hidden bits needing attention.

 https://photos.app.goo.gl/qd9gkLaRmmPPhgYt7

https://photos.app.goo.gl/hRQH6bQCsYSEPp777

16V GTI under restoration
Learning a lot  as I go along

Re: Mk 2 16v restoration

Reply #10 –
So, off to the body shop. Genius Paul in charge. Chassis rail, wheel arches and bits and bobs then full exterior and under bonnet respray, if you please. See you in a few months.

https://photos.app.goo.gl/fe7zTb1FdRQCuSSb6




16V GTI under restoration
Learning a lot  as I go along

Re: Mk 2 16v restoration

Reply #11 –
And so to the engine. Whats that oil leak from?

Well, stripped it down without much misadventure, shearing only two top-hose connection studs in the head.   Have to say, doesnt seem too worn to my lay eye, but at £125k miles, best to get a second opinion. Into the car then.

https://photos.app.goo.gl/JjagNcNW1iHzJCr37

https://photos.app.goo.gl/a99XNbfcVxGTrCoVA

https://photos.app.goo.gl/ZQ2vzc3nYCfmwNJx7

Kelvin at SES in Bognor agrees, its very lightly worn for the miles. Borderline rebore or just new pistons. But the bores are a little a bit oval, so rebore it is. Skim the head, (block is flat and doesnt need it).  Inlet valves and guides will come up nicely no change needed. Exhaust valves are fine, but guides are worn. So, good clean up, new exhaust valve guides and 3 angle cuts all round.  Crank is 'good as gold' so just a polish. New Mahle  forged Pistons and rings, and a new oil pump.  See you in a few weeks!
16V GTI under restoration
Learning a lot  as I go along

Re: Mk 2 16v restoration

Reply #12 –
So now, my car body has gone away, the engine has gone away, and i'm left to clean up all of the bits and bobs. Without losing the labels that say what it ids and where it goes...

https://photos.app.goo.gl/M2vzZhhXx1zFUHzS6

https://photos.app.goo.gl/dC2onRK2G9z43Q1n9

So-  looms are scrubbed,

https://photos.app.goo.gl/SNgcJkXrd42jRxm68

door trims came up fabulous

https://photos.app.goo.gl/BsRFkMJ33ooRtk3PA

Wishing i'd taken the seats out of the body now, but they can wait. Mirrors and door handles are refurbed and remotes working.  Engine ancillaries and injection bits all cleaned and ready to go back in.

https://photos.app.goo.gl/zAgea2Zdxn8dpZqv5

Taking the chance to re-plate some of the nickel bits - like this gearbox bracket

https://photos.app.goo.gl/23HaqDeFc5WWbTh69

now looks like this - wow.

https://photos.app.goo.gl/pDdc1wjvyAkHZi476

And to make the alloy bits stand out. This is Allochrome finishing. Double wow.

https://photos.app.goo.gl/mFAArtrUU5HyDDa29

https://photos.app.goo.gl/6pgJ3NK2CUtvAtu39

I've decided to take a gamble on the gearbox and not strip it down completely, as the engine was so lightly worm. That may be a mistake, but I can only cope with so much of my car in single components at a time! Ive replaced the linkages and it'll have a new clutch.

When the body comes back i'm going to:

1) Pull the suspension off it, shot blast and powder coat and back on with poly bushes.
2) Standard - but gas filled - struts, I think.
3) These cross spoke BBS wheels I have picked up (to be refurbished, obvs) as they were a standard option in their day ,  are 15 inch and easier to get decent tyres for than the original Bottle top 14s.  https://photos.app.goo.gl/pZpkcCYwuDn9Cpws7
4) Pull off the fuel pump and tank and underseal the entire shell while its bare.
5) Take out the seats and send them off to the trimmers.
6) Put in a new headlining.
7) Get an electrician to sort out the loom that ive by then  put back in all wrong (i suspect)! correct the multiple mods that have been made over 30 years of alarms and stereos, then put in a decent immobiliser.
8) I have a OE 1990 power steering rack and a selection of pulleys  to play with, so I may get the rack checked and see if I can add this period option.... views?

Then the rebuild begins.  Please do watch this space....


16V GTI under restoration
Learning a lot  as I go along

Re: Mk 2 16v restoration

Reply #13 –
Quote from: nige t on
Sounds really good. Do you have any photos of the work being done?
Has it had many owners since you sold it back in the 90's?

Hi, I have done a brief history and pictures to date in the thread now.
16V GTI under restoration
Learning a lot  as I go along

Re: Mk 2 16v restoration

Reply #14 –
Quote from: nige t on
It's a shame the insurance company wrote the car off, was it badly damaged or just cosmetic?
Has it been well looked after, with a decent service history?

Some chassis rail damage, not too bad, but understandably complex for the insurance company to write it off. 

Ive done some pictures of my findings and working to date. 
16V GTI under restoration
Learning a lot  as I go along