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Model specific boards => Golf mk2 => Golf mk2 gallery => Topic started by: jv on 30 October 2007, 20:07

Title: Darnpistonbroke - Golf G60
Post by: jv on 30 October 2007, 20:07
:)
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 31 October 2007, 10:03
Thanks JV.
Well I cant put too much down at the moment as I am working in Germany, so I dont have access to my pictures. I will return home every two weeks or so to give updates as and when.
I bought the car after selling my white 8v. I was going to buy a 16v, but this one came up at the right time and price, so it was bought for around a grand. The car has done 135000 kms which equates to just over 79000 miles. She is lacking in a little TLC as you will see later in the photos. I bought the car, and drove it straight into my garage where she has stayed ever since.
The list of jobs to do is long but distinguished including a full respray, compressor overhaul and a new camshaft. I may strip the head down later as she was smoking a bit. But I want to do the compressor first to make sure that was not the cause of the smoke.
I have done a bit to the car but dont want to give too much info yet without the pics, so please be patient. Also I need to experiment with photobucket. :cool:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 06 November 2007, 08:41
Well as mentioned in my last post, I bought this thing. The problems that I knew about were that the compressor needed overhauling and the camshaft needed looking at. I drove it home gently as the cam was very noisy. The compressor seemed to work ok but I didn,t push it, and then the throttle cable detached itself from the pedal. I fould out later that it had been rigged wrong. So someone obviously has been playing with this car without too much knowledge about what he was doing.
Well hopefully this will work. Here are a collection of pictures of the project so far.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007042.jpg)
These are the views of how it was when I first got it.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007043.jpg)
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007044.jpg)
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007045.jpg)
As you can see, the wheels have seen better days. Not too sure what to do with these.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007046.jpg)
Pock marks on the paint. A common sight here in Spain. Other people when parking their cars don't really care too much for other peoples property.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007047.jpg)
Scuffed bumper.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007048.jpg)
More pock marks but there is actually a dent there too.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007049.jpg)
A bit of adhesive required here. I would like to change it but I think I would do more harm than good.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007050.jpg)
NICE!!!
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007051.jpg)
The last owner had someone break into it. They stole the radio and also butchered the dashboard. There are three holes in it as in the next picture.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007052.jpg)
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007053.jpg)
Speaker grilles need replacing.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007054.jpg)
I threw the parcel shelf away as it was hanging. As you can see, the poor old girl has been a little neglected.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007055.jpg)
A filthy engine. Actually its mostly dust and dirt. Spain gets very dry and breezy and that is the result of 16 years of Spanish summers.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 06 November 2007, 08:50
As you can see from the pictures, the old girl would and will benefit from a respray. The paint work will polish up of course, but once the paint dies, its dead and will very soon dull off again very soon. Plus the damage done to the paint leaves one option. Respray.
I intend to strip the car down to a rolling shell, for a decent job. Bumpers, plastic trim, grille, lights and interior will come off for the paiting. The windows will also be coming out and the windscreen, which actually has a crack in it, will be replaced for one with a top tint. All the plastic work will be replaced including the bumpers.
Still not sure what to do about the wheels. I would like to fit ATS Cups, but the brake disc's are too big. I am thinking of buying a set of Cups, but with the offset for that of an Astra, then use 10mm spacers to set them right. Then the calipers will not scrub against the domed spokes of the wheels.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 06 November 2007, 09:02
I started in earnest about stripping out the car about two weeks ago. I was amazed at how different the interior goes together compared with my old 8v. The carpets were an absolute bugger to remove.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007056.jpg)
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007057.jpg)
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007058.jpg)
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007059.jpg)
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007060.jpg)

The dash came out fairly easily, better than I thought. And I didn't break any of the clips. I also found that the steering wheel was damaged. It looked as if the mice had been in there.

I went to the scrapyard to go shopping and came back with a Vectra estate boot full of stuff. Including a dashboard and some bits and peices of trim and carpet. And surprise surprise, there was a Golf G60 there with the compressor still installed. Looking back, I should have removed the copressor to have a better look at it, but they wanted too much money for it with no warranty. And as the car was still in one piece, ie not accident damaged, that meant it had been scrapped for a terminal failure of something. I didn't risk it.
Hopefully this week, I will get the old girl shipped off to the painters for work to be done whilst I am back in Germany working.
Stay tuned.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 07 November 2007, 21:49
A very brief update.
Went to the scrapyard again yesterday, (Tuesday) and found a half decent heavy duty parcel shelf. I intend to modify, strengthen and recover it. I will post a seperate section on this when I actually do it. I did it before on my 8v as shown below.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Golf%20II/September2007219.jpg)
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Golf%20II/September2007220.jpg)

I also located an unbroken 4 lamp grille with both its spots still in place.
And today, I solved the problem of what to do with my wheels. I found a refurbisher in Madrid, so now they have two of them. I will post before and after pictures later. Now I need to locate a set of centre caps for them. So if anyone knows of any...
And to round off, I ordered my bumpers from VW today along with the wheel arches, sill covers and, this I cannot believe, a red G60 badge as fitted to the grille!! :smiley: I thought these things were extinct. I am though, expecting a call saying that they are no longer available.
More to follow, but not for a couple of weeks as I have to go back to Germany on Friday. :cry:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 10 November 2007, 13:01
Just a quickie as I am now back in the Fatherland. Got round to hosing down the underbonnet area and found some accident damage on the front right quarter that has been bodge repaired.  :cry: B-LOX!! And there is also some on the rear left quarter but not so bad. I am told that the repairs are not difficult so fingers crossed.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 03 December 2007, 19:07
Well it's been a while since I posted, but to be honest, progress on the beast has not really advanced due to time, although money has been spent.
Christmas came early about three weeks ago. My new bumpers arrived along with new wheel arches and front bumper lower spoilers. These I bought OE from VW. I was going to use GPC but these guys proved to be extremely un-helpfull.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/December2007070.jpg)
I found a place in Madrid that refurbishes alloy wheels, so in mine went. The following are before and after pictures. I managed to find centre caps for my BBS and had them sent over from the UK. A huge thanks to Les of Veedubmachine.
Before.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/December2007061.jpg)
Another before.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/December2007064.jpg)
After.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/December2007065.jpg)
Another after.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/December2007066.jpg)

I bought another dashboard from the scrappy, because if you remember, the old one had holes in it. It came from an older car, and the carcass is made from another material like fibre cardboard. It needed a little repair work which I did on the plenum entrance. I did this with the help of araldite, sheet paxoline and a couple of rivets. I then gave it a good clean and it came uplike new.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/December2007069.jpg)
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/December2007071.jpg)
I have also bought a new set of speakers front and rear. Thy are nothing special as I am not after a base thumping mobile jukebox, just decent quality sound to listen to my eighties collection.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/December2007067.jpg)
The front tweeters I have already mounted to my dashboard as access is easier with dash rmoved. I mounted them in sheet paxoline and screwed them in place.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/December2007068.jpg)
Today I actually got some work done, buy as I said, not much forward progress. As the dashboard is out, I decided to quickly tidy up the mountain of spagetti. Did I say quickly? It turned out that the previous owner did not have a clue how to wire up radios and cable chasing was in order. He had wired up the speaker system, piggy backing the fronts to the rears, thus rendering useless the fader of the unit he was using. After pulling the various cables to bits, about 20 metres got binned.
I also temporarily fitted my rear wheel arch carpet covers to see where my speaker cables would come out.
Now I just need to run my rear speaker cables and the sub woofer amp cables, before I refit the dash.
The respray has been put off till the middle of January. Shame car body shops don't have January sales.
Thats all for now. There will not be anything further until January as I have to go back to Germany for a few weeks.
A Merry Christmas and a Happy New Year to you all. Thanks for looking.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 13 January 2008, 17:18
Not much done. Just removed the G-Lader today to take with me to Germany on Tuesday to have overhauled. Hopefully its not too bad.
Going to the scrapyard again tomorrow, then will attempt to fit the dashboard.
Also bought a power amp for the subwoofer yesterday.
Thats all.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 29 January 2008, 22:45
Well an update with pictures is long overdue. More money has been spent. I am now a friend of ebay and its amazing what stuff you find on there. I bought a pair set of leather gaitors for the gearstick and handbrake. The latter I was a little worried about finding a replacement, as G60 handbrake gaitors are different to other MKII's. Don't have photos of these yet, but I'll put them in the next post.
Anyway, as said, the dashboard is now in and wired up.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Jan200805.jpg)
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Jan200804.jpg)
I still have to fit the radio, but before I do that, I will lay in the cables for the sub woofer and amp.

What do I do with this lot then?? :undecided:
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Jan200806.jpg)

2 channel bridged amp. Nothing special but I'm not after a mobile jukebox.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Jan200808.jpg)

And the sub woofer.
This I got at a real bargain. It was about 80 €uros, but this one is an ex static display one and some thieving mongrel swiped the guard rods whilst it was in the shop. Anyway, I got it for 35 €uros, which is about £22.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Jan200807.jpg)

I set about cleaning up the inside of the doors too. The amount od crap that was in the bottom of the doors was unreal. But, there is absolutly no rust in any part of the car. Just shows how dry Spain is. Anyway, while the door cards were off, I sprayed LPS3, which is the aircraft equivilant of waxoil, on the interior of the doors. Then I refitted and patched up the door liner membrane. Those of you in the aviation industry may recognise the tape. :lipsrsealed:
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Jan200803.jpg)

I am now in the middle of laying in the cables, then the carpets will go in, followed by the heater.
The G-Lader is in Kassel, Germany at the moment, having magic done to it, I hope. I have also bought the new camshaft. A Schrick split duration 268/276. Photos of this will appear when I fit it.
I also have bought from ebay, and am still waiting delivery, a headlight wiring loom to make the headlights really shine. I am also waiting for aftermarket G60 badges for the rear panel and door trims. These are black and chrome effect. Pictures when they arrive. Another thing I have bought is the G60 front grille badge. But this will need modifying as it is from a Corrado, and does not fit the Golf standard grille.
Thats all I think for now. Getting near having it painted, but I need to make sure my next contract is a little more solid first.
Thanks for looking.


Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 07 February 2008, 22:26
Well, a bit more has been done today. I started stripping the exterior of the car to prepare it for paint. The bumpers are off as are all the plastic trims including wheel arches. I also fitted the new second hand slam panel as the existing one is quite badly damaged.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200801.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200802.jpg)

These are close ups of the damage I found on the old slam panel.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200803.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200804.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200805.jpg)

And this is the new one prior to cleaning and transfer of bits.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200806.jpg)

The car looks a little naked now and resembles a MK1 GL. The trim came off easily and did not hide much damage. But it did show that the car has had a little unhappy history. The front left wheel arch was butcher fitted and I had to resort to a mild form of butchery to remove it. I also found out that the right hand front wing is from a non G60, and has had to be modified so that the arches could be fitted. G60 have cut outs in them and square holes round the radius to allow the arches to be mounted properly. Or at least that is how it seems on mine.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200807.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200808.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200809.jpg)

A little damage here hidden by the rear left plastic arch cover. Nothing serious and the panel is not bent.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200810.jpg)

The following are the 'shiny bitz' that I have recently acquired.
Hand brake and gearstick gaitors...

Before...plastic stuff that is a little past it

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200811.jpg)

And after...nice smelling leather

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200812.jpg)

Cam shaft and tappets. Camshaft is split duration 268/276

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200813.jpg)

And lastly for today, rear panel and side strip badges.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb100814.jpg)

These last items have really thrown me into a dilema. I was going to go for smoked indicators and rear clusters, but now I have these lovely badges, I think that crystal may suit the car better. Please feel free to comment on this.

Anyway, tomorrow I will continue to strip the car, ie aerial, mirrors etc. Then off to paint next week.
I may update again tomorrow, it depends on how much I do. Thanks for looking.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 14 February 2008, 21:13
OK. A few more bits and pieces have been done to progress the beast. The seat bolster on the drivers side, that is the left seat to me here, and also to all ORIGINAL G60's, was way past it. There was foam crumbs all over the carpet when I first bought the car, and when I removed the seat and stripped it down, I found this:

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Jan200801.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Jan200802.jpg)

I had an hour or two trying to repair it like I did with my old Audi Coupe a couple of years ago, but the foams are slightly different, so I lost interest. Now the foam bases are the same for the both front seats, so I set about finding a decent passenger side one, and came up with this.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200815.jpg)

This is also the result of washing it and waiting for over a week, yes, a whole bloody week, for the damn thing to dry out. But the end result was this.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200816.jpg)

Before putting the seat back together, I puy tape over the sides of the bolsters in an attempt to give it some protection against the constant rubbing from the fabric covering when ever the seat is occupied, (spelling check please!!). The result is a very comfortable and firm seat. I then cleaned it with foam upholstery cleaner. Now I have to check the passenger side and then clean all the seats.

I set about today finally preparing the car for the paint shop. I removed the windows successfully, ie, didn't break one. But found the only bit of rust on the car. Two tiny scabs where the rear quarter windows fit into metal clips. Well the clips were rusted away and it had started into the window aperture.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200820.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200819.jpg)

These last photos are rubbish. I think the camera was trying to focus on the things in the background.

It's not bad at all and I am certaily not worried about it. Now the car resembles a ghost car with no windows except the windscreen, which is the original from the factory, and is bonded in. It's amazing how the G60 differs from its 8 and 16v cousins. I didn't even attepmt to remove it as the glass would have gone in a big way as it is already cracked. I have spoken to the body shop and they said that they will remove it. I intend to replace it with a top tint windscreen and have it fitted with a conventional rubber.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200818.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200817.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200821.jpg)

The shaded areas that you can see high-light the parts of the car that I want re-profiling and repair work. There are also a couple of holes that I want smoothing over, one of which is the VW badge recess in the rear panel.

I came to the UK on work business for a couple of days and took the opportunity to do a bit of shopping. I went to GSF and bought an eyebrow spoiler for the front, a set of exhaust mounting rubbers and pair of new door handles. I also visited Stomper in Reading and bought his steering wheel, which I am delighted with.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200822.jpg)

The silver ring in the middle is actually black, the camera flash caused the silver effect.

The car was meant to go to the body shop tomorrow, but it has now been postponed till Tuesday, so it is sat outside under a silver car cover which has a habit of blowing away. I just hope no-one takes too much interest in the car as it is really open to the elements, not even sporting door handles. Fingers crossed.
More pictures next week as I watch get transported away.
I am not sure if I will be able to get pictures of the body work repairs, preparations and final painting as I will be back in the cars' home country, Germany, whilst it is being fettled. But as the painter is a neighbor and a BBQ pal, I will ask him to also take my camera.
Thats all for now. Thanks for taking the interest.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 19 February 2008, 15:36
Ladies and Gentlemen, the car has left the building.... And is now in the body shop!
I took some photos of the loading and of it nestled in the body shop amongst other cars such as Mercedes, Jaguar etc. My old bug brought the neighborhood down a peg or two, but soon it will be up there with the best, where it should be.
I had to buy a new wing yesterday. Did I say new?? A new one for the G60 is 154 €uros + VAT. G60 wings are a little different from normal Golfs. Anyway, the reason being is that when the shoddy repairwork had been done previously, a pattern wing was used and modified. But the panel gaps with this wing on were 'orrible. So of to the scrappies again and I wrenched off a minter, in the same colour. I also bought a rear windscreen as mine had a deeeeep scratch, almost a crack, and the demist heating element is a little past its best. Total spent, 40 €uros. I spent this morning modifying the wing to G60 spec and placed it in the car for the paint shop.
I have photos, but I gave the camera to my mate the sprayer so that he can take stage photos during the prep and paint process.
I get the car back in a couple of weeks. Meanwhile, tomorrow I return to the cars' home country Germany for two weeks. I have a feeling these two weeks are going to drag...
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 08 March 2008, 23:16
Well the two weeks dragged. 14 days of 12 hour day shift without fixing a single plane. Yawn.
But anyway, back to the more interesting stuff.
As I said before, I bought a replacement wing which I had to convert to G60 spec. The wing as bought:

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200801.jpg)

The wing after mofification by me.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/march200802.jpg)

Then came the time when the old girl was loaded up to be taken to the body shop.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/march200803.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200804.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200805.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/march200806.jpg)

And this was taken showing the old girl in her new home for the next couple of weeks.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200807.jpg)

It was at this point that I left the camera with my friend the painter, and he did me proud. Continued on the next reply.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 08 March 2008, 23:36
Well two weeks went by with me in Germany, but when I returned, the following was the result. There are rather a lot of photos, so I hope thay won't be too boring.

The work started with reprofiling the passenger door. (Remember I live in Spain and anyway, original G60 Golfs are left hand drive.)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200809.jpg)

Then the bonnet came off for masking and better access to the passenger side front corner.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200810.jpg)

The dent was removed from the rear panel and reprofiled.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200811.jpg)

And the 'crap repair' from a previous accident was also reprofiled.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200812.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200815.jpg)

Filler primer going on.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200813.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/march200816.jpg)

The rear apperture where the VW ensigner was, now filled.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200817.jpg)

Masking up for priming.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200818.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200819.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200820.jpg)

Primer on.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200821.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200822.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200823.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/march200824.jpg)

Masking up again for final paint.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200825.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200826.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200827.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200828.jpg)

In the spray booth/oven.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200829.jpg)

Final masking.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200830.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200831.jpg)

End result. The picture are quite poor. There was dust or paint on the lense.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200832.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200833.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200834.jpg)

New top tint window going in. G60's and Rallyes have the windscreen bonded in as it adds to car rigidity. It also adds to the cost! :cry:
The chap pictured is Javier, and did all the work including the paint. He is a good friend of mine and lives just round the corner from me. He was just giving the glasier a lift with the glass.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200835.jpg)

Beginning the journey home.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200836.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200837.jpg)

More to come over the next few days. There will be a couple of before and aftershots as well as the rebuilding of the beast. Stay tooned.



Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 12 March 2008, 22:30
Well work has progressed with the rebuild, but first a couple of before and after shots.

The dent in the left hand rear wheel arch.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200810.jpg)

The same wheel arch now.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200841.jpg)

You can probably make out where the VW badge goes, or should I say, went.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Feb200817.jpg)

Same panel now.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200839.jpg)

There used to be an antenae hole here that had a rubber grommet blanking it.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200840.jpg)

This panel behind the drivers door, (LHD) had a big dent in it. Not any more!!

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200838.jpg)

Colour coded armour door plates.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200842.jpg)

I have spent most of the last couple of days fitting the interior and trying to remember where everything went. I also cleaned up and fitted the door and body plastic trims. I bought two new door handles from GSF and quickley wished I hadn't. Where the passenger side works to effect, the action is nothing short of disgusting, and the drivers side just jams. These items are very poor quality and I would suggest to anyone to buy OE. I will be keeping the passenger side one, but I need to go to VW soon to get a real one for the drivers side.
Anyway, I got most of the interior in, including the rear seat, although ideally this needs replacing as the condition of the interior of the seat is poor. But it look OK from the outside. I replaced the backing of the seat upright as the original was 'orrible. Anyway, a couple more photos of the interior.

Before.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/October2007050.jpg)

After.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200844.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200843.jpg)

The carpets I cleaned thoroughly before I fitted them. Took a few hours. The photos are just fitted and after I had my grubby, (well, a little dusty) feet all over them. So a little more vacuuming is needed.

Finally, I fitted my new leather gear stick gaitor and new gear knob.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200845.jpg)

Now, about this gear knob. When I bought it, I thought it was the same as I always buy for my Golf. However, when I removed it from the package, little neon lights started flashing and beeping on the top of it. HOW CHAV IS THAT??? Well, the batteries came straight out!! Needless to say.
I will be continuing with the rebuild over the next few days. Tomorrow, I hope to have the interior fitted, all bar the radio and sub. Then it will be to the brakes and wheel arches.
I have new slotted discs and green stuff pads to fit. These took a LOOOOOOOOOOOONGGGGGG time to arrive from the UK, but at least now I have them.
Hoping to get the bumpers on by the weekend.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 17 March 2008, 21:24
Well alot got done this week. The plastic work got fitted as did the bumpers. The bumpers, I had to put together first as, if you buy them from VW, they are able to sell just the covers, and you fit them yourself to your existing bumper frames. Cuts down on the cost of buying a complete bumper.
I also fitted the disc's and green stuff pads. The exterior of the car is now nearly finished as you will see from the pictures.

This is with the new arches on and the wheels, which were refurbished a while ago, with new centre caps. The rear bumper is also fitted in this shot.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200846.jpg)

Close up of the front wheel with the new slotted disc behind it. You may be able to just make out the green brake pads.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200847.jpg)

Bumper fitted and replacement smoked light clusters which were bought from ebay. Also a brand new number plate.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200848.jpg)

The next couple of shots are of the colour coded mirrors. I fitted these earlier today.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200849.jpg)

Another view of the mirrors. Also today, I fitted the new window window rubbers. That was a job that takes time to get right...with the aid of a plastic hammer!!

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200850.jpg)

The front bumper I put on yesterday after cutting out the holes for the fog lamps. It fitted perfectly with no adjustments needed.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/march200851.jpg)

Front view.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200852.jpg)

This is a shot of new tail gate struts. They are a bit bling for my taste but thet are stronger than normal ones and will support the weight of the stealth shelf when I get round to fitting it.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200853.jpg)

This is as far as I have got so far.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/March200854.jpg)

Off to Germany again on Thursday. When I return in two weeks, the engine will be seen to with a new cam fitted, overhauled supercharger and remapped ECU. I will then fit the grille and finish off the rest of the interior, and hopefully, give the old girl a blast for the first time. Hoping to take it to Le-Mans this year, but we'll see.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 16 April 2008, 09:47
Well, I have been back from the fatherland for nearly a week now and have done some more to the velocopede. The weather here in Spain is warming up, so time for a little ICE. (I'll get my coat.)

As you have seen from the precious posts, I have been gradually accumalating various bits 'n' bobs including audio equipment. I have not got round to connecting up the amp or sub yet, but this will hopefully be done later this week. But anyway, to start with is the stealth shelf.

The top.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200801.jpg)

The underneath.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200802.jpg)

Stealth shelf split. The speakers are actually fitted to the smaller board, then the board is fixed to the main shelf.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200803.jpg)

I neglected to take a piccie of the holes cut in, but these are the speakers fitted.
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200804.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200805.jpg)

Because of the height of the tweater mounts, I have had to add a small frame around the circumfrence of the board so that the said tweaters to not foul the main shelf once mounted. You should be able to see the frame in the last shot. This also meant I had to find some longer screws.
The shelf is not yet finished as I need to buy some metal mesh to go over the speakers so that anything placed on the shelf, will not damage the speakers. I will then cover the lot with parcel shelf covering. I will cover the remainder of this part at a later date.

The head unit fitted. This unit is also blue tooth. So I can make phone calls legally. (Ish).
(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200806.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200807.jpg)

The next shot is of a rear window demist switch. I will not need the sub woofer working 100% of the time, but as the power amp is switched on when the radio is, I incorporated this switch into the power amp switching circuit, so that I can turn the sub off when I don't need it.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200808.jpg)

The next photo is of the switch installed. I painted out the picture of the demist sign, but the paint was still wet when I took the picture, hence the reason why it looks shiny. It is actually painted satin black.
I am sure you will agree that this will look better than a chrome toggle switch mounted onto one of the blanks.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200809.jpg)

The next shots are of the inner door membrane. I was not entirely happy with my repai effort of a few weeks ago. Here is a reminder shot. Looks pretty cack I am sure you will agree.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/Jan200803.jpg)

So I bought from ebay what I thought was a door membrane kit from Cheshire salvage.  What I got and paid a fortune for was nothin short of two sheets of clear plastic that is available for pence practically anywhere. I was not impressed and I urge people to stay clear of these rip off merchants. But as I am in Spain, it is pointless to do anything about it, and make the best of what I had.
So I cut to shape these sheets and fitted them with industrial strength double sided tape. (Being I was supposed to have bought a kit, all I got was the plastic and nothing else! :angry:)
Anyway, the end result is this.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200810.jpg)

Then the door card, along with chrome door handles, polished aluminium mirror adjusters and lock pins. (Very sad)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200811.jpg)

Lastly for this post, I fitted the G60 logos to the rear of the car and the door trims. I like these alot.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200812.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200813.jpg)

That is all for now.
Today I will be fitting a new suspension and lowering kit. I have also seen on the post tracking that my compressor and ECU should be delivered today. I was going to send these to Germany as I said a few months ago, but I had a change of heart and sent them to Jabbasport. Talk to Brian there. He is very knowledgeable and helpfull. I have had the compressor overhauled to a stage 2 with a 68mm pulley. I considered a stage 4, but decided against it as I want to preserve the life of both the compressor and the engine. As it is, with a ECU re-map, a 68mm pulley and my special cam shaft, I should be pushing in excess of 190bhp. And later when I replace the exhaust and manifold for a tubular one, and fit the larger intercooler that I won off ebay, I could be reaching an optmistic 200bhp. Well, we will see! I am a realist, not a dreamer.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 16 April 2008, 12:53
Breif update. The post has just come with my compressor, ECU and new tension spring. Oh yes, I'm a happy bunny. Was going to fit the suspension today, but now I'm going to get the old girl running.
STAY TOONED!!! :laugh: :laugh:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 22 April 2008, 09:07
Well, this is a long overdue update, purely because I was concentrating on working on the car. Anyway, progress has been made.
As in my last update, these arrived in the morning.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200814.jpg)

So I dropped the idea if replacing the suspension, and started the engine work.
First was to fit the cam shaft. This is the old one still in place.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200815.jpg)

Then both side by side. Spot the difference.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200816.jpg)

I went about fitting this, but as I don't have a manual for the G60 engine, I had to rely on experience to get it right. Alas, I do not have any further pictures of the engine work as, to be honest, I got so engrossed into it, I forgot!! My bad!
Anyway, I got the cam changed with no problems at all, along with all the drive belts, including the serpentine belt that runs the compressor , the water pump and the alternator.
The tensioner pulley for the cam belt was absolutely knackered. I would have given it not even one hundred more miles before it would have caused some serious damage to the engine. It was as dry as a bone, half the bearings were missing where they had broken up and if you got all the bearings to one side, the pulley would cock over to one side. Far from satisfactory.
Word of warning to those who do their own maintenance, or even to those who get it done at the garage, always replace or insist on having replaced, the cam belt tensioner with the cambelt, whatever the condition. Its false economy not too! I always do, and this is the first time I have seen one in this state.

Next I fitted the compressor. Once it was in, I had to try to remember the routing of the serpentine belt as it had been a while since I took it apart. I finally got there and fitted the new tensioner spring. This thing is similar in appearence to a shock absorber from the suspension and I suppose, does exactly the same job. I bought a new one from Jabbasport, who also modified for me to make it a tad longer. Remember, I am using a 68mm pulley.
Whilst all this was going on, I had the oil draining away for a oil change and filter change. I used fully sinthetic competition oil suitable for turbo charged applications. We will see how it goes.
I have no pictures of under the bonnet, as quite frankley, I am too embarrassed. :embarassed:
I have done no detailing of the engine bay at all and it does not look very good. The reason being is that I want to prove the engine first before cleaning it up. If it goes bang, then the engine would need to come out anyway to be repaired. I aim to remove said lump later during the year to do detailing work, and I only want to do it once. That is my excuse, (and I think its a bloody good one) and I am sticking to it. :smiley:

Anyway, back to the car.
I got the engine started after a while, as I had not put the distributor shaft back in the position it was in originally. The last person to do this got it wrong and adjusted the timing accordingly, which is common practice, and to be honest, a bit gash. So I fitted the cam belt with the distributor drive shaft in the correct position, which of course threw the timing out. So after fiddling with the distributor, I finally got the engine fired up, but it ran horribly. When I come to the UK next week, alas without the car, I will be buying a Corrado G60 Haynes manual so that I can check my own work against the book of words, and also set up the engine properly. But, it is drivable and you can tell, even though it is not running right, that the power from the cam (Schrick 268/276 split duration), the 68mm pulley on a stage 2 compressor, and the re-chipped ECU is wanting to unleash itself. Can't wait to get it running right and get the compressor run in.

Back to the interior. In my last post, you saw me starting to build up my stealth shelf. Well, yesterday I finished it. I added a little more material to the shelf in order to support the wire grille to cover and protect the speakers.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200817-1.jpg)

Then I added the grille.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200818.jpg)

I then covered the whole lot in parcel shelf material and fitted it to the car. It still needs a little tidying and I will do that at a later date.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200819.jpg)

I then set to finish the rest of the interior. Pictures of this will appear later today once I have given it a good clean.
But yesterday, I did clean the exterior and threw some polish at it, so here is a taste of what is to follow later when I take her for a little photo shoot. :smiley:

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200820.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200822.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/April200823.jpg)

I am more than happy with the final results. She will never be a show car, that was not my intension. But she will not let herself down if I ever attended one.
Now take a moment to look at the photos of her when I first bought her and compare.
More piccies to follow, hopefully later today.
Thanks for looking. :smiley:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 22 April 2008, 15:15
Unfortunately the photo shoot will have tp be postponed due to running out of time. :cry: I am off back to Germany tomorrow and time has caught up with me, plus I just took the old girl out for a spin to the fuel station and back, only to find that one of my new G60 badges that fit to the door outer trim is gone. :cry: :cry: So I have to try and order another one from the UK. This time I'll araldite the b@+*$£d on there!! :evil:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 22 April 2008, 21:22
Unfortunately the photo shoot will have tp be postponed due to running out of time. :cry: I am off back to Germany tomorrow and time has caught up with me, plus I just took the old girl out for a spin to the fuel station and back, only to find that one of my new G60 badges that fit to the door outer trim is gone. :cry: :cry: So I have to try and order another one from the UK. This time I'll araldite the b@+*$£d on there!! :evil:

My wife found the badge lying on the garage floor. :smiley: Now where did I put that araldite?? :rolleyes:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 05 May 2008, 23:15
Sorry, no pics in this thread, just a small update.
I am in the UK at the moment, and today I picked up a full Jettex exhaust system for the red velocopede, and a larger rad and intercooler that I won off ebay a few weeks ago. Can't wait to get home now to fit the exhaust and also fit the new suspension kit I have bought for it. I need some plumbing for the larger intercooler and radiator, so if anyone can help me source these items, I would appreciate a P.M.
Thats all for now. Hopefully an update with piccies next week.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 02 October 2008, 21:04
Well, where do I start? I will try not to cover old ground even though some of these pages have been lost during the forum down time, but loads has been done. I just have to try and remember chronologically what I did.

As you have seen, the Jetex exhaust has been fitted but there are a couple of problems with it. I will get to that a little later.
A couple of piccies, most of which have been put in other pages of this web site.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/June200806.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/June200810.jpg)

I have bought quite a few things for the old girl and they will be covered when I get to that part of these post's. I had my set of Sebrings refurbished and I intend to use these as my winter wheels. They were in a horrible state when I got them, but alas, I forgot to take any snaps of them. But here they are finished.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/151.jpg)

I was thinking of doing them black, but thought better of it and had them done in original silver. Easier to sell on if I needed to.

I am not happy with the passenger door, (UK drivers door. This one is a lefty!) as it has suffered damage in the past and the lines are not straight. Even when it was in the paint shop, the body repair chap said it would be almost impossoble to get it right as he had reconed it had been repaired on at least three separate occasions previously. So I bought this from the scrap yard.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/152.jpg)

I stripped it of all the parts and gave it to the body shop that painted the car where they sprayed it as a freebee. But my pal no longer works there and the job I got back was disgracefull! I was and am not happy. :angry: I did not ask for a freebee, it was their choice, but you would not put this on your dogs kennel! So I still need to get it redone before I fit it. I also got the window for it as my existing one has a deep scratch.

Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 02 October 2008, 21:17
On with the job!

I though it was high time I fitted the new headlamp wiring loom as it has been sitting in my garage for a few months now. It is pretty easy to install, but routing it safely is a pain in the arse. I installed the relay pack directly behind the drivers side (LHD) headlamp.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/153.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/154.jpg)

I offered the relay pack up and marked the hole positions, then drilled and fitted rivnuts. For those who are not familiar with these things, they are tubular nuts that are fitted almost like a pop rivet. You need a special tool to fit them and are a more proffessional way of mounting components rather than using self tapping screws.

Then these came throught the post courtesy of Les Bray of Veedub Machine ebay.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/155.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/156.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/157.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/158.jpg)

 :cool: :cool: :cool:

I also bought a few new sets of adjusters as the old ones were in a pretty poor state.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/159.jpg)

Then I set about fitting the spotlamps to the grille.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/160.jpg)

And this is the final result.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/161.jpg)

A sad mirror shot!  :embarassed:

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/162.jpg)

Then the main headlamps were fitted.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/163.jpg)

More coming!
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 02 October 2008, 21:44
No piccies here.
I wanted to sort out the bad running of the car and practically eliminated everything except the brake servo, so I went out to get one.
I went to VW, but they wanted blood money for one, so I went to my trusted hole in the wall to see if they could help. They got back to me within the hour and came up with an original Bosche one for half the money VW wanted. So that was bought and I had a smile on my face. :smiley: I then got a new master cylinder from ebay. I wanted to replace these two anyway as my brakes were not the best in the country.
So now the interior had to be stripped around the pedal box area to get to the connection between the servo rod and the brake pedal.
The servo was replaced along with the master cylinder with no real drama's. One of the brake pipes was a bugger to get on, but a cup of tea's rest sorted that out. Bleeding the brakes was a different story. Because the master cylinder was new and empty, only air was being stretched and compressed. So I got hold of the tube from the vacuum cleaner, took a deep breath and blew into the top of the reservoir whilst my assistant pumped the brakes, in a vain attemped to force fluid into the master cylinder. It worked and the brake bleeding was completed with an hour, with all the brake fluid replaced. I don't think the system has ever had a fluid change before as the colour of the fluid coming out was pretty crap.
Now I have very hard brakes all the time so it was all well worth it.

I then set to set up the cars injection system. I bought a new CO meter the last time I was in the UK, so this came out of its box for the first time.
I connected it all up and started the car. It was run up to operating temp, so the games commenced. The initial reading was 15.2! :shocked: :shocked: :shocked: No wonder I had no freekin' power! I wound out the grub screw and the revs went sky high, so that was adjusted too. I finally got the emmissions down to about 2.5, still a little high but MOTable. I want to run it like this for a while to let everything settle down, then I will re do it. But I still have the problem that I lose power with the lamnda connected!!  :undecided: This is throwing me a bit, but I'll sort it in the end..........I hope! :lipsrsealed:
A quick test down the road, and I would not say that I have all the predicted 190BHP, but its definately getting there! :smiley:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 02 October 2008, 21:56
Back to the exhaust problem. The damn thing was banging on the axle beam. Now those of you who have the Jettex system will know that it rest's with less hangers than the original factory system. And it's heavier. So I took it to a garage to see about having an extra hanger welded. The problem, admittedly is because the car is lowered, but I need to investigate other avenues before embarking on yet another suspension kit.

Anyway, before modifications.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/164.jpg)

After the hanger was welded in place.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/165.jpg)

The extra hanger was removed from my old system with an angle grinder.

I took the thing for a test drive and it still banged, so back up on the ramps. I loosened off the clamp that connects the back box to the main system and pulled the joint apart to raise the bend higher over the rear axle. It is better, but not perfect. I now need to look at the suspension and raise it a little. Coming to thing of it, I believe the shocks can be adjusted by removing the snap ring that supports the spring housing and moving it up to the next ring groove. I will look next time I am home. Having said that, the thought of having to strip out the suspension again is not an appealing thought.

Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 02 October 2008, 22:24
I have been winning a few items from ebay, (Dubster, I missed out on that spoiler because I cocked up at the last minute! :angry: Any ideas where I can get another one?) including a spare ECU, (which incidently had to be returned as it was incorrectly advertised and not for my car) a replacement polished rocker cover, a G60 grille badge, (still yet to be delivered) some sharks fins that fit over the spokes in the lower part of the front bumper, (again, still to be delivered) and a genuine Golf G60 carpet set which I won from German ebay! I say genuine as they are different to the 8V and 16V carpet sets due to the different shape and size of the centre tunnel.
This is what this part of my update is on.

The original carpets that came in the car stank! The sound proofing was wet and the drivers footwell plastic heel guard was damaged.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/166.jpg)

Also the edge trimming and stitching was in poor condition and bleached with wet and age.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/167.jpg)

So out came the interior again, this time including the centre tunnel carpet, which I did not remove originally. And guess what, it was soaking and stinking. That's what you get for not removing it in the first place. (puts two fingers to temple and pulls the thumb)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/168.jpg)

The 'new' carpet did not come with the sound proofing, so I went down to the local equivelent of B&Q and bought some builders grade high density foam sound deadening stuff.
I used the old sound proofing as a pattern and cut out the required shapes. I then removed all the old sound proofing felt from the old carpets. This is glued onto a sort of plastic or plastic coated high density card backing, and it was this backing I needed. I then removed the backing and used spray contact adhesive to glue the new foam to the backing. I then glued onto this my new carpet.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/169.jpg)

I did this twice, one per side and the results are very satisfying. I then proceeded to fit the new carpets and finally managed to force them round behind, or should I say in front of the air mixing box. It started to look very nice.

Whilst I had the interior out, I decided to mount the sub amp where I intended to in the first place. I looked up on Dubsters project pages to see how he had done it and, well, basically did the same. I had this idea a long time ago but not much of an idea on how to do it. :lipsrsealed:
I de-rivetted the side panel support and packed out the cavity with the foam I had left. I then cut up an old seat back I had as a spare and trimmed it to fit inside the cavity. I then mounted the amp to it and fitted it inside the cavity and wired it up. After a quick test I carried on with the refit of the interior.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/170.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/171.jpg)

All the carpets went in quite quickly.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/172.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/173.jpg)

What?.....No amp....? :smug:

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/174.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/175.jpg)

Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 02 October 2008, 22:34
This last post is really to show where I have got to with the car to date. It is out of ITV, (MOT) but that will be done when I go back home.You will also see that the rear wiper is now laid flat!  :cool: Anyway, photos to enjoy or laugh at!

Crystal headlights, spotlights and foglights. The headlamps incidently have 100watt bulbs, and togeter with the wiring loom upgrade, well, put it this way, I saw the planet Mars the other night!

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/176.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/177.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/179.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/180.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/181.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/182.jpg)

Thats all for now. I will be taking a trip to the scrapyard again when I get back as I need a couple of bitz 'n' peices such as a new grille, a piece of trim, intercooler shrouds (from a deisel) and a peice of trim for VW Virgins MKIII. (I have not forgotten you! :wink:) and the list goes on.
Thanks for looking. :smiley:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 03 February 2009, 19:21
Not really an update, but more of a 'what's gonna happen' post.
My car was banished to the street for a while, until we get our new shed built. So the contents of the old shed ended up......in the garage! So no room for the car. Anyway, after all the snow and rain we have had lately, I found a nice little puddle in the drivers footwell and in the rear right footwell too. :angry: So now the carpets have to come out yet again. Bugger! :cry:

SO! Once the new shed is built and I can have my garage back, the car is going to reside in there for the forseeable future, because I am going to rip the engine and gearbox out. :evil:
Whilst it is out, the whole of the engine bay is going to get sealed and detailed with new paint and repaired as required. The engine is going to be partially dismantled and freshened up with new rings and bearings and a new oil pump too. It will then get a coat of paint along with the gearbox, and be re-installed with new rad and intercooler a la Rallye! It will also go in with a tubular manifold thingy too!
I already have a full set of new engine mounts for it and the gasket set. The rest of the things will get bought once I know the state of the engine. If the bores have gone oval, then it will get bored out to 2.0 litres. But I don't really want to go that route unless I really have to.
Thats about all for now. This I hope will start within a couple of months, so watch this space. :smiley:

Oh, nearly forgot. I have a car set of poly bushes which may get fitted in the mean time. I also have a brand new G60 grille badge which cost me a fcuking fortune! :angry:
I am also thinking of returning the ride height back to standard as the ride is a little harsh and I can't stop the exhaust from banging against the rear beam.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 04 February 2009, 19:46
Well, I posted that too soon!^^^^^^^^^^
Just lost my job, so project is on hold for a while. :cry:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 15 March 2009, 20:58
Not much of an update and no pictures as a door looks like a door. The passenger side door, (drivers side to you) had damage on it which was very difficult to re-profile during the painting a year ago. So as you may remember, about 6 months or so ago, I bought a replacement door and got it sprayed by the same company that did the original paint job on the car. However, my mate who sprayed the car had since left and the paint job I got back was crap! :angry: So I waited all this time to get it sorted, but have since found a job in England, and the shed is coming with me. So I decided to fit this door without having the crap paint seen to. The damaged door paint had flaws in it too so I lose nothing by changing it. I would rather have a straight door and crap paint rather than a damaged door and reasonable paint.
Anyway, all went went well and now the lines down the car are much more acceptable. :smiley: I transfered all the internal workings of the door including electric window mechanism, door latches and lock, harness etc, from the old door and into the new one, and it all works. I plan to get the whole side of the car, including a replacement wing resprayed at some point when I return to England.
My job for tomorrow is to raise the suspension to stop that infernal exhaust from clouting the rear beam and to try my other ECU and see if I can resolve this lambda probe business. Then on Thursday, it's pack the car up with half a ton of tools for my work, pack in the suitcase and other things and hope the car is reliable enough to get me to Bournemouth via the Bilbao/Portsmouth ferry over Friday and Saturday. Watch this space! :wink:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 16 March 2009, 12:51
Well, I adjusted my rear suspension up a little and now you can see the tyre all the way round, but that damn exhaust is still rattling on something!
I also fiited my replacement ECU and it has not made any difference at all to the running with the lambda probe connected, so a bit of a fruitless morning by all accounts.
I am going to need a major re-think as far as my suspension goes as I am not entirely happy with it anyway. I may put together a hibrid system by mixing different makes of spring versus damper. If anyone has any suggestions, please post them up.
As for the exhaust, well I think I need to take the car to a fabricator who can adjust it to fit a G60. Remember that jetex were not made for the G60, but I have no idea how they would be different. The reducer within the system may be a little to long, thus pushing the system backwards, and making the radius over the rear beam in the wrong place causing me this headache.
The lambda probe problem I think is going to someone who knows more about these things than I do, as I am out of ideas. :sad:
I am going to have another little play with it later today, but I don't think I am going to get anywhere with it.
Title: Re: Darnpistonbroke - Golf G60
Post by: Dubster2 on 23 March 2009, 01:32
I've got a Jetex exhaust and that knocks on the rear beam too! I think most aftermarket exhausts do! I think it's too heavy for the runner hangers so need something beefier/firmer to hold it up in place. Not sure what other people have done, but that's another job that I need to sort!
Title: Re: Darnpistonbroke - Golf G60
Post by: monzablue16v on 23 March 2009, 15:41
Powerflex exhaust rubbers :)
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 23 March 2009, 18:43
I've got a Jetex exhaust and that knocks on the rear beam too! I think most aftermarket exhausts do! I think it's too heavy for the runner hangers so need something beefier/firmer to hold it up in place. Not sure what other people have done, but that's another job that I need to sort!

I have mine also supported with ti-wraps very high and it still bangs! Bloody thing! I am going to take the car to a fabticator and ask if it is possible to 'move' the bend in the exhaust that goes over the rear beam forwards, so that the top of the bend is over the beam and not to the back.
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 18 April 2009, 19:44
A very satisfying day today, with one minor hic-up. But more about that later.

I went to Mike Stokes Motorsport this morning to have my very heavy Jetex exhaust sorted, and I now have a very smooth, rattle free shed with no cat. I am extremely happy with it, although obviously it needs to settle down. Anyway, here are some piccies.

This one is of the 18 year old cat. It has had its nine lives so it was put out of it misery.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/188April2009.jpg)

GONE!

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/189April2009.jpg)

This is the cat replacement pipe made on site. It's the same diameter of the Jetex too, so no reducers needed. This is usefull for when I get my tubular manifold later.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/190April2009.jpg)

As you can see, the radius is now completely over the rear beam with loads of clearance.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/191April2009.jpg)

And now the tail pipes sit nice and central and higher than before.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/192April2009.jpg)

He removed on hangar from the top of the rear silencer inlet and replaced it with two more on either side of the silencer inlet pipe. This gave him more room to play with to raise the exhaust up a little more. The absence of the reducer and a custom fit cat replacement pipe meant that the radius was ideally situated where it should be. The tail pipe support bracket was also shortened and all the rubbers were replaced by much stronger items. He spent 3 hours on the work and I was not charged half as much as I was expecting so I am a happy bunny!

Further updates on the rest of the day later. :smiley:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 18 April 2009, 21:45
And now for the rest of the day!
My clutch master cylinder decided to leak internally making driving rather interesting. I had been borrowing my friends MKIV which, I have to say, was a refreshing change from the hard ride of the shed. I can drive a car without the aid of the clutch, but negociating junctions and roundabouts can be a little tricky. Anyway, after I got my exhaust fixed, I drove to my friends house to do more car work. He had picked up for me the 3rd master cylinder to try, and it was third time lucky as it was the correct one. So this got fitted and bled with no fuss or bother and fairly quickley too. So then, it was to the rear suspension.
If you saw my write up about my trip to the UK from Madrid, you would have seen that I had to raise the rear suspension so that I could load up the boot with all my tools for work. Well today, I put it back down to where it was. This was accomplished in reasonable time too, and whilst I was doing that, Jon was cleaning up my rear wheels, internally as well as externally.
Now for the glitch in the day.
I though that the car would have a little more power now the cat was out of the equation, but I was a little dissapointed. I took Jon to where I am staying for the time being, to pick up his MKIV, and on the way, hoofed it a little to show the power of a G60. But there was no power. :undecided: Then I heard a loud pop and the power reduced to near enough zero. We pulled over and had a look and found the Mas Air Flow sensor was gone! :shocked:
We drove back to my place and had a look round for the sensor as I thought it may have fallen out of the intercooler when I had the car apart yesterday, but to no avail. Jon took his car back and had a look round his place. but again to no avail. So I retraced my steps to where I heard the pop, pulled over and had a look over the road and grass verge, but could not find it. So I went home. When I got there, I had another look under the bonnet and looked to where the sensor would have been aimed, and found it, still within the engine bay, on a ledge under where the clutch master cylinder hides. So I refitted it and wire locked it in place to make sure it would not 'dissapear' again. All was well after a test drive and I have to say that the car is so much nicer to drive without the exhaust causing mayhem, and a high and very predictable clutch pedal.
Now I have to investigate the lambda probe problem. DannyP has given me a few hints, so hopefully, that will be sorted shortly. :smiley:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 12 May 2009, 22:18
Silly post really! :embarassed: Just won on ebay a set of big intercooler hoses to fix up my big intercooler that I have had for over a year now, so expect an update soon! :laugh:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 02 September 2009, 16:06
Been a while now, and seeing I am staying in this windswept overtaxed country of ours, I have made a start on doing the necessary work to import it. So I started with the clocks.
I won a set of 160mph clocks from a 16v, but they had the pointers painted red and the mileage was too high. So I had to take them apart to correct them.

The Spanish, ot more PC, European clocks.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/193July2009.jpg)

The English ones.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/194July2009.jpg)

The mileage as I said before was super high, so I removed the speedo to wind back the mileage. It took a looooooooooong time to rewind the clock, but I eventually got there.
I didn't take step by step photos, so this is not a comprehensive 'how to do' thread. The pointers on the replacement were red, so for a number of reasons, I decided to keep the original binacle and just change the speedo. So I carefully removed the pointers from both clocks and glue into place the white pointer from the original clock onto the mph speedo.
The other reasons for keeping the same binacle is to make sure that I retained the MFA functions for the G60 and also I know that the original binnacle works without fault, as well as having white pointers for the tacho, water temp and fuel quantity.

As you can see, the mileage now reflects the kilometers.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/195July2009.jpg)

And final installation.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/196July2009.jpg)
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 02 September 2009, 16:24
Well this little lot have been lying around for a while now, so I decided that it was time to fit them.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/197August2009.jpg)

I bought those a year ago, but just recently bought the necessary plumbing to fit them.
So, out with this lot...

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/198August2009.jpg)

And on with the installation.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/199August2009.jpg)

I did not have the correct hardware, so I had to go to B&Q to make up some bolts out of threaded bar, nuts, nyloks and capped nuts to make a reasonable job. These were needed for the 'U' bend fixings. You may just be able to make them out in this next picture.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/200August2009.jpg)

And the finished result.

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/201August2009.jpg)

(http://i221.photobucket.com/albums/dd2/Darnpistonbroke/202August2009.jpg)

The result is alot less engine bay clutter and more power, and the power difference is very noticeable. I was quite surprised.

For the next project installment, the plan is to put on some British numberplates and SORN it straight away. I will then be hooking out all the suspension, the engine and the gearbox. Then gradually bring her back up to standard with new bushes, a tidy engine bay, a painted engine and undersealed underside to prevent the British weather from killing her. At the moment, she 100% rustfree, which for a MKII of 18 years, is unheard of.  :cool:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 26 June 2012, 22:45
Well its been a few years since I updated. I still have the old beast but she has been residing in a dry garage waiting for me to carry on with her. Alot has happened over time personally so she has been on the back burner.
My aim within the next few weeks is to import her to the UK, which means installing new lights and getting the engine sorted. Once she is MOT's, imported and running, I will be selling her as I am buying back my old Cobra.
Anyway, I will try to remember adding pictures of what I am doing with the old girl, one of the things is to replace the suspension with original specification units.
 :smiley:
Title: Re: Darnpistonbroke - Golf G60
Post by: DarnPB on 18 August 2016, 21:31
Car now for sale. See classifieds.  :smiley: