Author Topic: Neo Badnesses mk2 ABF 16v project  (Read 41973 times)

Offline Neo Badness

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Neo Badnesses mk2 ABF 16v project
« on: 17 February 2011, 23:35 »
Thought I'd post what I've been up to when not geeking out on the computer...

For those who don't know I bought the car a while back as a replacement daily for my rotten mk3 16v which I cannabilised for it's engine, electrics and g/box. Suffice to say things haven't exactly gone to plan... It's not got MOT or Tax and is tucked up in my mates leaky workshop.

The plan is a tried and tested one. Take one ABF engine and transplant into my late spec mk2 16v.


Transplant ABF in place of KR on stock CE2 management.
Rubjonny modified loom/ ECU
Retain narrow track for time being.
Use mk3 cable change box.
fit the 280mm brakes I have
Track down a suitable hydro pedal box/ servo etc
Chop out the rot
Weld all back together
Prep for respray with few nips and tucks
Respray it in OEM Oak Green

Taken last July


How I bought it with some tasty BBS RX I's 16in



How it looks after some shiny new coilovers

Shiny new coils with G60 top mounts


Came across a factory grey leather interior to replace my worn rainbow interior.

Turned this

Into this :lol:


My WUR wasn't working right causing car to cut out when hot and generally driving me nuts. Unfortunately the one I had spare was bought in a job lot and the vac' attachment to 5th injector was snapped :erm:

So, my first attempt on the metalwork lathe was a good idea, but turned out crap.

This is a pic of the second one I came up with, was pretty pleased, took me all lunchtime but got there.





So replaced this one with my faulty one and fingers crossed so far so good. Mpg improved and not cut out yet when hot, yet.

« Last Edit: 18 February 2011, 22:32 by Neo Badness »

You don't own a Mk2, you support it.

Offline Neo Badness

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Re: Neo Badnesses mk2 16v project
« Reply #1 on: 17 February 2011, 23:42 »
The car had been languishing in the garden with no MOT since the Kames weekend after I over-tightened a bleed nipple having replaced the master cylinder, managed to get away with removing the broken nipple and cleaning threads.

New and Old...

Thinking I'll replace the old servo too


The car's speedo cable broke twunts at the garage had cable tied it to the block , so have replaced that.

Wipers stopped working, replaced a relay sorted.
Blower/fan not working on any speed now. Either blower motor or control, I think.
Really needing this fixed but may just replace the whole lot for know working one.

Had a wee visitor


I've been taking the plastic trim off in preperation of going into the workshop to discover the horrors below...


The young persons guide on how not roll arches, previous owners = animals...



Dodgy patch job, the chimp that did this shouldn't get any bananas for a week for this


Got a new sill, rear arches, petrol filler panel and front wings to go on. New tailgate and passenger door. Probs would've been shorter list to say what I'm keeping.

Picked these up


And so it begins....

You don't own a Mk2, you support it.

Offline Neo Badness

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Re: Neo Badnesses mk2 16v project
« Reply #2 on: 17 February 2011, 23:45 »

Picked this up the other day though



Those into their old school ICE may recognise this, picked it up for a v.good price, chuffed.




Need to get on and finish these alloys that I started refurbing about 3months ago. Got an idea for a front grill but wings to prime, rust proof and stone chip.

Not much of an update but it's an update.

Been away, got engaged :D

Now back to the Golf.

Only had a few hours today so took a grinder to the rust in the rear seams.

Started out like this.




Ended up like this, sorry quality isn't great but I culdn't see the screen from the glare from the sun.
Did primer it for short term but didn't take a photo as I was falling down tired...





Powdered Mk2 anyone? Just add water...



That's it for now. Will post up some more photo's of the other things I bought for the project when I get the chance :rthumb:

Cheers for looking.

NB

You don't own a Mk2, you support it.

Offline Neo Badness

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Re: Neo Badnesses mk2 16v project
« Reply #3 on: 17 February 2011, 23:46 »
Started out like this, only had an hour mind... :D



How NOT to roll an arch   (Prev' owners I hasten to add)



Looks a bit like this at the mo as had to go to work :bang:

Selection of the screws and adhesives used to bodge the big kit on ( Note the rather tasty brass screws!)



Will update more when I've done a bit more.


You don't own a Mk2, you support it.

Offline Neo Badness

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Re: Neo Badnesses mk2 16v project
« Reply #4 on: 17 February 2011, 23:46 »
Right some pic's, got started on the wings I bought.



Started trimming the lip for folding the steel back to retain strength.




Got a bit anal and trimmed off the swarf  :)



Tiger sealed all the seams on the wing to make sure rust should kept at bay for a few years yet.



Folded lip and sealed it




All sealed up


Then these arrived, cheers Fraser. :rthumb:


Cleaned this up for welding,


My first weld in anger :D


No doubting the penetration of these welds...


opted to flush the wing repeaters rather than fit the mk3 ones.


More to come....

You don't own a Mk2, you support it.

Offline Wayne

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Re: Neo Badnesses mk2 16v project
« Reply #5 on: 17 February 2011, 23:47 »
Excellent progress, the self rolled arches are shocking, new ones look loads better :afro:

Offline Neo Badness

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Re: Neo Badnesses mk2 16v project
« Reply #6 on: 17 February 2011, 23:49 »
Excellent progress, arches are shocking

They were a bit "special" whoever did them, consigned to the heap of rusty bit outside the workshop now though :smiley:


Most pleased with this one...



You don't own a Mk2, you support it.

Offline Neo Badness

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Re: Neo Badnesses mk2 16v project
« Reply #7 on: 17 February 2011, 23:52 »
 welding up the other arch, indicator and ariel hole banished...









Trimmed up the lip for some folding tomorrow.



Right, had a cr@ap load of stuff going on last week and a bit but I've tried to keep momentum up on project rotbox.

Nice new (rot free) door. Lovely colour but unfortunately not the right one for my car.


Started rubbing down



No Mig welders were harmed in the smoothing of this door (Phil, if you're reading this, it's not as bad as it looks) Dropped a bolt when loosening off the wire spindle, got it out and put back together, that was an hour or so well spent...



Door scotchbrited



Door trim holes prepped for welding



Holes plug welded (See Phil, your welder still works great :D _



And then ground down



Light skim of filler



Coat of primer and trim holes are no more



Other wing stone chipped



And then gloss blacked so the crud slides off easier



Guide coat



Started rubbing back the wing blank



Flatted properly, but ran out of primer... and that is that for now. Cheers for looking


You don't own a Mk2, you support it.

Offline Neo Badness

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Re: Neo Badnesses mk2 16v project
« Reply #8 on: 17 February 2011, 23:56 »
Right some progress,.

Broke the 13mm bolt when trying to fit the ARB that I got.   

*EDIT, Boab to the rescue with a pair of these. Cheers



13mm bit I broke with my uber manliness  :smiley:

Reet, here is some of the glamour I have been indulging in over the past week or so and the reason my other half is a DUB widow...



Quick hell ride tow (no brakes or windscreen wipers :blink: ) from my old boy, cheers Dad :rthumb:





Arrived at mates workshop despite the steepness of the drive.



Stripped off rear bumper to find any further horrors. Turns out whoever repaired the car last put the sunroof drainage tube into the boot. That'll explain the damp boot then


You don't own a Mk2, you support it.

Offline Neo Badness

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Re: Neo Badnesses mk2 16v project
« Reply #9 on: 17 February 2011, 23:58 »
Fuel filler is a bit rotten then



Bit where repair panel was attached suffered from dampness creep, all treated now though



Rest cleaned up, another tiny wee hole which I have welded ( but not taken a pic of)



Last worst bit, will tidy it and when I redo the lower valance at a later date ( have a mod I'm desperate to do)


Grotty bit cut out revealing, yup you guessed it, more grotty bits...



As you probably noticed I'm leaving the tank in situ as I'm not getting involved with dropping the tank at this stage.



Oops, this was because the pipe wasn't where it was supposed to be. That's my excuse anyway.



Not a too shabby repair, sealed with hot melt. Will replace with my spare one when goes into the spray shop.



Part of the grot underneath that failed the MOT on.

Snapped bolt :bang:


Poly bush ARB bits


ARB, courtesy of Boab :cool:


He still doesn't know his 10mm from his 11mm spanners



Panel welded in.



Needs a bit of grind to be perfect. Didn't blow myself up which is always a plus



Welder splatter= hot  :grin:



I then promptly accidently switched on the grinder whilst swapping discs. Sliced my fingers and it bounced on the floor and bit a lump out my my leg. So I said bollox to it I'm going home... Done other bits too but will take photo's tomorrow when I've had beer


You don't own a Mk2, you support it.