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Model specific boards => Golf mk1 => Golf mk1 gallery => Topic started by: jv on 28 November 2005, 13:10

Title: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: jv on 28 November 2005, 13:10
Here you go :)
Title: Re: Madone - Mk1 Golf Cab GTI - BLACK SOY'
Post by: Madone_si on 28 November 2005, 13:24
Hi all,

Short story for you - bought the car early in 2005 (April 2005) with a light rear end smash (mainly bumper damage)- got it repaired, then had engine issues - replaced bottom end, lots of upgrades and replaced parts throught out.

Spec of car

1992 (K reg) Black Mk1 Golf Cabriolet / Convertible – (Black code: L041)
Electric Hood - works perfectly and hood in A1 condition
59,000 miles (at least 45k under average!!) – April 2005 (61,600 miles in Dec 2005)
Karman interior – perfect condition
14” Snowflake Alloys - they have been refurb now - so they look like new :)
Immobiliser / Alarm installed, Plus some other devices :)
Central Locking
Excellent bodywork
1.8 GTI engine
5 Speed Gearbox

Work done on the car from April - August 2005

New rear bumper, flog light, rear end boot lid put on car - when repair to rear was done - see pictures below see difference :)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/before-after-frontofcar-repair.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/before-after-rearofcar-repair.jpg)

Installed the VW Scuttle cover
Replaced all broken side trim clips
Installed my three pedal covers - I will always buy all three of these now - they look wicked...
Complete service on engine - oil and air filters, spark plugs, spark plug leads, dist cap and rotary arm, plus oil flush and new oil, brake fuild top up, including Timing belt and fan belt changed - checked all gaskets on car - just need to replace rocker cover gaasket... will do sunday...

Parts brought for servicing of car
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-cab-parts.jpg)

Installed new front disks and pads (Mintex brake pads front and rear - bought from http://www.atozmotorspares.co.uk/suppliers/mintex.htm)
Checked rear brakes - cylinders were completely shot - so replaced them with new items
Fresh brake fluid as well - always good to do.

New front brakes set-up (old and new)
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-breaks-old-new.jpg)

New and old pads
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-pads-old-new.jpg)

Rear brake repairs
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/rear-brakes-work17-07-05.jpg)

Tune the car after service - it runs even smoother now.  :smiley:

Feel alot better now driving the car knowing that all new parts installed (always worry about timing belt... - you should check if you are unsure when it was last changed, they don't cost alot to replace, but if they snap - say good-bye to your engine...

Bought full set of Carpets matts interior and boot matt from JustMatz with GTI design in middle of all 4 interior matts - A1 quality products.

So I went to London VW show in August and meet up with Lewy from the forum and here is picture of our cars  :smiley:

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/si-lewy-cars-aug05.jpg)

Work done Aug - Dec 2005

Wasn't happy with the way the front of the car was - plus I noticed the battery tray was rotten and wanted to smooth off the front of the bumper. When I took off the front bumper to work on - drove the car around for a week with no bumper and some lovely person in a shopping car park smashed in to the front of my golf and ripped the front slam panel on the right hand side in - so that was it - new front slam panel going on the car - you can see picture below were I took the front of the car apart.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/1-2.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/2-2.jpg)

So I replaced front slam panel - VAG part
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/new-front-cab.jpg)
Replaced battery tray panel - VAG part
cleaned up rad/fan cover and other parts and painted

I ordered new front badge less single lights Mk1 grill
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-golf-debadged-grill.jpg)
New crystal main lights
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/Mk1-golf-crystal-clear-front-lights.jpg)
New crystal front bumper (same spec of VAG ones - not the smaller bumper ones) indicators
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-golf-clear-front-indicators.jpg)
New arch inside and outside screws

I prepared and painted the whole front of the car including wings, front arch's and bonnect as well as inside engine bay area and front slam - looked great. :)

Put car back together again and then was off to US for work and then on holiday to Egypt in Nov 2005.

Title: Re: Madone - Mk1 Golf Cab GTI - BLACK SOY'
Post by: Madone_si on 11 December 2005, 22:48
Picture below is work I did on car in August 05 - strip off front car to do a complete replacement of front panel and battery tray, and respray complete front of the car. Fun fun - full details of car will be updated in a few days to see what the car looks like now..

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/3a.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/6-1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/7a.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/9a.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/12-1.jpg)

Poor front panel.... hehehe
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/17a.jpg)

New front panel installed and new battery tray as well - all ready for going into garage for respray

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP2055.jpg)

Title: Re: Madone - Mk1 Golf Cab GTI - BLACK SOY'
Post by: Madone_si on 14 December 2005, 15:16
Front of car sprayed up after completing the prep work. Also smoothed off the front bumper and relocated the front number plate. Also changed the rear lights too :)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/Mk1-black-changes1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/Mk1-black-changes2.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP2192.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP2187.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP2185.jpg)
Title: Re: Madone - Mk1 Golf Cab GTI - BLACK SOY'
Post by: Madone_si on 26 December 2005, 15:43
Work for Jan/Feb 2006 on the black cab

Install new suspension
Install new wheels....?? Let you all guess on that!! hehe
Find and install new Hand brake switch - playing up last few days
Find and install A Pillar Trim - one of them is broken
Finish off install of Electric windows - cabling

Had issues with front CV joint the other week - so had that replaced while up north :)
Also second gear in gearbox is playing up - so got to take gearbox out and work on that when got suspension off.

Cleaned car today :)
Title: Re: Madone - Mk1 Golf Cab GTI - BLACK SOY'
Post by: Madone_si on 04 January 2006, 18:06
So over the Xmas period I thought I would install and finally create my boot area stereo panels for my new amp, 6x9 and sub.

In short I made up from MDF - boot floor (with cut out for getting to spare wheel), sides and special speaker shelf to hold 6x9 and 12" sub with amp cover - so you can't see any cables and everything is locked into the boot with hidden large blots.

A few days later all was completed and I have to say its looking rather professional finish!

From this;
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/PC180037.jpg)

To this;
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/stereo.jpg)

Ordered a few bits today - so can install new suspension next week.
Title: Re: Madone - Mk1 Golf Cab GTI - BLACK SOY'
Post by: Madone_si on 05 January 2006, 14:46
So my new parts for my suspension turned up today - I'm trying to keep the car to standard spec if poss.

New VAG Front Pair of (heavy Duty) Uprated Gti struts (will sell the dampers on ebay... as replace them with Weitec dampers)
New VAG 2 Top spring carrier plates
NEW Uprated 2 bump stops fitted with VAG gaiters
NEW VAG 2 spring steel washers
NEW VAG 2 strut top locking nuts
NEW VAG top mounts

Have Weitec Ultra GT Suspension Kit front and rear - 35MM drop - kicking around in the garage - so will use this. This includes new springs, and dampers for front and back. I'm only going for 35MM drop as I don't want to loss to much of the smooth ride of the car (K&W Coilovers may go on the car if I'm not happy with the end result....!!  :grin:)

Weitec kit..
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP2438.jpg)

New front suspension parts..
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/front-suspension-parts.jpg)

New Top mounts
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/suspensiontopmounts.jpg)

So the old and new against each other!!!
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/Suspension-parts.jpg)

So I've sent my new wheels off for refurb - due back in 2 weeks time....


Title: Re: Madone - Mk1 Golf Cab GTI - BLACK SOY'
Post by: Madone_si on 18 January 2006, 16:45
So I've had issues with my hand brake light in the dash staying on. So a few weeks ago I tried the following out;

1. I've checked the switch itself with another one - all fine. 
2. I've taken the one cable off the hand brake switch - good connection and switch itself is fine as well.(The wire or switch on the handbrake lever is just an earth wire)

From the lovely people at golfgti.co.uk - thanks all that replied  :smiley:

Was told to check all wires to light/switch as the wire might have worn down to the wire somewhere and be touching bare metal thus making an earth.

Was also told if the brake fluid level if low this will make the hand brake switch stay on. Light doubles up as a low fluid level indicator.

So the fix is.....

Well after getting a tad bored with working from home - I thought what the hell - lets fix that hand brake switch issue on the car.

Before I started to take the dash apart... (got that down to 20 minutes now   ) I thought I would double check switch itself again and the dash board switch - all worked fine.

So I then thought lets check the brake fluid level - all OK up to Max level, then I noticed the cable onto of the brake fluid chamber was slightly off - so I pushed it back - checked the light switch in the dash and guess what????? The light went out - pulled the hand brake up and the light come on - took hand brake down - light turned off.......   

It's fixed and all due to cable on brake fluid chamber not being on correct.... happy again... another item off the list to do.
Title: Re: Madone - Mk1 Golf Cab GTI - BLACK SOY'
Post by: Madone_si on 18 January 2006, 16:50
Suspension update....

Ok so I've installed the new suspension in the car its 40mm drop at front and back not 35mm as I said before - I've got loads of pictures and I have to say alot of write up on it as well - so I'll get pictures uploaded this week and get write up down this weekend - car looks much better now and the ride is still smooth - Weitec Ultra GT Suspension Kit is A1 and a bargain.  :grin: :grin:

Pictures of car lowered...

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/lowered-front-view-jan06.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/lowered-backside-view-jan06.jpg)

Items I bought this week.

Second hand rear window frame - as mine is starting to rust in one corner - for a bargain £25.00 - will get it professional restored so will last forever.
Also got two sets of A pillar trim covers - £10 each set - one of mine was broken so replaced that today as well  :grin:

On the look out for Electric Recaro front seats to install in cab - so please keep a look out and tell me if you find any? thanks
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 26 January 2006, 12:12
Whole project Section updated with more details for all  :grin:

Work for Jan/Feb 2006 on the black cab - update

Install new suspension - COMPLETED
Install new wheels....?? Let you all guess on that!! hehe - keep changing my mind now...
Find and install new Hand brake switch - playing up last few days - issue Fixed - COMPLETED
Find and install A Pillar Trim - one of them is broken - installed - COMPLETED
Finish off install of Electric windows - cabling - will be in Feb 2006

Today I'm off to get my exhaust sorted - front down pipe is making alot of noise...
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 28 January 2006, 21:35
So fixed the exhaust today with the help of Mr Lewy at his RAF base... the exhaust was moving alot at the front down pipe, so needed to replace C clips and exhaust ring - the noise was bad!

Let's just say to replace 2 x C clips and exhaust ring that goes in between manifold and the down pipe, took a good 2 hours if more, even with the right tool to remove the C clips, it was a complete B**tard to do. We had to take the whole exhaust off it rubber mounts, then after alot of swearing and sweat - we completed it - cheers Lewy for help mate.

Also got back from wheels after refurb. Think I will be selling these.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/snowflake-wheels-14.jpg)





Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 02 February 2006, 16:48
Added a IPOD adaptor to my Alpine Tape stereo (keeping style of stereo with car year 92/93) only took all of 15 minutes to do, took stereo apart and added the adaptor direct into stereo circuits, run cable out back of stereo - after drilling hole in back and then ran cable to glove box, will install IPOD power adaptor at weekend.

Another job completed :)

Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 04 February 2006, 16:38
When does fixing cars stop?????????!!!!!!!!!  :tongue:

So today I thought I would start taking the gearbox out again as my clutch went on the car this week - lucky for me, I managed to slowly drive home for 5 miles at max of 10mph.... I think I really pissed off alot of people behind me....

After borrowing a jack - need two to get a gearbox out (if you've done it before your know how much of a pain it is!!!), I managed to get the gearbox out and now sitting on the garage floor - waiting for me to clean it up and spray it - so it looks all nice and new! The clutch is some what dead.  :laugh:

I also checked the CV joints and it looks like my drivers one is worn a bit and starting to make noises when turning, so I will replace both sides.

I will also replace the wheel bearings on both sides... :)

There goes my plans for going racing tomorrow...  :sad:

And I ordered my new wheels for the cab 8 x 16''

(http://www.tunershop.de/felgen/images/schmidt-ml-3tlg-gr.jpg)

 :cool: :cool: :cool: :cool: :cool: :cool: :cool: :cool: :cool:

Will have to do a bit of arch work when they arrive....  :cool:
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 15 February 2006, 15:43
So at the weekend - I put my cab back together as I took out the engine and gearbox as a whole - as it was easier to do then fussing about with just the gearbox just to put a new clutch in.  This also gave me space to give the engine bay a bit of clean and check all brake pipes, cables and gearbox linkage... which I replaced all rubbers - gear linkage is now even better!!!

The new Clutch was installed - all lined up by my own eyes.... best way in my view!! I put on a spare gearbox I bought a few weeks ago so I could focus on rebuilding my gearbox as the first/second synco were gone.... (not good when driving I can tell u!)

While I was at it I gave the engine a oil change - amazing how you can put 3,000 miles on car over a short period of time...

So the car is back on the road again  :cool:... but I still have a few items waiting to turn up...

My new wheels...  :grin: :grin: :grin:
New Rocker cover and rocker cover gasket - will clean up the one I have on it now and sell on later...
New 6 bolt manifold -  :smiley:

Once all this is installed - I won't be doing much more to the car until late summer - when I think a bit more BHP is due, upgraded braking and change of suspension.... well your have to wait and see....


Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 22 February 2006, 13:37
Parts turning up...

New rocker cover - now painted in Black - same as car  :cool: and a spare rocker cover in chrome... hehe bling bling!!!

Also took off the door armour plates and painted up as well :smiley:

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/door-armour-plates.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/rocker-covers.jpg)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 08 March 2006, 21:15
So after having a NEW full set of Deluxe black with White GTI sign matt's from JUSTMATZ sitting in the spare room from since Ed38 last year I thought I would install them at the weekend. They really do finish off the interior:cool:

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP2541.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP2516.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP2517.jpg)


I also cleaned up and painted a lower front adjustable strut brace (given to me by a friend - thanks alot man) - will be installing it soon... picture below

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP3780.jpg)

I also adjusted my gear linkage as it wasn't going into the gears smooth - a nice and easy job to do and worth checking if you have any issues with getting into any gear - I replied all the bush's when I did the clutch - so its lovely now.

Picture of car  :smiley:

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/Black-mk1-golf.jpg)




Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 10 March 2006, 15:43
So I picked up my 6 bolt exhaust manifold and downpipe the other weekend and cleaned it up and put it on the car - not really any increase of BHP - but its alot easier now to take off and put back on when doing work on the engine  :smiley:

Will be getting these lovely new wheels 8 x 16  :cool:

(http://www.tunershop.de/felgen/images/schmidt-ml-3tlg-gr.jpg)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 20 March 2006, 20:31
Car sold.......!!!  :laugh: (am thinking about it...... I want another porkie... another 911 '964' Turbo would be nice!!)

So with a alot of motorway driving in the last few weekends, the poor front end of the car has taken alot of stone chips, so the front bumper and slam panel will be sprayed again in the following weeks - Cheers Dad!!!  :smiley:  :smiley:

Late last week I resprayed the rear bumper again as I wasn't happy with a large amount of paint that come off it after working in the boot area... well it happens sometimes!!!! - look lovely now.  :cool:

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP2539.jpg)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 01 April 2006, 13:51
New wheels!!!

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/wheels-1.jpg)

So I went and picked up the above new wheels from Rocco Jocco in Swindon (I know!!). I got tyres for them and put on the car (see pic's below)

You maybe asking what is he doing with the Schmidt ML's... well they are just too wide for the car until I get the arch work done and car resprayed some time in July/Aug 06, so they are staying in the shed for a little longer....  :smiley: So until then I'll have a nice set of wheels on the car for summer  :cool:


Rude not to clean the car after putting the new wheels on.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/wheels-front.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/sideview.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/backsideview.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/frontview-hooddown.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/sideview-hooddown.jpg)

Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 22 April 2006, 17:43
Well I have to say I used my AA recovery service for the first time yesterday evening.... car just died on the A303 on me, no warning or anything.....  :angry: well 20 minutes later the AA man and friend in hand joins me...   :smiley: :smiley: now that is AA service for you.. hehe outcome is the Alternator is totally Dead and not charging the battery... as I've got a Heavy duty battery must of been using up the battery for the last few days as I've only just got back from holiday this week.

So yesterdays trip to pick up my new gearbox has to be rescheduled now to next weekend....  so this morning popped to GSF and got a new Alternator for car and installed - back and working again with-in an hour. With the weather so lovely and hot today, it seemed rude not to clean the car. So after a few hours, the car is looking all nice and clean again




Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 29 April 2006, 15:10
I now need to install coilovers on the car, so I can really lower the car more :cool:
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 11 May 2006, 16:32
Well yesterday was Xmas for me...

My reconditioned Gearbox turned up from C&R enterprises :)  :grin: :grin: :grin: - it just needs a clean up and spray to match the car colour  :smug: Also got myself new outer window rubbers as mine had split and where moving around.

I will upload pictures of taking out current gearbox and install new one in the next few weeks, might even add a guide of how to do this as well....

I'll be installing KW coilovers next month as well... might get Lewy boy to help me install then at the RAF base?????!!!
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 28 May 2006, 00:23
Well been busy today, below is what I've been working on the car (pictures will be uploaded on monday)

1. Took engine out of the car - so to replace gearbox with my new one - I didn't paint the reconditioned gearbox in the end to match the car as this will be done later in the year.
2. Replaced new gearbox and mounted onto engine
3. Took complete gear linkage out and cleaned up and re-installed
4. Engine mounts required replacing so I bought from GSF a complete Prothane Bush kit containing the following;

 (note the side mounts you still use the original mounts, but put Prothane mounts in between the original ones - The new mounts really made alot of difference as I don't get alot of engine movement now 

Ft Trailing Arm busing Set 75-84
Rr - Axle Bushing kit 75-84
Ft Motor Mount - Installed
Rr Motor Mount - Installed
Motor Mount insert 2.530 DIA L or R - Installed
Motor Mount insert 2.943 DIA L or R - Installed

Rack and Pinion Bushing kit 75-84
Rr Shock tower bushing set 75-84
Strut Adjustable Bump Stop 75-84

Will be install other bushs later on.

5. While all engine parts where out I cleaned up the injection system internally as car had started to play up the last few days with rough tick over and running
6. Re-installed engine and gearbox and connected everything back up
7. When setting up the Gearbox linkage - use the following steps to set correctly - http://www.geocities.com/jonnyguru/vw/shifter.html

8. took the car out for a test drive - its now perfect in every gear - happy :)

Tomorrow (Sunday)
I am working on the front wings and front bumper as they will be resprayed - that should keep me busy for all sunday ;)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 02 June 2006, 00:52
Got problems with my new gearbox, so it will be coming out of the car tomorrow and will get sent back. I've got another new gearbox turning up tomorrow - so hopefully I will have the additional new gearbox back in car on sat and working for this sunday Stoner Park show.... if all goes to plan that is.....!!!!!!

The joy of cars......!!
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 24 June 2006, 18:03
So with issues with the new gearbox, I worked on the car two weeks ago to swop the gearbox out again and replace with another new one. Lets just say the 2nd new gearbox is lovely and I'm very happy, I also replaced the engine mounts with standard ones again, as the new upgraded ones just transfered too much vibration for me into the car.

So I went to the USA over the last 16 days for work and so no work at all on the car.... :( but today I had a new German parts Standard Exhaust (from German and Swedish) put on the car with a nice chrome rear cover as well... 150.00 in all for parts and install by a nice local Kwik Fit garage who I know well.

I've managed to get a few chrome parts for the car over the last few weeks from various places (MINT Porsche door handles, 2 x chrome front mk1 single and twin lamp grills, side chrome trip) but I will be selling these now, saying that I will be selling all my VW parts in the coming weeks of early JULY 06 - so keep an eye out in the FOR SALE section for parts and car.... trust me when I say I've got complete VW cab in spares or if someone wants a cab in parts, I have everything up for grabs for sale and some RARE parts up for sale also... everything will have to go...... but I won't be selling parts for silly low prices.

If your wondering what is going on, I am looking to move to the USA - Seattle in the coming  months, so I'm selling up and moving aboard... I'm still in two minds about my BLACK SOY cab, but I know I can get another one of those out there and do that up.... after I get my 1969 Mustang fastback!!!!!!  :laugh:

I have to say I'm finding it hard now to change anything on the BLACK SOY cab as it really is to the point where I've done most upgrades, so I am happy to say who ever ends up getting the car will have a lovely low mileage car....  :cool:

Well I will update everyone in the coming week on my full plans, but I'm moving for sure.

Don't worry I will still be around on the forum and knowing how I am, will have another VW soon when in the USA.... and will be driving the GOLFGTI.co.uk forum in the USA and I am sure I will be back in the UK now and again....

Si


Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 31 July 2006, 14:44
Few items:

Completely rebuild of steering rack, new clips, rubbers, grease, etc - COMPLETED (details covered below)
Complete respray in BLACK
Put on the complete front car bra (looks amazing custom made for my car) - pictures are uploaded in later entry below.
Install new Coilovers onto the car (sell the Weltic suspension)


Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 06 August 2006, 16:27
Steering Rack rebuild information for Mk1 golf cabriolet

So you might think if you ever have to replace any steering rack or steering column gaiters you will be able to get these from VW, GSF or Europarts. Well I can tell you from trying to get all the gaiters for a mk1 golf cabriolet on a 92 model, you can't. I ordered parts from VW direct and GSF and they provide the same spec rubber gaiters for the steering rack (2 gaiters) and one for the steering column - but none of them fitted my rack at all - even though VW's ETKA system shows I got the correct steering rack for my car, the gaiter information wasn't.

So I did a bit of research and it looks like ETKA system doesn't have the later VW GOLF MK1 CAB rack information correct and so here are two companies that can get you the correct gaiter for you.

http://www.typ-17.de - German site Click on: 'Technik, Aufbau und Verschleissteile Golf ,Caddy I, Jetta, Scirocco I und Polo' on RHS Nav | then 'Vorderachse + Lenkung' - scroll down and you will see items

I always email the company with details from there site on what I want - they always turn up really quickly from this company.
 
http://www.germanautoparts.com/Volkswagen/Cabriolet/Steering/24/1 - USA company..

Pictures of items are:

Steering rack (RHD only)
Drivers side gaiter - near steering column
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/drivers-side-steering-rack-arm-boot.jpg)
Passenger side gaiter
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/Passenger-side-steering-rack-arm-bo.jpg)

To replace steering rack gaiters it really it best to remove the steering rack, but this does involve alot of work;

1. Jack up front of car
2. Take wheels off
3. Take the front downpipe of exhaust off
4. Take the gearbox selector out totally - as this is bolted onto the steering rack on mk1 golf cabs
5. Undo the steering rack rod ends
6. Unbolt the steering rack - 4 bolts

Then can work on steering rack as easy - remember when taking the end off to mark up the adjustable one side - or else your car will be toeing in or out and you will need to get the wheel alignment done afterwards..

Here is a picture of the new correct rubber installed on the rack and the wrong one from VW and GSF... the VW and GSF ones don't even go on properly.... You know when you have the correct gaiters as the drivers side one doesn't require any clips to hold it in place as it has a inside lip that holds it onto the rack when the steering is on full lock, the VW and GSF require clips and not properly go over the steering rack lip.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/close-up-rightrubberandwrongonefrom.jpg)

So here is my completed steering rack rebuilt - with new gaiters, clips, end rods and geased up - nice and new  :cool:
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/rebuiltsteeringrack.jpg)

While I had my downpipe out of the car I cleaned it up and sprayed it to make it a little nicer with high temp paint, and checked the heat sheild as well which was perfect.

Another two jobs completed :)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 06 August 2006, 16:36
So over the last few months I've had lots of fun with gearboxes.

Thought you would like to see the gearbox once back from being rebuilt (June06) before I put it in the car.. (July06) - so nice to have a smooth gearbox again

When I both gearboxes out in the garage.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/gearboxsforblacksoy.jpg)

Refurb one back and painted black - all ready

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/gearbox-resprayed-5-8-06.jpg)

Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 04 September 2006, 19:29
Managed to get my car bra on today after a bit of heating up and pulling it onto the bonnet. What you all think? I do have the bumper cover as well, but will require another person to put that on properly, so try/will do that at the weekend.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/car-bra.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/car-bra1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/car-with-a-bra.jpg)

2 black cabs!!!!!  :laugh:

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/two-cabs.jpg)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 06 September 2006, 18:04
VDO voltage gauge installation

I bought the following Porsche gauges from a good known US source.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/vdo-mk1-cab.jpg)

I am going to only use the voltage gauge in the BLACK SOY cab, below is close up of the gauge.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/vdo-mk1-cab1.jpg)

Here is the back of the voltage gauge with all the correct parts.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/vdo-mk1-cab2.jpg)

Information you will need to know to wire this voltage gauge up.

The voltage gauge is easy, just connect between the +12v feed to the other gauges and the brown 0V wires. A suggested route is between the ground point next to the fuse box, and pin G2 on the back of the fuse box, (a spade connector).

Here is my centre console cover which I'm going to install the voltage gauge into.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-cab-console.jpg)

After a few minutes of drilling out a hole with power drill... hehe, I put the voltage gauge slightly to the right so I could still keep the rear clips to hold the centre console plate to the centre console

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-cab-console1.jpg)

Here is the voltage gauge installed into the centre console plate and installed in the car.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-cab-console2.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-cab-console3.jpg)

Another job completed...

Useful link on VW Golf gauges - http://dana.ucc.nau.edu/~kaw5/gauges.htm



Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 10 September 2006, 18:19
So over this weekend I restored a mk1 golf red grill for my car.

The grill has been in garage for about a while - not in good condition...!

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-cab-red-grill.jpg)

Took the red grill trim off for restore. Close up pictures...

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-grill-trim.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-cab-trim1.jpg)

I stripped all the paint off the trim and then painted them, ending up as below :cool:

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-painted-red-trim.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-painted-red-trim2.jpg)

I took a new single mk1 grill and added a new chromed VW sign

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-new-front-grill.jpg)

I then added the new freshly painted red trim :smiley:

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-new-grill-with-new-red-trim.jpg)

Here is how the car looked this morning

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-cab-before-new-grill.jpg)

and now with the new red single lamp grill.... have to say I'm really pleased with the outcome...

With number plate on

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-cab-with-new-grill.jpg)

With no number plate

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-red-grill-no-plate.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-car-new-grill.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/mk1-cab-pic.jpg)


The car is going in for a complete spray job next month - October06, really can't wait..  :smiley:  :cool:
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 26 September 2006, 09:19
So a Little update today...  :sad:

well the gearbox is some what bu**ered, it makes a really bad noise all the time now and so it will be coming out again in the coming week....

I had our man Joe (tvrgolf) pop around yesterday and just have a quick look over the car to provide information on what I want, so I'll be checking a few areas (rear arches) to make sure they are mint underneath the clipper arch kit on both sides. So hopefully mid to late October, Joe should be taking the car and respraying it completely in red.



just kidding on the colour, it will be BLACK...  :laugh: :laugh: :laugh:

Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 07 December 2006, 22:10
well the car has been a sick kid this month and so lots of money has been spent on it....

New recondition gearbox - 425.00 from http://golfmk1.co.uk (Richard Masters) - great services and great price for reconditioned gearbox. If you ping Richard on details, which I would as I've reviewed all the gearbox suppliers and Richard's services come out best for price and quality of work... say Simon - Black Cab advised you to speak to him. I provided my gearbox on a sunday and I got my gearbox back the following sat.

The gearbox is being installed in the coming weeks.

I've had alot of issues with noisey tappets in the last few weeks, so I've order all new tappets to replace and possible replace of CAM as well ;)

I've not been happy with the brakes in the last month as I've not used the car at all (with traveling around and sorting out moving to US) so I brought a mk2 16v Servo and T-pieces and am in mid conversion of upgrading the car, with new brake lines at the front at the moment only, with a view of upgrade the rear brake lines too.

Due to our famous man TVRGolf having a few issues the last several weeks no work on the respray has happenned  :cry: but this is promised to me to happen soon.

I've been on the hunt for a lovely 2.0 16v engine with bike carbs to go in the car, but the right spec and price has not come along yet, but I am sure this set-up will be brought and in the car VERY sooner  :grin:

I will be uploading details of the new gearbox, brakes upgrade and few other little bits I've been doing of late in the coming week.

thanks

PS I've managed to buy myself today through my other half friend a nice custom mk1 tin top - powering steering A/C LHD golf from 'LA' area for a lovely sum of $400.00 which is driveable and with no rust  :wink: - will be shipped to Seattle area in Jan07 for me to start as a new project in USA, pictures will be available soon...........
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 13 February 2007, 17:15
So I'm in the middle of moving to USA at last - spent most of Dec & Jan in USA, leaving the car in bits in the UK and progress is very slow......

The engine & gearbox is still out of the car in bits, as I'm cleaning everything up and painting everything and replacing all gaskets. I was cleaning up the engine area this weekend just gone (10-2-07) and then I thought.... why not spray the engine area RED.

What you all think? Will the red look great in the engine area?

Bought some more goodies as well - all new gaskets for engine, new clutch, new rad, new water pipes and Stainless steel manifold from TUNINGLEADER Raceland & my fav - custom made true 4 point lower strut brace - fully adjustable from USA.  8)

I'm thinking of upgrading the Cam, but not sure what to go for.

Some pictures of bits arrived.... more to come later in week

The true 4 point strut frame - so cool!!
(http://i90.photobucket.com/albums/k261/madonesi/IMGP4163.jpg)

What is this?????!!!
(http://i90.photobucket.com/albums/k261/madonesi/IMGP4161.jpg)

The Exhaust manifold....
(http://i90.photobucket.com/albums/k261/madonesi/IMGP4162.jpg)

Bling Bling!!!

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4169.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4170.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4171.jpg)

Look at that welding....
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4172.jpg)

Rocker cover gasket kit
(http://i90.photobucket.com/albums/k261/madonesi/IMGP4164.jpg)

Gear level linkage bush kit - only need lever part though!!
(http://i90.photobucket.com/albums/k261/madonesi/IMGP4165.jpg)

Alot of work will happen this weekend and next as the car has to be on boat by 3rd March 2007 after cancelling shipment twice... man this is costing me alot... of no its not work are paying for it!!!  :grin: :grin: :grin:
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 18 February 2007, 20:43
Here is a few more pictures of the engine parts....

Engine Head...

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine2.jpg)


Bottom end in parts...

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/pistons1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/piston2.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine4.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine3.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine5.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine9.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine7.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine8.jpg)


Mk2 16v Brake Servo...

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP3676.jpg)

and the Exhaust wrap ;)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/exhaust-wrap.jpg)

More to come in next few days... engine parts are being cleaned up
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 21 February 2007, 18:49
So the clean up of the engine is in progress, alot of getting dirty each night at the moment to get everything ready for this weekend to put all back together again. I will provide more picture of before and after on each item so you can see the difference....

Took some pictures of the gearbox before I starting to rub it down ready for painting black later this week... Hopefully this one will last longer than my other two!!!!!

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/POR_4634.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/POR_4633.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/POR_4632.jpg)

Main update on sunday...
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 01 March 2007, 00:38
Well the weekend gone was a complete nightmare I've been ill with the flu and so not alot of work happened  :sad: only yesterday and today I've felt better, so more work on the car!!!

So I though I would test my fuel injectors as I know one of them was not working right in the last few months... Here is a very useful test to try this out on - see link below  (you need your car work of course) so I tried this out on my old cab in the garage at home, found that out my second injector was not working right - not spraying or release right amount of fuel  :angry: - so I'll be ordering new fuel injectors tomorrow - more money!!!! 23.00 each new!!!!  :shocked:

Some useful links for people...
How to Test your Fuel Injectors on golf - mk1
http://www.vwgolfmk1.co.uk/Main/Testinjectors.pdf

Bosch Fuel Injection (up to and including Lambda) - useful info...
http://www.vwgolfmk1.info/Fuel/bosch.pdf

There is only a few place I've found that sell new Fuel Injectors for mk1 in the UK - one being VW dealers and the other - http://www.golfmk1.co.uk - same person as I got my new gearbox from... I went with golfmk1.co.uk as they are cheaper but still VW ones  :cool:

So with Injectors out of the way I thought I would focus some time on the head, I've taken all the tappets, cam, values etc off the head and the head will be going off for a clean and a head skim, so with most people just replacing the tappets, I thought I was check my first, as most cabs later model golf cab have hydraulic tappets instead of early models that have solid lifter tappets. So the fun begins!!!

I will update tomorrow on the fun with the tappets!!
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 01 March 2007, 12:36
You also want to know that the fuel injectors on earlier cabs are different from later cabs... I found this out just this week...

My 1983 Gli version - DX 1.8GTI - has code 049-133-551 - larger injector tops  - see picture

My 1992 GTI - DX GTI - has code - 035 133 551 - small injector tops - see picture

I am not sure what the benefit is of the difference but I would love to know if anyone else has same spec injectors as my 92?

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/PAS_4763_copy.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/PAS_4764_copy.jpg)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 01 March 2007, 13:57
So with Injectors out of the way I thought I would focus some time
on the head, I've taken all the tappets, cam, values etc off the
head and the head will be going off for a clean and a head skim, so
with most people just replacing the tappets, I thought I was check
my first, as most cabs later model golf cab have hydraulic tappets
instead of early models that have solid lifter tappets. So the fun
begins!!!

Very useful link on this site covers both tappets services -

http://www.golfgtiforum.co.uk/index.php?topic=33994.0 - I followed

steps from US forum which was very close to what you need to do -
below is steps I used from guide with a few added points that I
did.

1. So I first of all took the cam off the head - quite easy really
- 8 bolts holding it in place. Once these are taken off and you
remove the cam holders you can easily lift the cam off the head,
showing the lovely tappets.

2. Now its best to place the cam and the bolts and cam holder on
bench in order as you took off the car - everything must go back as
it was before
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/1-1.jpg)

3. Now with a magnetic I pulled each lifter (tappet) out of the
head - again make sure you line the tappets up on the bench against
the cam so you know which one come from which value or number them.
 Its best to give them a wipe,  so to clean off any excess oil.
Once this is done, find a wooden surface, in the garage, as it will
get quite messy, (old MDF board or similar). Hold the lifter with
the open end facing downwards and tap quite hard several times, and
see if the piston has moved downwards? If it has it will come off
fairly easy with either further tapping or with assistance of a
pair of mole grips.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/2-1.jpg)

4. This next step can and will would be time consuming, if your lifters are badly gummed up. In which case the best
thing to do is soak them up in a bath of Gunk engine cleaner or
WD40 or fuel overnight. But as you soak them in, with a pair of
pliers try to free up the piston in all lifters so it goes up and
down in a smooth manner as this would free it, if it had become
gummed up. What you will find in the morning is most of the oil
would have flowed out of the lifter, simply take them out and flush
them with fresh cleaner and a cloth.

5. Now, what you will need to do if get a old pot or something and
as you pull the piston up and down a lot of oil and gunk will shoot
out of the hole in the lifter keep doing so until no more fluid
comes out. After this try to tap the pistons out, by knocking them
on a hard wooden surface.
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 01 March 2007, 14:06
(http://img.photobucket.com/albums/v314/BLACK_cabbie/Engine%20Related/Tappets/tappet2.jpg)

This picture shows the piston that is fitted inside the lifter,
look to the centre, and you will see a ball bearing, this acts as a
release valve to let oil in and out of the piston.
(http://img.photobucket.com/albums/v314/BLACK_cabbie/Engine%20Related/Tappets/tappet3.jpg)

7. Now that we have established this, you can get a pointed object,
like a small punch or similar and depress the ball, what you will
get is the oil will begin to come out, keep doing this until all
the oil has come out.

8. Having done this what you need to do now is to test to see if
the spring inside is ok, or whether its collapsed or broken, this
is done by compressing the piston. If all is ok, just clean up the
piston, making sure the sides are totally clean with no varnish or
gum.

(http://img.photobucket.com/albums/v314/BLACK_cabbie/Engine%20Related/Tappets/tappet4.jpg)
(http://img.photobucket.com/albums/v314/BLACK_cabbie/Engine%20Related/Tappets/tappet5.jpg)

9. We will now go onto see how we can sort out the tappet itself,
i.e. the bucket shaped part where the camshaft lobe pushes against.
Normally after several thousand miles, you will no doubt have some
wear. You will now need to linish the tops of each tappet, this can
be done by using P240 wet/dry paper using WD40 as a lubricant, put
the paper on a flat surface (a machined pieces of steel or a small
sheet of glass) and then rub the base of the follower is a circular
motion over the paper, make sure you turn the follower regularly as
you linish, keep going until there are no scuff makers present.
It should look something like this!
(http://img.photobucket.com/albums/v314/BLACK_cabbie/Engine%20Related/Tappets/tappet6.jpg)

If you have some wear on the sides of the tappet, then very
carefully and lightly smoothen up with some 1200 or 2000 grade wet
and dry paper, but don't over do it as this need s to be a tight
fit inside the cylinder head valve bores.

10. Finally once all the lifter have been cleaned assemble the
lifters - see my steps below with pictures, and put them in a bath
of *hot* oil, the hot oil will cause any air inside to expand and
be forced out, mind you don't burn your self.. put the lifters open
side down. Then allow the oil to completely cool, the remaining air
will contract and be replaced by oil.. that will get them nearly
full, test each of the little ball valves before you put them back
together.

11. Pop each lifter (tappet) back into the head values - make sure
each one goes back to its original location.
How to put lifters back together again after taking apart to clean
out. (These pictures are of a lifter Tappet before it was cleaned properly - I know, will get the cleaned up ones upload in next update)

1. All items in bits
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/11.jpg)
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/10.jpg)

2. Fill the lifter (tappet) up with oil - see my choice of oil in picture..
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/12.jpg)
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/14.jpg)

3. Then put together the piston - three parts - you put the spring
inside the piston, I then added a little oil, and then put the centre part inside the piston to complete. I then pushed the piston together so to make sure its working properly.
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/15.jpg)

4. Then time to put the piston into the lifter (tappet)
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/17.jpg)
Then push the piston down - you will see oil pour out of the tappet - so be clearful its messy!!, then with a wooden hammer, I used the end of the hammer to push down on the piston in the lifter to make sure it moves up and down - be careful when doing this, you will notice oil pouring of out the lifter which means its working :)
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/19.jpg)

Well for me the lifters (tappets) are all ready to go back into the
head once its been cleaned up and skimmed, so another job done...
and saved about 80.00 pounds instead of buying new ones :)

Tomorrow time to work on bottom end more...
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 03 March 2007, 17:38
A little update, here are the new Bosch Fuel injectors...  :smiley:

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4360.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4362.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4361.jpg)

Old and New...
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4364.jpg)

and I bought off ebay a tool to adjust the idle mixture - 3mm Hex wench for 20pence - bargain...

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/CIS-tool.jpg)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 06 March 2007, 22:47
I needed to find out some details on injector inserts as 2 from the head where broken, so needed to replace them. So I thought I would look through my books this evening to find out a little more....

My collection of VW books!!
(http://i90.photobucket.com/albums/k261/madonesi/General-vw/book2.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/General-vw/book1.jpg)

No details in them just one picture :( Even been on vagcat.com and still can't find details on this....

Might just have to call VW tomorrow instead and ask them  :banghead:

Anyone else know where to look? - if you do please PM me.  :smiley:
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 10 March 2007, 22:07
So today I had to clear out the garage due to family member moving house. Being the nice person I am, I am storing some crap for them, so not alot of work today on the engine, just clean up of Throttle body..

Alot of crap outside as well as inside the throttle body
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/1-throttle-body.jpg)

Look at the crap inside?!
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/2-throttle-body.jpg)

Clean up a little before strip down.
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/cleaning-throttle-body.jpg)

Then strip down time
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/throttle-body-rebuild.jpg)

A lot of cleaning up and some paint
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/painted-throttle-body.jpg)

Will be rebuilding throttle body tomorrow, so another item completed.

Will be picking up the head on monday as well  :D Bottom end is stripped down now and will be painted later this week, the bores had hardly any wear on them, so just new piston rings, big end bearings and all new gaskets, more on that later.


So here is the injector inserts that where broken, I only required lower parts of all the inserts in the end, so ordered these from VW, only few pounds each, picking them up as well on monday with a few other bits.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4407.jpg)

Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 15 March 2007, 23:24
So picked up new Injector inserts - I ordered top and bottom ones in the end as they were not that much anyhow.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/injector-inserts2.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/injector-inserts1.jpg)

I replaced the cam oil seal

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4308.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4310.jpg)

Old and new cam oil seal

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4305.jpg)

I also made a thread cleaning tool for the injector inserts from one of my old top injector inserts - works a treat..

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/head-injector-homemade-thread-clean.jpg)

A few parts painted and ready :)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4566.jpg)

A few more bits in the box as well :)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/boxofgoodiesready.jpg)

The Head is all ready now... will start put parts back together tomorrow

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/head2.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/head1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/head.jpg)

Also throttle body is now all rebuild and ready to go back on the inlet manifold

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4513.jpg)

More soon
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 18 March 2007, 01:20
So lots of work on the bottom end - 1.8 DX Engine rebuild... I'm waiting on the piston rings to turn up, but this little gasket kit is wanting to be installed...

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/bottomendkit-1.jpg)

So I stripped the bottom end down a while ago and took pictures so here is the progress...

Engine in garage... (you can see downpipe as well, thats up for sale!)
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/1-bottom-end-standard.jpg)

So time to get it on the bench and start taking off the flywheel. You can undo the flywheel
by using 9mm socket in racket (there are a few bolts to undo!!) Clamp the flywheel to prevent it from
turning and start releasing each bolt half a turn at a time until all are slack, then take
all of them out.

NOTE: When you pull the flywheel off, the friction disc will come away as well, so be
careful - see picture below. You now need to with a screw driver release the release plate
ring, which the release plate will more than likely fail out.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/2-flywheel-off.jpg)

Flywheel off, release plate off too :)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/2-clutch-on-bottom-end.jpg)

Now need to take off the pressure plate, which is held to the crankshaft flange by six blots
(see picture above) These bolts are fitted using a thread locking compound, so these will be
difficult to remove as they were tightened to a high torque. Now to properly take the bolts
off you need a clamp to hold the pressure plate in place, I made one using a spanner, or you
can put a 19mm spanner on the other end of the crankshaft pulley and then undo the bolts.
Now have pressure plate off (as below)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/3-clutch-off-bottom-end.jpg)

Now need to take the gearbox plate off, by un-bolting the 3 bolts. You can now unscrew the
bolts holding the end crankshaft oil seal plate in place. NOTE: There are two bolts also from
the bottom of the seal plate to remove. I used a small screw drive to lever off the seal
plate once all bolts are removed. I then took off the green gasket from production :) I
took this off carefully as it was in excellent condition.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/4-Clutch-plate-off-bottom-end.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/5-bottom-end.jpg)

Now time to strip the timing belt end :)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/6-engine-end.jpg)

As seen in the above picture, I removed the inner timing belt cover and I then removed the
front pulley with 19mm socket, I used a large screw driver inbetween the pully against the
block to lock the pulley while I unscrew the bolt. Now can undo the 2 x 13mm bolts and pull
the intermediate shaft out.(see picture below of shaft - sorry its the only picture I have of
the shaft out)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/11-oil-pimp-off.jpg)

Now time to take the sump off the block. Do this by unbolting the mainly 10mm bolts. Remove
the sump off (see below picture)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/8-sump-interior.jpg)

Now see the bottom end of the engine (see below picture) again you will see the sump gasket,
again my is green from production and in great condition. I carefully took this off.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/10-bottom-end-strripping.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/9-bottom-end-stripping-starting.jpg)

I now need to take the nut holding the timing belt drive pulley off. This is a real (****) to
get off, I mean a real so and so to shift. I put a block of wood between the crank and
block and using a very long lever.... the bolt will undo in the end!!!

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/12-taking-off-end-crankshaft-bolt.jpg)

I can now unscrew the bolts holding the oil seal plate in place. most of them are 10mm, but
one is 13mm/16mm.

I now removed the dipstick outer shaft with a bolt and hammer it out.

I then removed the oil pump, this can be done by using 13mm socket, to remove 2 bolts. The
oil bump will now slide straight out. Have a look in the oil pump pickup for debris (I had alot of crap in mine)

Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 18 March 2007, 01:24
So its time to remove the pistons.

NOTE: Please take care here as you need to know exactly which piston goes into which bore and
which way, so its best to remove each piston at a time, take you time doing this.

1. You need to Undo the big end rods using a 14mm socket.
2. To remove the end caps, you need to loose them by tap them using a rubber/nylon mallet on the rod bolts.
3. Now use the hammer to tap each piston out of the bores.
4. Now put the cap back on the mating conrod making sure that the aligning marks line up. It is absolutely essential that each cap fits the correct conrol and is fitted the right way around. then put the nuts back on as well.
5. Repeat 1-4 for each piston. I put each piston on the bench and marked them each to know which one goes into which bore.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/12a-pistons-and-end-seals.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/13-bottom-end-stripping.jpg)

Pistons out of block...
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/14-bottom-end-stripping3.jpg)

So time to remove the main bearing caps to remove the crank.

1. Undo the bearing cap bolts using a mm socket and racket. These will be tight. The cap
itself will also do its best to stay put.

Here is a hint for you , place two of the bolts back in to the top of the cap and use tme to lever the cap while you tap it with a hammer,
working it to and fro, until you can lift it away from the block.

2. Repeat for each bearing cap.

Note: The middle/centre main bearing cap has thrust washers on each side of it. On some
models like mine the thrust washers are an integral part of the shell itself and you won't
see separate thrust washers.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/15-bottom-end-stripping4.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/16-bottom-end-stripping5.jpg)

All the internals of the block on the floor (I used some spare old clothes I found in the garage to put them on, the other half's I think!! hehehe)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/17-bottom-end-internals.jpg)

I checked the bores for wear and there was no wear but then again with only 68k on the engine I'm not surprised.
So with the head now stripped down, its time to give it a clean inside and out. Here is the tools I used. What I didn't take picture of my Clarke large floor standing Parts Washer, made life alot easier for me, plus also used the compressor to blow out off water from head. :)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/18-clenaing-tools.jpg)

I did a bit of research on what options to clean and spray engine parts, here is the options I listed.

Option1
1. Clean up all parts remove any rust or paint (using hot power washer, wire Brush in drill and Deox C)
2. Paint direct using Hammerite smooth (colours as you require?!)

Option2
1. Clean up all parts remove any rust or paint (using hot power washer, wire Brush in drill and Deox C)
2. Paint/Spray on POR15 Metal Ready
3. Paint on POR15
4. Paint on enamel top coat (colours as you require?!)

Option3
1. Clean up all parts remove any rust or paint (using hot power washer, wire Brush in drill and Deox C)
2. Paint/Brush on Zinga
3. Paint on Etch Primer
4. Paint on undercoat
5. Paint on enamel Top coat (colours as you require?!)

Option4
1. Clean up all parts remove any rust or paint (using Wire Brush in drill and Deox C)
2. Leave the parts as natural look for!!!!!!! hehe

Useful sites I found:

http://www.hammerite.com/
http://www.por15.com
http://www.zinga.co.uk
http://www.frost.co.uk (useful site)
http://www.enginewise.co.uk - did not response to phone call or emails
http://www.rustguardian.co.uk
http://www.rust.co.uk


For this engine rebuild, I have gone for option 2, but I am also doing option3 on another complete engine next month (April07)

So with alot of cleaning this is how the block turned out.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/24-engine-cleaned.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/23-engine-cleaned2.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/19b-bottom-end-stripped8.jpg)

I then sprayed the whole block in metal ready.
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/20-metal-ready-bottom-end.jpg)

I then prepared the block ready for POR15 paint.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/21-preparing-bottom-end.jpg)

And with POR15 painted on - the end result

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/22-bottom-end-painted.jpg)

I will get more pictures up once all is dry

Here is picture of the engine bay now...
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/29-engine-bay.jpg)

I will start cleaning up the bay later, I'm going to respray the bay area so its nice and fresh.
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 22 March 2007, 00:14
So here is a picture of the engine block with the head on it just for fun?!

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine-head-painted.jpg)

So I've managed to stay in the country until the 30th of March, so full on work each day on the car and working in the evening to be in sync with my work in the US.... long days but I'm having fun!!

So I forgot about a few bits I was meant to get ready to go to the powder coaters, so I had to give a few items a quick clean today

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/powder-coat-items.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/25-IMGP4584.jpg)

I also ordered the following items today as well  :D

1. Audi, VW Lower Timing Belt Cover
2. VW Oil Pan German 5 Quart New A1 (this is for my other engine)
3. VW Oil Pan Baffle & Windage Tray OEM New A1
4. Seal ring, lower fuel injector holder. 16.5 x 19.5 x 1.5mm
5. CIS Rubber (goes into Battery tray)
6. VW CLUTCH BOLT KIT Flywheel & Pressure Plate
7. Head Bolts
8. DIP Stick Top
9. Coolant hose - From pump to flange on head
10. Coolant hose - From radiator to expansion tank, cloth covered rubber hose. two new hose clamps shown below, the original clamps are not re-useable
10a Hose clamp, 13-14mm size range
11. Timing belt
12. Fan belt
13. Oil filter
14. Oil 10/40
15. 020 Clutch Alignment Tool

I also cleared the work bench of all un-wanted items, so I can start rebuilding the head and bottom end this week, I really wanted to start today, but I want to be able to take notes and pictures of each stage.

I also removed the old engine mounts from the left and right side engine brackets, all I can say is what a nightmare. You have to drill out the middle parts of the mounts and then with a small hack saw make two cuts into the metal part of the mount and then mount will then fall out of the bracket. All and all two mounts - 60 minutes later, can now press in, the new engine mounts into the brackets (I've yet to get mounts pressed in) - another job done.

Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 27 March 2007, 21:00
Had fun just before the weekend, I had a slight accident with a grinder and my arm, which took off a few layers of skin, very lucky person to be honest, quick check up and a few metal bits taken out of my arm and back to the job at hand.....

So over the weekend I finish off the gearbox painting...

I took my spray guns into action

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/spray-guns.jpg)

and here is the results... all the little parts are back on the gearbox now as well as the Starter motor!

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/gearbox.jpg)

I picked up a few parts from the power coaters today, pickup the rest tomorrow... one pic to see the results... - very happy  :cool:

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/gearbox-covers-painted.jpg)

Few other parts which where painted over the weekend

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/parts.jpg)

Now the close up of the Throttle body completed :)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/throttle-body-completed3.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/throttle-body-completed1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/throttle-body-completed.jpg)

and I painted my new water bottle cap - that OEM look - BLACK!!!

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/water-top-painted.jpg)

My next update will be the stage by stage update of putting the engine back together and all together before I put back into the engine bay... its coming along nicely now



Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 28 March 2007, 22:59
It was like Christmas today - parts from powder coaters turned up :)

All wrapped ready for me to be like a kid again on christmas morning?!!!
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/goodies.jpg)

The end result - the finish on every thing is A1.
(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/goodies-powder-coated.jpg)

Even got clips painted as well.... (two in pic where new clips - silver ones)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/IMGP4737.jpg)

Well I've got everything back now... except this..... hopefully will be here by weekend, so I can complete the engine build....

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/86_1.jpg)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 01 April 2007, 21:17
Here is a little update... (I'm in the middle of writing up the step by step rebuild doc at the moment, its taking a tad longer than I thought, but it will be useful for all.. (The old man will be putting the rest of the engine back together for me and then engine will be left in garage until I pop back and to put in the car... going back to USA on wednesday :( ) but back in Mid May07 for European holiday! hehe)

Engine built - 90%
(http://i90.photobucket.com/albums/k261/madonesi/engine.jpg)

Inlet Manifold
(http://i90.photobucket.com/albums/k261/madonesi/inlet-manifold.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/back-inlet-manifold.jpg)

Rad
(http://i90.photobucket.com/albums/k261/madonesi/rad1.jpg)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 14 April 2007, 20:58
Due to the engine is now all together and sitting in the garage waiting for the engine bay to be ready - thanks Dad.. (waiting on pic's to put up), here is some work I did in last month, must keep you all interested while I'm away and all.

So here is pic of the engine bay before I started stipping it down and working on it... (notice all cables in black bags - to keep the wet weather away as I left the car like this for a while)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/before-engine-bay-Feb07.jpg)

I then stripped as much as I could, out of the engine bay. I tired pulling the loom back into the car, but had a lot of issues due to lack of space so I pulled this all into the middle of the engine bay into a new black bag for the moment.

So with all the bits off, I started on the strip down of the brake arm as this needed some love and attention..

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/brake-arm-before-March07.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/brake-arn-before1-march07.jpg)

After a few hours!! of cleaning off the grease and crap, I then added some undercoat and then a few top coats and here are the results... (I went for the natural look as you don't really get to see most of this once the engine is back in.)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/brake-arm-after-cleanup-March07.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/brake-parts-march07.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/brake-arm-aftercleanup1-march07.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/brake-armcleanup-closeup.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/brake-armcleanup-closeup2.jpg)


I then started on a few other parts that needed cleaning up and painting. still need to get final coats on these items.... black of course!!

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine-parts-primer-march07.jpg)

So after a long day, I managed to rub down the whole engine bay area. I had to grind down some parts back to metal due to some welding was required and rust. All I can say is after doing the welding and then cleaning up (very time consuming I can tell you and a few cuts on the hands and arms) I sprayed the engine bay in Red primer, it went on so lovely and covered everywhere.... even a few rubber parts I forgot to pull off and cover up...  :banghead:  never mind a little bit of after cleaning up to do later, to make it look OEM.... nothing that can't be fixed.

I didn't paint the lower parts of the engine bay as this will have black smooth hammerite put on. To be honest it won't even be seen once the engine is in place and plus hammerite is better for lower parts due to all the weather conditions hitting those parts every day.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine-bay.jpg)

Well that's it for the moment, more updates next month when back.
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 11 May 2007, 18:15
A little update... some more parts arrived while I was away (pictures being taken by old man - thanks)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/PAS_53081.jpg)

I'll be back on 20th May so can then focus on getting the engine bay finished painting and then drop the engine back in (its all together now, will show pictures once have engine installed (as usual will be staged pictures how to install engine)

New date for car being shipped to USA - 15th June 07  :cool:
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 25 May 2007, 18:08
So the last few days I've been busy pre-paring the engine bay for top coat (BLACK) and so today was the first few coats.... I let the pictures show the results....

I'll be rubbing it all down again tomorrow with 800 & 1200 wet and dry and then 2 more coats on and then it complete =) then its time to get the engine installed which should be this Sunday and Monday  :D

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/DSC00064.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/DSC00065.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/DSC00057.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/DSC00071.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/DSC00060.jpg)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 28 May 2007, 00:18
Pic's of the complete engine.... and the completed metering head, which I completed refurb and then painted... 8)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine-2.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/Engine-complete-1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/end-view-engine.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/top-engine.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/DSC00209.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/DSC00184.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/close-up-inlet-manifold.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/throttle-body.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/metering-head.jpg)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 10 June 2007, 15:52
So I had a lot of fun this week getting the engine in the car only to scratch the front panel and scratch up the front bumper (was not happy)
so engine out again and spray up the front panel and bumper and the outcome is better than before!!

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/DSC00239.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/DSC00253.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/DSC00252.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/DSC00244-1.jpg)

Engine went back in this morning and final config today and tomorrow  :D  8) (taking break at moment to update all!!)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 16 July 2007, 17:34
More details of progress I did on putting the engine back in the car in June07.

Engine parts back in... run all cables back to locations - giving them all good clean and replacing only 1 broken end with new Vag parts.

(http://i90.photobucket.com/albums/k261/madonesi/IMGP5068.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/IMGP5067.jpg)

Had to replace alot of rubbers in the engine bay, makes it easier to putting everything back, all nice and clean..

Details on replacement heating pipes rubber grommet in engine bay:

VW No: 861819699A - 4.25.
(http://i90.photobucket.com/albums/k261/madonesi/IMGP5065.jpg)


Time to install the refurb Braking system, with upgraded Brake servo and Cylinder, the two front braking lines & from T-junction to Servo are new, with just adjusting the rear lines to fit into the T-junction on the RHD of the braking bracket.
(http://i90.photobucket.com/albums/k261/madonesi/engine-part-back1.jpg)

Close up of braking system..
(http://i90.photobucket.com/albums/k261/madonesi/brake-setup.jpg)

How I set-up the four lines into two, nicely out the way :)
(http://i90.photobucket.com/albums/k261/madonesi/brake-setup2.jpg)

Also as part of the upgrading of the braking system, replaced brake Hoses front & Rear & also handBrake cables, left and right.

Next update I promise will be the engine going into bay details... just a tad busy these days to update..
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 30 July 2007, 00:03
So Final step - putting the engine in the car!!

On this engine install, I will be installing from the bottom of the car and then lift the engine into place with a engine crane. I hired a engine crane from HSS for only 32.00 for a complete weekend. So before I started on the engine install I needed to do some prep work.

1. Put the exhaust wrap on the exhaust manifold.
Items required - exhaust manifold, High Temperature wrap and Stainless Steel High Temperature Ties.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/exhaust-items.jpg)

After about 60 minutes of fun putting the wrap on here is the end result.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/exhaust-wrapped.jpg)

As I bought a new gearbox, some parts needed to be taken off my old gearbox and transfered over. I needed to add the rear engine mount braket studs into the gearbox. I did this by used two nuts tightened together and then put spanner on both and turned to loosen them off of the old gearbox and then add to new gearbox (see pictures below)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/gearbox-1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/gearbox1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/gearbox2.jpg)

I then added the new fuel injectors onto the fuel pipes and then added these to the engine

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/injectors-lines.jpg)

I then repainted the engine mounts for gearbox and front mount - wasn't happy with last spray results

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine-mounts-1.jpg)

So now I jacked up the front of the car and put two large axle stands on the front, so it was high enough to slide the engine under and then I put two small axle stands on the rear. I then took off all the wheels and filled the brake lines with brake fluid and then bleed the brakes.

I now moved the engine under the car and into the middle of the engine bay

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine-in-bay.jpg)

I now removed the drivers side complete brake set-up with the drive
shaft and also removed the front anti roll bar as these items would
of been in the way of lifting the engine into place.

Now the engine is under the engine bay, time to add the rear engine
mount and the raceland manifold, I then added the raceland adapter
to the end of the middle section of the exhaust still on the car.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine-lift-1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/add-rear-mount.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/add-exhaust-to-engine.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/add-exhaust.jpg)

I then rolled the engine crane over the engine bay and roped the
engine to the crane and lifted up the engine into place. First - driver
side engine mount, then the rear engine mount and then
passengers side.(The front engine mount will be added when the
start motor is added)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine-lift-1.jpg)

This method of installation I find easier, as I can control engine better and I didn't scratch any of the engine bay paintwork of engine :)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine-in-1.jpg)

Now I had the engine in place, I then connected up the Raceland manifold to the rest of the exhaust. Next putting back the drivers side complete brake set-up with the driveshaft and also the front anti roll bar. Then bolting up the drive shafts - adding grease and then adding new bolt.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/new-drive-shaft-bolts.jpg)

I then spent the next 3 hours, running all the cables to the engine and added all the remaining engine parts, so it looks like this now.

I'm really please with the results.

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine-complete.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine-complete-1-1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine-10.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/BLACK%20SOY/engine-11.jpg)

I also spent a while setting up the engine so it was running nicely  :D  :D
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 13 November 2007, 00:25
Well after all the hard work, I am now going to sell the car instead of shipping to USA. Car is still in the UK. Full details will be in sale section in next few days.

thanks....

New project will be published soon... its a LHD is all I'm saying!

Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 17 January 2008, 23:55
I have left my car with a good friend on this forum, who put it through its MOT last week and passed :) - good old mk1's  :smiley:

A few bits will be done on the car, before it will go up for sale near spring/summer time.


(http://i90.photobucket.com/albums/k261/madonesi/side-front.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/front.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/back.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/side.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/IMGP5374.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/engine-1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/IMGP5371.jpg)

and under shot :)

(http://i90.photobucket.com/albums/k261/madonesi/engine-underneath.jpg)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 06 April 2009, 09:14
The SOY is on the move......

Last month the car moved from up North to down south again (back to my parents place) Thanks Lewy for looking after the car.

The car is going to be prepared for shipping to the USA :) later this year when I am back in the UK to finalize everything.

I've got big plans for the car once in the US, but I will explain more once I have it moved over.

Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 04 August 2009, 09:55
Only a few weeks until back in the UK to start sorting out moving the BLACK SOY :) :) :) :) :) :)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 21 August 2009, 13:50
Back at last in the UK and got the car out of the storage unit yesterday.

Lets just say it needs a really good clean, inside and out, which is my job for the next few days. Overall everything is as before and it started up first time after a battery charge and everything works - good old Volkswagen technology. :smiley: :smiley: :smiley: :smiley: :smiley:

Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 14 February 2010, 05:27
Seems alot of my old pictures on this build thread are not showing anymore.

I have gone through and updated all the links so the pictures are showing again, hope you enjoy.

Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Lewy on 20 February 2011, 12:04
Where is it now buddy, the US or blighty?
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 23 February 2011, 05:33
US parked up in garage, waiting for summer to come by for me to start the new look and a little bit of air-ride :)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Lewy on 23 February 2011, 14:35
Sweet, is it going to have the bonnet changed for a hood, and boot for a trunk to comply?

 :laugh: :laugh: :laugh: :wink:
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: SoundillusioN on 23 February 2011, 16:51
Sweet, is it going to have the bonnet changed for a hood, and boot for a trunk to comply?

 :laugh: :laugh: :laugh: :wink:
Also going to be converted from Petrol to GAS, have the windscreen replaced with a windshield.  The list could go on.   :grin:
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 26 February 2011, 01:27
come on guys stop telling everyone my secret plans, the best part of those plans are they are free :) lol
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 24 April 2011, 02:57
I'm starting to work again on the BLACK SOY on Monday :) Pictures to follow in a few days, time to rip the cab apart!!
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Lewy on 24 April 2011, 10:43
Pictures or it doesn't happen!

 :laugh: :wink:
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 24 April 2011, 19:25
Pictures or it doesn't happen!

 :laugh: :wink:

you will see pictures, I think it will be shock though to everyone....! Where are you updates on your White mk2?!
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Lewy on 24 April 2011, 20:18
Where are you updates on your White mk2?!

Done.
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 06 May 2011, 23:48
I want to see more updated on the car Lewy!! :)

So I've been doing some research for my audi mods and been thinking hard on my wish list for cabs new look. This is going to be long term project people, but this is my list of goodies for the car.
 
-  Take car completely apart and check all body work, inside and outside, I want to make sure the shell is 100% rust free and do some mod's
-  Take off clipper kit and go small bumpers, looking into custom one off piece bumpers
-  New engine - G60-16v or 20V (easier to go 20v route in US) \
-  Clean smooth engine bay.
-  Upgrade brakes - Pedal Box
-  Electric power steering (Corsa steering set-up)
-  Refurb interior, thinking about going old skool BMW dashboard, but I love the mk1 dashboard so much, might just custom that a bit! (still thinking on this one!)
-  New wheels
-  New suspension - researching on air ride for the audi, I'm really wanting air ride for the cab too now, might be able to get a good idea buying 2 of everything!!

I'm doing alot of research at the moment on engine conversions and air ride, so if you have any good links on engine conversions and air ride, let me know please.

Feels good to be mod'ing the cab again.
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 26 July 2011, 23:47
Well I've been busy currently on holiday in UK and France, and managed to go to the mk1 AMG Show last weekend :) loved it. I so want to buy more mk1's and send over to the USA with me.

You can view AMG pictures at - http://www.vwgolfmk1.org.uk/modules.php?name=Forums&file=viewforum&f=70

I managed to start going through my load of spares I've had at my parents garage and I'm amazed at what I've found and forgot about, so am now sorting out parts to keep and what to sell on forums/e*ay!

When I get back to the USA, start to clear out the house garage and start really getting to work on the car. I promise pictures :)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 14 November 2011, 20:38
..

Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 21 November 2011, 23:30
Been working on brakes system on mk1 and used the following pages, thought would be useful for other :)

In short the rear brakes locked up, so taking everything off for complete refurb.

[
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 01 October 2014, 16:24
The BLACK SOY Cabriolet is now back in the UK and I will be putting this up for sale in November timeframe. I will post full details here and in the FOR SALE Mk1 section.

I don't really want to sell it but I have too many other commitments and some of the toys have to go.



(http://i90.photobucket.com/albums/k261/madonesi/side-front.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/front.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/back.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/side.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/IMGP5374.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/engine-1.jpg)

(http://i90.photobucket.com/albums/k261/madonesi/IMGP5371.jpg)
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Lewy on 01 October 2014, 20:02
Damn, I move away and now its for sale....

Your timing is nearly as bad as mine!
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 01 October 2014, 21:06
Damn, I move away and now its for sale....

Your timing is nearly as bad as mine!

I say road trip for you then ;) WOW already had several enquiries on this, I don't think it will be up for sale long, but then again, someone is going to get like a new cabriolet.
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 01 October 2016, 04:16
Well its time for me to clean out my mk1 spare parts, I have a complete garage full of mk1 parts. I am going to be back in the UK in October, if you want a mk1 part, PM me and I will reply with details. Too much to list out, I have used (complete mk1 golf gti broken into parts, less main shell itself and new parts)

Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Madone_si on 09 August 2018, 22:54
Well 13+ years ownership and this lovely cab is moving onto a new owner in the UK. I am sure it will appear again in future shows as the new owner is a legend.

Look out for my new project details soon... the goal is to show new project at SEMA 2020.
Title: Re: Madone - Mk1 Golf Cab GTI - 'BLACK SOY'
Post by: Lewy on 06 January 2019, 23:03
Oops.