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Model specific boards => Golf mk1 => Golf mk1 gallery => Topic started by: Madone_si on 22 February 2019, 21:28

Title: US VW Cabriolet 85
Post by: Madone_si on 22 February 2019, 21:28
Hi Everyone,

Brought myself a 85 cabriolet locally in Washington USA, brought from family from new and only had 2 family members drive it. low miles, LHD, runs and drives, has AC and power steering but needs some love and few things are not working, but who wants to buy a perfect mk1 anyhow! :laugh:

Plan is to get it running and working 100% and then I will focus on body work, new paint, interior and suspension, wheels and other areas I am thinking about upgrading.

Biggest issue to focus on straight away is a good clean inside and out, its seen better days!

Here is car!

(https://farm5.staticflickr.com/4847/31215535887_a5218e4d76_c.jpg)

(https://farm5.staticflickr.com/4902/46154846121_93e2fa2166_c.jpg)

Hopefully should be fun project and I hope to share my experience, what I learn, how I fix things and overall engage again with Golfgti family - you might also see now and updates on my other build - mk1 Golf Racer R updates too.

Thanks Si
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 28 February 2019, 04:47
Well the northwest rain is keeping me from giving the car a good clean inside and out, so I started to check all the electrics inside the car and here is what I found

Open either door and inside light does not come on (does come on if push switch to on position) - need to check door switches and cables
Dashboard cluster - functioning correctly, expect - no lights coming on (will check blubs, fuses and dimmer switch)
Dashboard cluster clock (digi) not coming on - will check cluster, fuses)
Looks like the main lights only come on, I don't see any side light bulbs in my main light units - is this normal for US spec cabs? They come as standard in European models.
wipers work - little slow for my liking (will take out wiper unit and refurb or upgrade)
side indicators working at front and passenger rear, look like the drivers rear not working (discovered the whole light unit is not working) - need to investigate more.
Hazard switch works for 3 corners working
Heater unit works, due to this vw cab has AC installed, I need to read up more on each of the selections, I cannot hear the heater unit as I would from previous vw cabs I've had, but then again none of them had AC installed. Interesting when select #3 on heater knob the radiator fan comes on - not sure if that is normal either.
Original stereo / Radio - working fine, speakers are blown and the Aerial Antenna  needs replacing.
There is an alarm system installed in the car, but it looks like someone disconnected it - there are wires everywhere - that will be a job for weekend to trace it all and take out. (Clifford alarm - I hate these makes, had one in the UK and it used to go off whenever it liked!)
Rear window defroster switch is solid and not working (I pulled this out of the dash and found the following below) - need to trace the cabling back to the main loom and see if any other cables are impacted too.


Well looks like the switch over heated and melted, I need to order a new switch and rear connector as well. switch should be easy to order, but I'm not seeing connector for sale anywhere. Time to widen my search to various online forums :)

(https://farm5.staticflickr.com/4863/45585383704_b7ec11a42d_c.jpg)

(https://farm5.staticflickr.com/4817/45585384854_b8fa4ca13d_c.jpg)

(https://farm5.staticflickr.com/4826/45395886475_f35ba04d83_c.jpg)

When I drove the car back home, the oil pressure light and buzzer was going off when I went over 2k, I know this is one of the oil switches on the oil filter unit, I tested it after it started to happen on the side of the road (Full details on this issue is well documented but for others here are few links)
https://forums.vwvortex.com/showthread.php?2049336 (https://forums.vwvortex.com/showthread.php?2049336)
http://www.cabby-info.com/gauges.htm (http://www.cabby-info.com/gauges.htm)
https://www.reflectionsandshadows.com/cabby/dopws.html (https://www.reflectionsandshadows.com/cabby/dopws.html)

I wonder what else I will find wrong with this cab???
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 28 February 2019, 22:36
So here one of the other mk1 cabs I have as well, its actually in good condition. This one is automatic 1983. Not sure what I am going to do with the second one, might strip it and make into a cab racer with 16v or R32 conversion as a friend of mine wants to learn how to work on cars and race.

Need a good clean and starts and runs.
(https://farm5.staticflickr.com/4869/31395560027_33bf1830ec_c.jpg)

interior is in amazing condition - big bonus
(https://farm5.staticflickr.com/4912/46334719011_f2730ee914_c.jpg)

So back to 85 cab got a custom car cover, as this car sits outside most of the time, due to other cars taking up garage space and the car port area.

(https://farm5.staticflickr.com/4894/31395560147_a3616746bb_c.jpg)

So I started to look and find where the alarm system was - well it was not hard, it was glued to the underside of the lower dashboard right next to the main loom and also sensor unit (Broken) inside the center console and wiring to the starter and battery. I have most of it out, just got few pieces of wires to clean up.

Who ever installed it was a cowboy, the wiring is a mess.

(https://farm5.staticflickr.com/4881/46334718901_f5a08c9592_c.jpg)

(https://farm5.staticflickr.com/4914/31395559247_364d778af4_c.jpg)

I have complete gear shifter kit, so not too worried about this one being rusted out, but it now makes me want to take out all the seats and carpet to make sure there is no further rust anywhere else.

Fuse cover has seen better days!

(https://farm5.staticflickr.com/4907/44517921470_a7c86bed5c_c.jpg)

Also ordered myself mkII throttle body - get better throttle response once I have all the other mods done too (going to keep the 8v engine with CIS.

(https://farm5.staticflickr.com/4914/45611367104_04cf825bbf_c.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 01 March 2019, 17:26
Productive few hours today.

1. Finished up removal of the alarm system - Clifford you are done!
2. Removed cluster from dashboard - some switches broken ;(
3. Fix the cluster clock and tested everything
4. Managed to get nice upgrade item - could not stop myself!

All the parts I removed from the car relating to the alarm - took hour to rip it all out, didn't even have to remove anything - that is how bad this installation was!
(https://farm5.staticflickr.com/4804/46363870732_de2818dfeb_c.jpg)

Before taking out cluster in dashboard
(https://farm5.staticflickr.com/4909/31474990807_5daec5f279_c.jpg)

sadly few of the switches broke as taking out - they just come apart with backs coming off - its happens no big deal, will order new ones. The worst one was main light and cluster light adjustor (this could be why my cluster lights not work - but will validate that with testing cluster and each bulb.
(https://farm5.staticflickr.com/4834/45691483484_283a1601d3_c.jpg)

I don't think this cluster has ever been taken out.. (which is good)
(https://farm5.staticflickr.com/4829/46414530671_357511c229_c.jpg)

Super clean cluster, so happy no damage.
(https://farm5.staticflickr.com/4857/46363874712_cd5792359a_c.jpg)

cluster taken apart and you can see broken switches at the top left and I got spare replacement clock unit too, as my original was dead. Also tested each cluster bulb and they all worked, so I think the main light switch is the main cause.
(https://farm5.staticflickr.com/4867/46414533851_a01d4e4981_c.jpg)

Testing the new clock unit - it works!
(https://farm5.staticflickr.com/4889/45502127145_00000dd477_c.jpg)

and all back together again, I also installed superbrightleds - bulbs - so I can see the cluster in dash!
(https://farm5.staticflickr.com/4879/45502132265_a612a373df_c.jpg)

The cluster with new LEDs - lit up on my desk - they really are bright now :peace:

(https://farm8.staticflickr.com/7820/45502566375_96b90a778a_c.jpg)

and here is my little upgrade item - vw mk2 recaro seats - I will be having them completely rebuilt (part of whole interior being done) - I will do most of the work but get an amazing local upholstery company redo cloth for me.
(https://farm5.staticflickr.com/4875/32502040768_ed727b4d29_c.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 03 March 2019, 17:15
oops another mk1 upgrade item bought today!

Managed to pick up set of 14x6.5 4x100 ET30 BBS RM wheels, need to sort out new center caps. With dropping the car on coilovers (need to figure out which coilovers yet) and these wheels should get a really nice low look but very functional.

(https://farm5.staticflickr.com/4843/45818252735_eeaf6af7b4_c.jpg)

(https://farm8.staticflickr.com/7804/45818252805_a55b588d7f_c.jpg)

Title: Re: US VW Cabriolet 85
Post by: Madone_si on 06 March 2019, 18:06
Well managed to stay dry for most of the day for me to do some electrical work on cab.

(https://farm8.staticflickr.com/7919/39851596173_9bdf511db0_z.jpg)

Start out with replacing the rear window defrost connector. Compare new and old, cut the wires ready for soldering wires so everything is done right and protecting the soldering of wires.

The issue;
(https://farm5.staticflickr.com/4878/31875439897_7dc76f7a92_z.jpg)

new connector
(https://farm8.staticflickr.com/7871/46091880154_47da603553_z.jpg)

wires ready
(https://farm5.staticflickr.com/4823/39851645813_6c52d10509_z.jpg)

loom wires ready
(https://farm8.staticflickr.com/7805/39851643483_3f7331107a_z.jpg)

tools of choice to solder and heat up protection over soldering
(https://farm8.staticflickr.com/7898/46091879244_d57f4d8833_z.jpg)

key to make sure wires are intertwined and then add solder and after minute, put protection sleeve over and heat up for perfect finish.
(https://farm5.staticflickr.com/4832/39851584553_980c8272e3_z.jpg)

all done on defrost wiring. I did add electrical tape just in front of the protection sleeves to make sure all wires are together just like OEM finish before.
(https://farm8.staticflickr.com/7846/46816882441_1aeeecb304_z.jpg)

Now moved onto the starter motor power cable in the engine bay. When I removed the alarm system they cut into that cable and well it was not done well so I wanted to repair it right. Here is cable pulled out and showing what was in place.
(https://farm5.staticflickr.com/4871/46816883441_6987548352_z.jpg)

I noticed the wires was about 4-5 inches short cut to cutting and cleaning up, so add a new section to the wire, clean wires intertwined and soldering and protection sleeves add.
(https://farm5.staticflickr.com/4883/45901921185_929de197b1_z.jpg)

All the crap taken out from that single wire.
(https://farm5.staticflickr.com/4810/45901924355_9fec43c3ed_z.jpg)

Tested the car to make sure starter kicks in and started the car :) - works perfect (http://"https://www.youtube.com/watch?v=wqf6bFdCJRo").

Now onto the rear of the car and why drivers side rear light unit is now working and replace the rear boot strut as it wasn't work.
(https://farm8.staticflickr.com/7821/32941213288_d1b7550702_z.jpg)

Well after looking at both sides of the rear lights unit, it was clear the issue was just rust on all the connectors, so took out both, cleaned them up and place back (20 minutes of work later) and lights all working perfectly.. I get a feeling I am going to discover more ground issues on this cab...
(https://farm8.staticflickr.com/7852/46091882064_652bc39e04_z.jpg)

Now moved back inside the car and temp installed the dashboard and most of the switches to test out work I did on cluster - happy to say clock is working and everything else works as need but with one issue. The cluster lights and some of the switches lights are not working..
(https://farm5.staticflickr.com/4846/46091850204_3490f766ea_z.jpg)

So time to check the fuses and relay and grounds to figure out why cluster and some switches are not lighting up.

Well everything looks ok on fuse/relay box or is it?
(https://farm5.staticflickr.com/4804/39851583033_6a8f73360a_z.jpg)

Well this is not good...
(https://farm5.staticflickr.com/4847/31875434907_6e8b6d4481_z.jpg)

and the top two relays had alot of rust too on relays and on the connectors too..
(https://farm8.staticflickr.com/7896/32941213418_5b00f63a8e_z.jpg)

So getting the fuse/relay box out was easy but the star ground connectors are pain to get too, so I remove the lower sub-bar dashboard (that was not fun to do)
(https://farm8.staticflickr.com/7895/45901921265_b4e19d8718_z.jpg)

checked all the relays, cleaned up most of the connectors, but two of them are bad, so I think I will need to take them apart see if I can clean them and test them - 26 and 37 are the worst ones.
(https://farm5.staticflickr.com/4846/46091870734_0f47ca3e1c_z.jpg)

Relay 37 taken apart.
(https://farm5.staticflickr.com/4811/46816896941_5b3b697b87_z.jpg)

Cleaned up well and was just the pins that had rust, rest was perfectly clean inside
(https://farm5.staticflickr.com/4881/46091848714_eef6a15f66_z.jpg)

Relay 26 on the other hand had rust inside and I could not clean it without breaking parts and seeing as I can get a replacement for real cheap - I ordered new one
(https://farm8.staticflickr.com/7851/39851578293_4177a3594a_z.jpg)

I took out the star ground x2 connectors they are so bad and had a lot of rust also on the bolt to the metal bracket, I need to order new ones and clean up the bracket too. Will show more on that on next update. I did so a quick test with ground from brown cluster cable to back of the dash metal and the cluster lights came on, so I know I have ground issues - well that is nothing new for a mk1 owner.. :banghead::laugh:
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 08 March 2019, 00:14
more investigation into the source of water leak. It could be the antenna its broken but its more than likely the 20mm hole on drivers side 50% outside and 50% under the front wind screen (its the only hole and rust area I can find on the outside of the car) - typical!

All grommets look good in the engine area on firewall area - I will check them all anyhow and replace if any break or not up to my standard.

I spent today clean my spare cabriolet top cover, got it in December. Plan is to clean it up see how it looks afterwards, if good use it, if not I think I will dye it Black.

before
(https://farm5.staticflickr.com/4910/46780282712_46824d39c9_z.jpg)

during
(https://farm5.staticflickr.com/4890/31891013897_ae36315f91_z.jpg)

after
(https://farm8.staticflickr.com/7903/32956861098_041ff68cdc_z.jpg)

one area looks to be unclean able :(
(https://farm5.staticflickr.com/4858/32956860778_e129ddd482_z.jpg)

So end result is it cleaned up well and everything is good enough to use, but I am going to dye it Black so now looking into how to get that done :laugh:
Title: Re: US VW Cabriolet 85
Post by: Simeon on 08 March 2019, 15:58
Great work mate, reminds me of watching Edd China work on cars on Wheeler Dealers, very methodical :)

Lots of rusty connectors eh, I hate electrical gremlins, usually such a pain to find and fix
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 08 March 2019, 17:20
Thanks Simeon - maybe I should start up a youtube channel  :laugh:  :smug:

yeah the rusty connectors are everywhere.. I think this car sat outside not used for long while  :cry:
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 12 March 2019, 17:53
little update - cleaned up the star ground connectors with vinegar - worked a treat.

Just placed into bowl with vinegar
(https://farm8.staticflickr.com/7841/39889897313_bb42e70c00_z.jpg)

few hours later
(https://farm5.staticflickr.com/4910/46129758894_dd9f28ef59_z.jpg)

and with wipe of cloth - looking like new again.
(https://farm8.staticflickr.com/7923/31913559217_9c593654af_z.jpg)

I have to wire brush the inside yet.

The next challenge is how do I get the rust of the end ground loom cable up inside the dashboard. Been thinking about putting vinegar in bowl and into a clear bag and placing the cables into the bag and bowl and then somehow hold the bag up in place so vinegar can do its thing to the cable end pins. Will try out and see what happens..

Next week is going to be exciting and big update... all exterior is coming out and sending off to get new look....
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 19 March 2019, 02:05
Been on the hunt for a while for a certain set of wheels, so managed to get these yesterday so happy 15x7 Fittipaldi

Going to do some spacers to push front and rears out to the lip edge.

(https://farm5.staticflickr.com/4892/46114788925_3e9221678b_z.jpg)

downside is I don't have the center cap tool :( 

The center cap tool is very rare key after some research, but not a problem... just end up making one.

time to measure
(https://farm8.staticflickr.com/7813/33221182358_8c2d4a4ee0_z.jpg)
<br />
(https://farm8.staticflickr.com/7894/47096238351_25723351cb_z.jpg)

(https://farm8.staticflickr.com/7914/46372753644_8bc116f24d_z.jpg)

(https://farm8.staticflickr.com/7918/32154532017_e8e28504fa_z.jpg)

I then made up a mock up of tool and then had new tool made on the metal lathe and here is result;
(https://farm8.staticflickr.com/7916/33339107448_cfd4dd800f_z.jpg)
(https://farm8.staticflickr.com/7836/32272461077_afdc9d599b_z.jpg)

now I get working on cleaning up and painting these wheels to go on the cab. I need to get coil overs installed and finish up with ground wires and then its driving so can get the car over to upholstery guy to finish up the revamp of the interior.
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 22 March 2019, 03:43
Finally with some dry weather I reinstalled ground units again and cleaned up the ground cables and plugged all back in. Also added the one fixed relay and new relay.

(https://farm8.staticflickr.com/7904/46527527524_1e5fdf09bd_z.jpg)

Relays
(https://farm8.staticflickr.com/7839/33375240958_6b0f37c61d_z.jpg)

and all installed :)
(https://farm8.staticflickr.com/7803/46336630805_7319332353_z.jpg)

I did a few things to the cluster. I add electrical tape on both sides of the plastic parts where the cluster electrical plugs go, this makes sure the connectors actually have a firm connection. I found that when I moved the cables connected to the cluster the cluster functions would stop and start.

Cluster in and now the lights in cluster are actually working. This I think was two fold. Ground issues and the cables connectors not having firm connections. Happy now.
(https://farm8.staticflickr.com/7878/46527528114_0f2fa0c0ae_z.jpg)

also all the other dash lights are now working too :) all except one center console dial :( will need to order new light for that one.

(https://farm8.staticflickr.com/7825/32308990987_3ef57acfb6_z.jpg)

(https://farm8.staticflickr.com/7926/40286184903_b0952dc811_z.jpg)

On the wheel front, had to make sure I had the right bolt setup to order my adapters - confirmed 5 x 112. Ordered 4x100 to 5x112. Due to wheels are ET35 been thinking I might do conversion to 5x112 would give me more options for future too.
(https://farm8.staticflickr.com/7902/33375234518_fe9f561c4e_z.jpg)

and could not stop myself to see roughly what they looked like. I think once the car is lowered on coil overs and adapters installed the wheels are going to fill that wheel arch nicely.

(https://farm8.staticflickr.com/7824/33375233128_20db27b8c0_z.jpg)

Happy Friday everyone!
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 25 March 2019, 20:00
Been checking brakes and suspension setup in preparing for coilover installation. Need to order new front rotors and pads and full brake flush and fuilds, lower arms going to replace too, overall what I thought the conditions would be.

Starting to clean wheel arch areas to see what it would look like under all the years of road usage and looks to be nice clean paint so good news.

Then I noticed something I've not seen on any of my previous mk1s - the wheels bolts are not bolts but nuts with threads. No big deal will be replacing front and rear setup back to OEM anyhow, so I can add adapters on to fit the new wheels.

(https://farm8.staticflickr.com/7849/47259705821_53b1d77ef4_z.jpg)

I also had the lovely job of getting the ash tray out of the lower dash as the light and lighter unit was not functioning. The actual light unit itself was a pain to get apart. Separating it from ash tray unit without braking it. Must not break small plastic parts oops!

I ordered a new light unit that can be used as power adapter as well from later VW model near perfect in spec and cheap.

Still needed to take apart the light bulb so can replace that too with LED version.

(https://farm8.staticflickr.com/7897/46380793835_3c7ddcd1c6_z.jpg)

Also took apart light bulb unit for one of the center dials to replace it and the other two with LEDs.

(https://farm8.staticflickr.com/7854/47295467251_781c749776_z.jpg)

Will be little delay in update due to having to work on all LEDs, getting interior completely out and to someone to redo all interior for me, plus I'm heading back to the UK :) for early April.

I will be happy to get done with all this electrical issues and more onto big items and upgrades...
Title: Re: US VW Cabriolet 85
Post by: andy28 on 25 March 2019, 20:06
Loving this thread madone_si
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 26 March 2019, 15:17


thanks Andy28.

Managed to get few bits done last night and tested in cab this morning.

Finally the day when I get to see all the interior lights working and with upgraded LEDs too!

New lighter unit turned up allowing me to charge my mobile and other stuff - this is from a later VW model - near perfect match. Just have to adjust the connector on the loom
(https://farm8.staticflickr.com/7828/46730342614_4fedd5e4d4_k.jpg)

Install into the unit
(https://farm8.staticflickr.com/7888/40487484743_a2edf680e9_k.jpg)

(https://farm8.staticflickr.com/7887/46730339944_5122b3f3c2_k.jpg)

(https://farm8.staticflickr.com/7814/33577240868_dd98fb0609_k.jpg)

Testing out the light
(https://farm8.staticflickr.com/7851/40487488323_257a56f961_k.jpg)

Moved onto the start of replacing all dash bulbs to LEDs - I will show few of them below, most are the same way I did them. Got this down to less than 4 minutes a unit to complete.

Each unit at the top of the pins where meets the bulb, there is little piece of metal push down - this hold the pins inside the bulb unit. you push these up, with tiny flat screwdriver from the ends and same time push pin upwards - this will allow you to remove bulb and pins from unit. Do this part slowly
(https://farm8.staticflickr.com/7824/47453460301_40821a80ba_k.jpg)

Give you idea of bad bulb, new OEM bulb and LED bulb
(https://farm8.staticflickr.com/7879/33577241358_6726fc79a2_k.jpg)

some other units doing at the same time
(https://farm8.staticflickr.com/7824/40487483713_ad6cab3826_k.jpg)

I usually do all my soldering using my multiple clamps but for the life of me I cannot find them :(so had to revert back to old ways of taping bulb down and using pliers to hold pins while using soldering unit. Worked out very well actually.

Then moved on to preparing LED light and then soldered first pin on (I will always get soldered on and then afterwards clean up weld to make flat)
(https://farm8.staticflickr.com/7881/46730340914_f1e48120bb_k.jpg)

Both pins soldered welded on
(https://farm8.staticflickr.com/7890/32511741357_42044ffa12_k.jpg)

Key to now test bulb (I always test each new bulb before trying to install as well)
(https://farm8.staticflickr.com/7918/33577246058_4944eeebe6_k.jpg)

Now time to install into unit. Key you do this part gently to start, you need to make sure each pin goes down into the bulb unit slows of each side and then using small screw driver you can push down on top of pins to get it down 30% into unit as you can see below.
(https://farm8.staticflickr.com/7853/46538309255_64d1fa4e95_k.jpg)

To get bulb and pins to sit completely in unit as below, I use two ways. 1. Keep pushing top of pins down with screw driver until the bulb gets in the way, this then allows the pins to show on each side of unit and I then use a pointed screws driver to put into the pin hole and pull pins down - works really well.
(https://farm8.staticflickr.com/7905/47400588272_6a0a4e5d53_k.jpg)

Time to test again to make sure LED is ok and working
(https://farm8.staticflickr.com/7902/47453460861_e171f04811_k.jpg)

Now I just repeat this process again to all the interior lights...

This is the unit I used with some electrical wires to test out the bulbs
(https://farm8.staticflickr.com/7865/40487486443_d6e3c3fee3_k.jpg)

I tested out one or two of the LEDs in the car.

Compare OEM to LED
(https://farm8.staticflickr.com/7813/46538304495_f64ce28a48_k.jpg)

LED is on the left the other two are OEM - but both will be replaced to LED.
(https://farm8.staticflickr.com/7857/46538304955_54fc3b1b4f_k.jpg)

Then replaced the light switch bulb to LED and can also see much better now the dashboard with LEDs
(https://farm8.staticflickr.com/7912/40487489463_ff304772cb_k.jpg)

What dash looks like at night...
(https://farm8.staticflickr.com/7820/45502566375_96b90a778a_z.jpg)

Well I for one am happy now I have all the wiring working and lights as I want it, just got to finish up few more units to LEDs and then we can put the dashboard all back together, or can I? (will explain in next update)

Hope you all are getting your VW fix on of fixing or installing new parts.
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 23 April 2019, 05:25
At last my collectors plate come in :) can actually use the car on the road.... yeah! and no more yearly tab costs ;)

plate and new plate holder
(https://farm8.staticflickr.com/7831/32537676827_bcd5a21afb_k.jpg)


and all installed!
(https://farm8.staticflickr.com/7832/47426732942_51680d21b5_k.jpg)

lots of parts arriving - so hope to get big update out in coming weeks.


Hope you all get your vw fix today of fixing and install new parts!
Title: Re: US VW Cabriolet 85
Post by: Mr_Orange on 23 April 2019, 07:14
Brilliant build thread. Keep up the good work, and the updates!  :cool:
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 20 May 2019, 19:06
Brilliant build thread. Keep up the good work, and the updates!  :cool:

thanks

Been working on my other mk1 white cab the last month getting it ready to sell... this one is automatic. Just finished up full service and clean waiting on side trim to turn up and this cab is complete and will be sold.

(https://live.staticflickr.com/65535/40926046833_7385eda7e2_k.jpg)

I took off the wheel arches and was amazed to find not a single bit of rust underneath = result :)
(https://live.staticflickr.com/65535/46976336995_e909652d3b_k.jpg)

Updates on the other cab will be coming soon - waiting on few new parts to arrive and then alot of work will be happening.

Title: Re: US VW Cabriolet 85
Post by: Madone_si on 02 July 2019, 16:58
Well I have been collecting loads of parts for the car, in short over next month I will be taking out suspension and all four corners setup and replacing everything. This will then leave me with focus on improvements to the engine, then interior and last paint job. Actually thinking more about it I really need to do that in the other direction..

I want to get the car completely repainted, sort out interior and then all running gear.

The most exciting part turned up - big thank you to KW suspension. Will be working with them more for my other build soon too. Quality of this suspension is very high.

(https://live.staticflickr.com/65535/48121655508_b5d5a5f522_k.jpg)

Also new manifold down-pipe turned up, I have some work to do to this so it has a flexi part. More to come on that later. (This so reminds me of the BLACK SOY work I did)

(https://live.staticflickr.com/65535/48144666376_3bda864c7b_k.jpg)

Did two pieces of work recently

1. Upgraded stereo and put in a aerial booster

(https://live.staticflickr.com/65535/48121718617_a763b0dd2c_k.jpg)

(https://live.staticflickr.com/65535/48121620506_93d35319e0_b.jpg)

2. Fixed the drivers door top trim

Lucky I save stuff over the years so pulled out of my own stock

(https://live.staticflickr.com/65535/48121659353_d38c4c3121_k.jpg)

(https://live.staticflickr.com/65535/48121716637_5ef150b4c9_k.jpg)

I then used 3M heavy duty weatherstrip - boy this stuff works great and gives you about 5 minutes before starts to go off.

You apply 3M to the back of the trim, make sure you have good amount at bottom ends (not too much that it goes everywhere) and using clamps hold it in place and let try for few hours.

(https://live.staticflickr.com/65535/48144667951_a4c8cbe9db_k.jpg)

Working on clearing out my garage at weekend, need to do some work on my MGA and then I can get some more photos of all the parts I have (currently in loads of boxes)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 29 October 2019, 12:26
Well I know this is way overdue, but sometimes family stuff just gets in the way of projects  :lol:

So in short, I have the interior fully out and working myself on new covers for the front and rear seats. I have everything now to completely take apart front and rear wheel areas and add new parts.

I also have most parts for engine refresh and service, but need to this winter really get the car stripped down more to fix some areas and get it repainted while I have interior out and all the old parts still on it.

Will get some photos up in coming weeks.

I am also going to see my old BLACK SOY Cabriolet 92 next month as new owner is doing some work on it.

thanks
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 30 October 2019, 12:00
1 front seat done.
(https://live.staticflickr.com/65535/48984725008_c0a77d0153_c.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 05 December 2019, 00:01
added the BBS wheels to cab to figure out how much I can lower the cab and figure out metal required to be notched out. Really like these wheels. my originals will go up for sale, if interested PM or look on C-list.

Before
(https://live.staticflickr.com/65535/49170983702_61f5659a64_k.jpg)

during
(https://live.staticflickr.com/65535/49170275303_8c675e4bad_k.jpg)

after!
(https://live.staticflickr.com/65535/49170275118_65a36b7b78_k.jpg)

Nice part is the wheels fit nice inside the arches so the drop can be really good. Some work to do on inside arches and front notch for the drive shaft clear metal ;)

All covered up again!
(https://live.staticflickr.com/65535/49170275673_e5298ee8e6_k.jpg)

(https://live.staticflickr.com/65535/49170275068_1cef858e2a_k.jpg)

Original ones, will clean them tomorrow and then up for sale....
(https://live.staticflickr.com/65535/49170981647_bc2229ec22_k.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 05 December 2019, 19:07
last month I have been working on the interior. Took out the complete front and rear seats, door cards for complete overall.

Taking everything out was easy, don't think anything has ever been taken out before, everything is solid, just covers of seats worn out and cards need refresh.

Door damp covers still working and foam at bottom still there!
(https://live.staticflickr.com/65535/49174348731_7fe964a545_b.jpg)

Rear speakers still work... will be upgraded later
(https://live.staticflickr.com/65535/49174348576_c7ef2db698_c.jpg)

Trying out the mk2 recaro seat base, make sure it works (had to do some slight welding on them)
(https://live.staticflickr.com/65535/49174567092_a0fa385540_c.jpg)

with everything out, time to strip down seats - so can use material for pattern to make new interior.
(https://live.staticflickr.com/65535/49174348631_6727fe44c6_c.jpg)

All part (forgot to take pics of front seats)
(https://live.staticflickr.com/65535/49174567317_4420b6d6c2_c.jpg)

Well after copying the current cloth and many many hours of helping someone managed to have complete front and rear seats redone in leather with red
(https://live.staticflickr.com/65535/49174348761_9e890b9003_c.jpg)

and little insight to front recaro seats
(https://live.staticflickr.com/65535/49174567162_b1898d04f0_b.jpg)

Next up is work on redoing the four cards and then I will install everything and show end results. lots to do, but having fun doing it :)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 16 December 2019, 16:34
my seat frames are all redone now too

before
(https://live.staticflickr.com/65535/49174567132_e8db6443ba_c.jpg)

after
(https://live.staticflickr.com/65535/49228751857_aa780426f7_k.jpg)

before
(https://live.staticflickr.com/65535/49174567317_4420b6d6c2_c.jpg)

after
(https://live.staticflickr.com/65535/49228522091_91acc2d15c_k.jpg)

heated seats parts
(https://live.staticflickr.com/65535/49228522706_c740c7a57c_k.jpg)

and managed to get these for a complete bargain:

(https://live.staticflickr.com/65535/49228058658_5d251e3774_k.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 09 January 2020, 03:01
more goodies turned up - European mk1 bumpers
(https://live.staticflickr.com/65535/49354397357_f724248f4f_z.jpg)

4 screws soaked for few days with WD-40 and out comes the metal structure of bumpers. I don't think these screws have been undone since production line 30 years ago.
(https://live.staticflickr.com/65535/49354399072_347db877b1_k.jpg)

(https://live.staticflickr.com/65535/49354183961_98aec89316_k.jpg)

Both metal parts of bumpers is now off to be powder coated. Areas in white on metal part of bumpers is rust treatment as I wanted to see how bad surface rust was.

the plastic part of the bumpers are in outstanding condition, just need a good clean and restore to bring black plastic back to its former glory.

waiting on few parts to arrive to complete my interior.
Title: Re: US VW Cabriolet 85
Post by: Simeon on 11 February 2020, 14:43
Great work as always mate, looks to be coming along well :)

Is interior finished now?
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 16 February 2020, 01:09
Great work as always mate, looks to be coming along well :)

Is interior finished now?

Nearly done on interior.

Big update in April, been slowly doing bit here and there and so will then do one big update.

Primary delay due to Grandson arrived on 7th Jan and so spending time with family right now is first priority.
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 13 April 2020, 22:25
Part 1 of VW Golf/Rabbit interior restore work done - rear seat area - repainted under the seat area, painted door cards and new leather, powder coated all metal and fixed foam.

Video can be viewed here;
https://www.youtube.com/watch?v=s81N_7yX2H4 (https://www.youtube.com/watch?v=s81N_7yX2H4)

Before
(https://live.staticflickr.com/65535/49770337438_33577e51b7_c.jpg)

After
(https://live.staticflickr.com/65535/49770869731_29989f069a_k.jpg)

Next update, euro bumpers restore complete and installed on car, part 2 of interior and coilovers on!
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 23 April 2020, 21:28
Actually finished up my European bumpers refurb.

Taking mk1 bumpers apart is easy and painful.

1. Painful - front bumper
2. Easy - rear bumper.

Here is why;
Each bumper front and rear have a outer and inside part, primary outer is plastic part you see and inside is metal structure.

Painful: The front bumpers are plastic pressure welded from factory to hold the plastic outer to metal structure inside which is used to bolt to your VW.
There is no easy way of getting the plastic and metal apart for the front bumper other than drilling plastic out and then its a pain to try and reproduce the OEM method. So of course when I tried it I tried the lets see if I can pry out the plastic, it worked for 1 of 4 areas of plastic weld. The other 3 broke and so now I had to come up with another solution. My idea was to use plastic weld make up mold, but I don't think I could get the pressure to hold the bumper in place, so I went with the bolt, washer and nut solution and I have to say it worked very well. I used a high pressure plastic weld to hold them into the existing holds and let set for 48 hours. Bumpers have been on the car week now and I've tested them out and solution for front bumper is working. I will keep on eye on this and report on this in 6 months and year to see how it holds up over time.

Easy - The rear bumpers are great and easy as there is only 4 screws you undo and the outer and inside parts come apart lovely!

I ended up having metal parts restored properly and powder coated and then got all new bolts, washers and screws.

If you want to see more in-depth video of process view here: https://youtu.be/tcwNPTbW8HQ

Before
(https://live.staticflickr.com/65535/49811239687_c39d27d22e_z.jpg) (https://flic.kr/p/2iTDCan) (https://flic.kr/p/2iTDCan) (https://www.flickr.com/photos/187933084@N08/)

(https://live.staticflickr.com/65535/49810390403_0928278a5f_z.jpg) (https://flic.kr/p/2iTzgGx) (https://flic.kr/p/2iTzgGx) (https://www.flickr.com/photos/187933084@N08/)

After
(https://live.staticflickr.com/65535/49811237237_3d74a3e5d4_z.jpg) (https://flic.kr/p/2iTDBr8) (https://flic.kr/p/2iTDBr8) (https://www.flickr.com/photos/187933084@N08/)

(https://live.staticflickr.com/65535/49810388823_c113c700f8_z.jpg) (https://flic.kr/p/2iTzgei) (https://flic.kr/p/2iTzgei) (https://www.flickr.com/photos/187933084@N08/)




Next update is on Part 2 of interior and some additional exterior changes.
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 29 April 2020, 17:43
More progress on interior refurb

Completed the front door cards.

Before:
(https://live.staticflickr.com/65535/48144667951_a4c8cbe9db_k.jpg)

Cleaned up and painted them using vinyl paint - 4 thin coats is perfect finish
(https://live.staticflickr.com/65535/49832035701_25a1cda6cf_z.jpg)

Installed. Just one screw plastic cover waiting on arrive.
(https://live.staticflickr.com/65535/49832346267_60f016b5be_z.jpg)

Really like the finish with few items with chrome.
(https://live.staticflickr.com/65535/49831504228_56d0c8364e_z.jpg)

Moved onto Recaro seat rebuilds - (Looks like these are not well documented online). These are taking far too long, but I want them perfect. I am recording every step to put into a video for others usage.
(https://live.staticflickr.com/65535/49832348842_dacd3e9cdd_z.jpg)

only one area that requires repair
(https://live.staticflickr.com/65535/49832348472_a0fb0d4f6f_z.jpg)

The side bolsters are being replaced with new and base and back foam will have a layer of 1/2" added to them to bring the shape back to what OEM is. Foam over time will always flatten down.

The key on doing seats is getting the right foam and this doesn't seem to be documented well online, so I will add this into my video.

(https://live.staticflickr.com/65535/49832034916_eac9efcab8_z.jpg)

and why I am using new bolsters :eek:
(https://live.staticflickr.com/65535/49832348687_3697e1f03a_z.jpg)

and back base rust repaired and painted ready for usage. I am working on base unit as that is really rusty. I basically treat rust, metal prepare, prime and P15 it, so it never rusts again!

(https://live.staticflickr.com/65535/49831503548_843343f04a_z.jpg)

I also stripped my original seats down for parts as Recaro seats and cabriolet seat parts are nearly the same. I was planning to use part of foam to fix my Recaro seat, but they are in near perfect condition I will be selling foam from original seats as they are perfect. Look out for those in sell sections or Flebay
(https://live.staticflickr.com/65535/49831504378_8170748165_z.jpg)

(https://live.staticflickr.com/65535/49832038606_dcf99067c6_z.jpg)

Hope everyone is enjoying your VW projects?

In other news, my GMC truck is now pushing 580BHP, who knew trucks can be so much fun!
Title: Re: US VW Cabriolet 85
Post by: jv on 29 April 2020, 20:08
Stunning work as always sir! Those door cards came out so well  :cool:
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 30 April 2020, 17:27
Stunning work as always sir! Those door cards came out so well  :cool:

Thanks John. Yeah they really did come out better than I thought they would.

I am creating short videos of process of Recaro rebuilds, part 1 here, I will do more videos with voice over on step by step stages, but also give shorter videos of just photo stages.

Part 1 of Recaro seat tear down and rebuild - https://youtu.be/U8pi0dPUUjw (http://"https://youtu.be/U8pi0dPUUjw")
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 15 May 2020, 06:14
One area of pain for the last week has been how do I figured out how to remove the lovely plastic lever handles on Recaro seats. I know this works for mk1 and mk2 VW seats as well (tested it out) might work for later model VW too but that would need to be validated.

Part: Seat Slider Handle part:171 881 253 (Plastic end piece)

If this part is warn out (most are) you can still get these online at various VW specialists or on fle—bay.

The challenge is how do you get the plastic lever off the metal rod without damaging both.

The part in question!
(https://assets.suredone.com/1517/media-photos/cp051770-seat-track-slider-handle-vw-jetta-golf-cabrio-mk3-passat-cabriolet-171-881-253.jpeg)

Solution:
The original knob is held on with a little metal clip inside. The clip helps it grip to the rod. It may take some pulling, but it should just pull off.

What I did was tape up the plastic lever and put foam around it, put it in a vise and pulled back and forth on the metal rod part and bingo, with few twists it comes off.

New part: you just push on the new part and you now have handle that looks new.
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 18 May 2020, 18:16
So managed to find time to focus on first Recaro seat;

Goal: 1. Check and fix foam. 2. Check and fix metal structure of seat. 3. install new seat covers

Overall Foam on Recaro seat was good except for few areas.
1. One upright back bolsters shot - require fixing with new foam
2. Base seat foam had split - required gluing
3. Base seat bolsters shot - bought new ones.
4. Head rest foam was perfect.

Overall I spent 2-3 hours working on below seat, mainly so I could take loads of photos for full write up I am doing and for video. Here is summary;

Before starting on fixing...
(https://live.staticflickr.com/65535/49832034916_eac9efcab8_z.jpg)

Cut bad foam out
(https://live.staticflickr.com/65535/49909370341_0ff7e053fe_z.jpg)

I ordered high density foam, cut foam and glues three layers together. I use 3M 74 Foam glue.
(https://live.staticflickr.com/65535/49909670897_d944ef1bc4_z.jpg)[/url]

Start shaping the foam.. I use Carving knife - works perfect to cut foam.
(https://live.staticflickr.com/65535/49908857698_bf79069a2f_z.jpg)

Then moved onto using my air tool sander 1.5" diameter end.
(https://live.staticflickr.com/65535/49909672647_d43b6abafd_z.jpg)

Then using cheese greater for final shaping (this one is not taken from my kitchen... not sure cheese and foam go well?!)
(https://live.staticflickr.com/65535/49909673122_24f25a5c5f_z.jpg)

To get to final shaping i made a template to check from one side to another.. for perfect finish - you go alone surface from back to front checking and take off foam where not needed. Also both sides are level in height too :thumbup:
(https://live.staticflickr.com/65535/49909372636_8f34d27679_z.jpg)

(https://live.staticflickr.com/65535/49909369401_1a54d94bbf_z.jpg)

Then moved onto cleaning up the Metal frame back, didn't take photos of this, but it had very little rust but I sanded and painted it anyhow.

Then installed the foam back to metal frame and added the backing on using 3M 74 Glue
(https://live.staticflickr.com/65535/49908857748_12536827b7_z.jpg)

Then installed the back new seat cover.
(https://live.staticflickr.com/65535/49908854428_70ddbc6cfb_z.jpg)

Then worked on back and base - I got into the zone for these and only did video for them, so here is the end result. No major repairs on foam, just install covers, put metal roads in and secure to foam and staple on the back
(https://live.staticflickr.com/65535/49908802978_3f560c781c_z.jpg)

All the new covers, had a 1/2" foam on the inside, so the seats all have now a nice smooth extra feel to them.

I need to leave these out in the sun for few hours and then they are finished.

Next up new base bolsters and seat cover install and then add to main base and install in the car :D
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 13 June 2020, 00:34
more progress on the front seats. Second seat back section complete, even got my base metal back from being powder coated.
One are I am not happy with is the head rests, can see in photo below the new covers just don't fit well, so going to redo them.

(https://live.staticflickr.com/65535/49999675051_1244511b95_z.jpg)

So with new bolsters, you have to cut these to make it perfectly. Notice extra form on new ones at bottom, so cut these and so there is extra foam at the rear on the underneath, so cut this out too.

(https://live.staticflickr.com/65535/49999675346_f7c3486664_z.jpg)

parts cut out of new bolster to make them perfect match to originals.
(https://live.staticflickr.com/65535/49999929392_ff4962d76d_z.jpg)

pulled the base foam together to make sure all fitted properly - very happy with results
(https://live.staticflickr.com/65535/49999155293_2462c60ccd_z.jpg)

Then install the new leather onto the new side bolsters and for about hour I am fighting to get them to fit nice and tight with zero luck, then I went and measure the new to original covers and bingo the new ones are 1" longer so I need to correct that and then retry installation again.

(https://live.staticflickr.com/65535/49999928807_2dcc6c779f_z.jpg)

Well I have some work to do on head rests and side bolster covers and then I can complete the seats. Next update will be once I have these done and installed in the vw.
(https://live.staticflickr.com/65535/49999155768_38680a78a2_z.jpg)

I also did some outside work on vw, I painted the side indicators to match the vw color. Interesting to note i found each corner was not even wired up!!
I also removed the arches and have new ones coming.
I also removed my front grill to change the color of chrome to Vw GTI red.
My european small ducklip turned up too, will install that this weekend and update once have grill done as well.

OEM side indicators;
(https://live.staticflickr.com/65535/49999727381_7352baedfc_z.jpg)

(https://live.staticflickr.com/65535/49999981717_66d833e9f9_z.jpg)

Paint!
(https://live.staticflickr.com/65535/49999175388_aa3f9c7332_z.jpg)

and painted...
(https://live.staticflickr.com/65535/49999948002_bf7ac1dd61_z.jpg)

and the end result on the car
](https://live.staticflickr.com/65535/49999946942_b9a5f6d227_z.jpg)

and the front grill off! thinking should I upgrade my lights or not?
(https://live.staticflickr.com/65535/49999947842_fe6c3c02d2_z.jpg)

I did remove one other part from outside of the car to paint black, can you see what that is?

Here is my new European lip and compared to the GTI one. I prefer the European version - mainly due to when I put coil-overs on I won't loss it!!

(https://live.staticflickr.com/65535/50000026012_4da781877b_z.jpg)

The GTI one will now become Art in my office!
(https://live.staticflickr.com/65535/49999772391_85c6cf6fcf_z.jpg)

and the car is all covered up again..
(https://live.staticflickr.com/65535/49999253203_3669528912_z.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 01 July 2020, 05:23
Did a few things....

Install of new euro lip
(https://live.staticflickr.com/65535/50000026012_4da781877b_z.jpg)

The right securing parts - what some people use on left...

(https://live.staticflickr.com/65535/50052851077_976abf4fb3_z.jpg)

Jack vw up a little... makes life easier when using tools to get securing parts in to hold lip in place
(https://live.staticflickr.com/65535/50021534366_ac7a7d9e15_z.jpg)

Hold the lip in place and place the middle screw and washer in and repeat working on outside in, do not screw them in completely, once you have all of them in place then slow tighten up. Don't over tighten or you could damage the lip.
(https://live.staticflickr.com/65535/50021792157_f1486e76e7_z.jpg)

and all done.
(https://live.staticflickr.com/65535/50020995753_7f8f46aa01_z.jpg)

Then onto the front grill
I already took off the grill to take the metal off to repaint it. Once off gently pry the little tabs back off the plastic grill to get them all.
(https://live.staticflickr.com/65535/50020991628_a4cd0165bc_z.jpg)

it was a really nice hot and dry day when I did this. I made sure all parts where secure so I could paint them. Before this I wet and dry sanded them down and de-greased them. (no sponsorship was given from shipping company but the box worked well - so thanks!!) :laugh:
(https://live.staticflickr.com/65535/50021533191_4ccde68a21_z.jpg)

First primer coats x2
(https://live.staticflickr.com/65535/50020994998_dc1a7df8be_z.jpg)

Then onto the correct RED color paint.
(https://live.staticflickr.com/65535/50020996493_60a1d1cfc7_z.jpg)

(https://live.staticflickr.com/65535/50020990598_1e66b16a1b_z.jpg)

While waiting for the paint to finish I cleaned up the grill itself..

(https://live.staticflickr.com/65535/50020991818_c55624f429_z.jpg)

I actually left the grill parts painted overnight and then put back together in the morning
(https://live.staticflickr.com/65535/50020993643_274bd72519_z.jpg)

All back together again
(https://live.staticflickr.com/65535/50021539231_c4d399bd4b_z.jpg)

and installed again on the car, overall I am really happy with the it.
(https://live.staticflickr.com/65535/50052029533_40d8e0b1c0_z.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 05 July 2020, 19:45
Additional changes on outside

Adding the CL rear arch covers;

All new parts and correct parts to hold arch in place;

(https://live.staticflickr.com/65535/50021790762_6e35326293_z.jpg)

installed!
(https://live.staticflickr.com/65535/50020994388_474969ff9c_z.jpg)

(https://live.staticflickr.com/65535/50021787527_0f69de1644_z.jpg)

now do I paint the side mirrors black or leave them white?

(https://live.staticflickr.com/65535/50052594786_de23d4b560_z.jpg)

and what car looked like when I first got it.
(https://live.staticflickr.com/65535/50052598701_3ff463e252_z.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 27 August 2020, 20:07
Few small projects happening;

1. lower and upper strut braces, the upper one required same cutting and welding, but that is ok I enjoy little bit of fab work :laugh:
2. Finally got small rear arch clip so installed that
3. Took off the rear badges to clean up and re-new them
4. Fixed driver side handle - metal clip inside the door broke!
5. Scored deal on front replacement axles

Strut braces lower and upper, upper one is hitting the throttle body and goes over radiator expansion tank opener. Easy fix I will adjust the setup of this. updates on that next.
(https://live.staticflickr.com/65535/50275934212_bed837c25a_z.jpg)

Rear arch cover clip arrived, now drive the cab without if flapping around!!
(https://live.staticflickr.com/65535/50275930152_dbae2ed38b_z.jpg)

Rear badges needed taking off and applying new stickers to make them new again!
(https://live.staticflickr.com/65535/50275934657_2a9e3c96ce_z.jpg)

New stickers for badges;
(https://live.staticflickr.com/65535/50275836136_e3c5d436de_z.jpg)

Broken in door handle clip
(https://live.staticflickr.com/65535/50275930397_b31067cf8f_z.jpg)

New parts arrived, ordered from Europe... these are hard items to find for sure
(https://live.staticflickr.com/65535/50275777771_85eac7b5a2_z.jpg)

Front axles, all part of new parts for front setup, so I can do new suspension, arms, brakes, etc in one hit (this will be winter projects)
(https://live.staticflickr.com/65535/50275775781_293ff76d2a_z.jpg)

I am on the hunt for BBS RS Wheels too 15" 4x100.

Thanks Simon
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 31 August 2020, 22:16
Managed to complete the rear badge refurb

(https://live.staticflickr.com/65535/50275836136_e3c5d436de_z.jpg)

Take you time as each letter and VW symbol are individual - use small long length pliers to pull off and place on badge lettering

(https://live.staticflickr.com/65535/50287738738_f91644c4ac_z.jpg)

(https://live.staticflickr.com/65535/50287738468_df20f12dc5_z.jpg)

Painted the Cabriolet badge white

(https://live.staticflickr.com/65535/50287738713_07018da8fa_z.jpg)

And installed :)

(https://live.staticflickr.com/65535/50288415351_0334af0013_z.jpg)

(https://live.staticflickr.com/65535/50288564262_e41c6caf9d_z.jpg)

another job done.

Still waiting on my final leather to turn up so can cut and do my Recaro seats.
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 11 October 2020, 22:07
Finally got my new materials to finish off my Recaro seats and so the last few weeks been busy creating the new bolster covers and head rests.

How Seat was before
(https://live.staticflickr.com/65535/50453917046_fa4af08324_z.jpg)

and now finished
(https://live.staticflickr.com/65535/50453207058_b834107d13_z.jpg)

and the Real Recaro covers and new handles
(https://live.staticflickr.com/65535/50453206918_0bec4550e6_z.jpg)

New supports (originals ones where ok, will be selling the originals ones)
(https://live.staticflickr.com/65535/50453207118_f5b3855431_z.jpg)

This weekend I am rebuilding the bases, been powder coated, all parts cleaned, new spring, new Bosch Motor, upgraded to later VW/Audi model, so much quieter now.
Just got some wiring to redo and then can install both of the bases onto the seats and into the VW.
(https://live.staticflickr.com/65535/50453206638_60e3d33b1e_z.jpg)

(https://live.staticflickr.com/65535/50453916556_ee4b3f2549_z.jpg)

and finally my new shoes turned up - brand new custom lips, restored centers, new caps, bolts. Very happy with the staggered setup
(https://live.staticflickr.com/65535/50449412667_2e959663d7_z.jpg)

and I might of just sourced and bought a RS3 engine and gearbox!
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 14 October 2020, 05:47
Sharing some research I did on Bosch motors and options if your original ones dies.

These work on mk1, mk2 seats, not sure about later models of VWs.

Seat motor (Make: Bosch API v12) spec;
0301-002-405 original VW
0301-002-5xx later bosch model fits too VW
8E0881183* (C, D, E) - VW
Rear Seat Lumbar Height Motor Audi A8 S8 D2 - Genuine Bosch - 0130-002-564
BMW lumber height motor Bosch unit 0130-002-400 also near perfect match to original VW ones

Original 0130-002-405 (on top)
(https://live.staticflickr.com/65535/50476067471_64581186ce_z.jpg)

Audi version 0130-002-564 - bigger motor in length and cable connectors are different.
(https://live.staticflickr.com/65535/50453206638_60e3d33b1e_z.jpg)

(https://live.staticflickr.com/65535/50476217417_0f54120c39_z.jpg)

(https://live.staticflickr.com/65535/50476067156_50d8d0f0fb_z.jpg)

BMW 0130-002-400
(https://live.staticflickr.com/65535/50476067991_96e8cecbd7_z.jpg)

(https://live.staticflickr.com/65535/50475367633_9e5fe4849b_z.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 26 October 2020, 21:54
finally bases screwed into the seats themselves.
(https://live.staticflickr.com/65535/50534146236_b8f3b0a4b6_z.jpg)

one of the key things I never see people report on is when putting new seats in or rebuilding, you must grease up all the seat runners and plastic parts that seat moves on, that including seat base parts too.
(https://live.staticflickr.com/65535/50533415768_e4be02a4f6_z.jpg)

(https://live.staticflickr.com/65535/50534147776_2763a2d865_z.jpg)

(https://live.staticflickr.com/65535/50534147031_f172d315dc_z.jpg)

Passenger seat in!!! nice compare of original to new
(https://live.staticflickr.com/65535/50533413138_3ff66011c2_z.jpg)

seat runner cover
(https://live.staticflickr.com/65535/50533416203_9ac4b54e49_z.jpg)

(https://live.staticflickr.com/65535/50534143296_89bbae3259_z.jpg)

May wonder why not head rest, its easier to install without it. I will do next update with full interior in - both seats with head rests.
Title: Re: US VW Cabriolet 85
Post by: jv on 06 November 2020, 22:55
Hideous  :cool:
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 09 November 2020, 00:34
Hideous  :cool:

haha. I should try harder right?!!
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 15 November 2020, 02:44
So finally have second front seat in and the interior is now 95% done. Due to raining I could not put headrest in, but see below on rebuild of those too.

Before
(https://live.staticflickr.com/65535/50602393108_e7ca943e66_z.jpg)

and the money shot!
(https://live.staticflickr.com/65535/50603132576_ed088e71b4_z.jpg)

Headrests metal needed cleaning and protecting as well as the headrest supports.

(https://live.staticflickr.com/65535/50602357783_b17a5482eb_z.jpg)

(https://live.staticflickr.com/65535/50603133391_9b40f52c38_z.jpg)

wire wheeled the metal to clean all up and used Metal ready and degreaser (POR15) in prep for paint
(https://live.staticflickr.com/65535/50602358313_00b4f69d8d_z.jpg)

all painted and protected with POR15
(https://live.staticflickr.com/65535/50603098651_56b2d51281_z.jpg)

(https://live.staticflickr.com/65535/50603237407_8093b6c6e5_z.jpg)

(https://live.staticflickr.com/65535/50602393533_522f5ab094_z.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 09 December 2020, 23:52
Finally the interior seats are complete and all together! Heads rests are in place...

(https://live.staticflickr.com/65535/50699277378_6e1b3fcb72_z.jpg)

I also got the gearstick gater and hand break matching leather

(https://live.staticflickr.com/65535/50700601937_653abe355f_z.jpg)

(https://live.staticflickr.com/65535/50699774813_1af6045e6f_z.jpg)

(https://live.staticflickr.com/65535/50699775008_eaf10f3144_z.jpg)

I also have a new steering wheel coming, which will review little mod'ing and then I feel the interior is complete and I can move onto my winter projects of suspension, running gear upgrades and then new wheels install!!!
Title: Re: US VW Cabriolet 85
Post by: Mr_Orange on 16 December 2020, 20:45
Amazing work and attention to detail  :cool:
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 23 December 2020, 02:27
Amazing work and attention to detail  :cool:
Thanks Mr_Orange.

wishing everyone a wonderful Christmas holidays and stay safe.  :cool: :smiley: :grin: :smiley: :grin: :smiley:
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 23 December 2020, 02:30
My Christmas gift to myself!

(https://live.staticflickr.com/65535/50706628766_771c59d52a_z.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 12 January 2021, 23:47
worked on Gear stick gator cover

Original one is actually in great shape after a little clean.
(https://live.staticflickr.com/65535/50788544587_aff228bf5c_z.jpg)

took it apart - clips rusted up

(https://live.staticflickr.com/65535/50788546472_72f70ea1bb_z.jpg)

(https://live.staticflickr.com/65535/50788437336_053309902c_z.jpg)

new cover
(https://live.staticflickr.com/65535/50700601937_653abe355f_z.jpg)

Put new cover over base (plastic) and added new nails and restored the rusted clip and POR15 them
(https://live.staticflickr.com/65535/50788437536_de8a161284_z.jpg)

Completed and compared to original
(https://live.staticflickr.com/65535/50793460168_6bca81101f_z.jpg)

(https://live.staticflickr.com/65535/50794329497_9d315a3997_z.jpg)

Also got my new door handle covers
(https://live.staticflickr.com/65535/50827449837_0d64ea166d_z.jpg)

More coming soon on changes to new steering wheel.
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 20 January 2021, 00:58
Gear stick cover installed
(https://live.staticflickr.com/65535/50853540392_bdd28119b5_z.jpg)

and gave the VW a clean!
(https://live.staticflickr.com/65535/50853449941_8277763d72_z.jpg)

Also noticed this heater lever came off way to easily, is this part actually broken (white plastic part) or is this is how its meant to be?
(https://live.staticflickr.com/65535/50852726508_7075092ab8_z.jpg)
Title: Re: US VW Cabriolet 85
Post by: Agreeable Slick on 31 March 2021, 12:46
Looking awesome Si. Hope you are keeping well.
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 05 April 2021, 04:03
Looking awesome Si. Hope you are keeping well.

Thanks a alot slick. Yeah all is well mate, just working on the home and when parts turn up, can get more work done on cab.
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 29 April 2021, 19:09
VW heater fix

So with top heater lever not working properly, dismantled the dashboard and found the issue, which is there is plastic part that has broken (Heater control pivot broke) Reading up and being informed from others on another forum, this is a common issue.

The white part in pic should have lever on top and a black plastic holds it in place and that is what has broken off
(https://live.staticflickr.com/65535/51146615561_87e347a910_z.jpg)

I followed this process to learn the fix and process (big thanks to Briano)
https://www.volkswagenownersclub.com/threads/my-heater-control-pivot-broke-cabriolet.46441

So here is what I did to fix it.

Once I got the unit out (not the easiest thing to do!) I inspected everything and gave everything a good clean.

(https://live.staticflickr.com/65535/51147379719_9a1a1640c1_z.jpg)

In the above picture I drilled through black plastic part that holds the pivot parts in place and placed a bolt, washer and nut on the end. This will help fix the problem.

Added the white plastic back on, added white grease to pivot and moving parts
(https://live.staticflickr.com/65535/51146595841_2c837fbd9a_z.jpg)

added the broken black pivot plastic part, now with drilled out hole through it to put the bolt, washers and nut through it to hold in place
(https://live.staticflickr.com/65535/51147380024_c1a0f25ee7_z.jpg)

Bolt installed from top with washers
(https://live.staticflickr.com/65535/51147381374_8cfc36944b_z.jpg)

Underside showing washers and threadlock (blue)
(https://live.staticflickr.com/65535/51145918652_ca261bf205_z.jpg)

Nut installed and tightened up enough to lock but allow the pivot setup to work for both levers
(https://live.staticflickr.com/65535/51146820963_e5c4bfa99a_z.jpg)

Then installed the A/C lever and added grease. I placed a washer underneath ready for install as this is known fix for common issue of a-c-slider-pops-out-of-place. nice easy fix!
(https://live.staticflickr.com/65535/51146819908_b040b0453c_z.jpg)

Next update, unit install in dashboard and time to do flush, clean and fresh coolant install (including Radiator inspection, replace thermostat and check all coolant pipes!!




Title: Re: US VW Cabriolet 85
Post by: Mr_Orange on 30 April 2021, 11:36
Nice repair job !
I hope this gets it all operational again  :smiley:
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 30 April 2021, 17:58
the cab is always working, just trying to do things to keep it in great health and fix things as I find them. Hopefully will have heating and cooling done this weekend!
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 18 May 2021, 23:57
Well the last few weeks I've been having fun with my blower fan motor not working (one of the carbon bushes and holder of it was burnt and bent!!)

I've managed to fix that issue (write up of that coming soon) but discovered another issue!!!!

Then I tested out the complete system on all the settings and noticed the Vacuum servo for air recirulation flap was not opening or closing, so I followed this amazing PDF - http://www.cabby-info.com/Files/HVACTesting.pdf and everything was working just perfect until I tested the vacuum distributor and bingo we have a leak.

Part #161820293B - another expensive part, not available from VW!
(https://live.staticflickr.com/65535/51187213675_80d4aa49eb_z.jpg)

So some research and looks like there is alot of good info on on various online forums - the best thread on how this unit works was found:

https://www.vwvortex.com/threads/how-that-darned-vacuum-distributor-really-operates-a-detailed-analysis.2883746/?id=2883746&highlight=vacuum+distributor
How That Darned Vacuum Distributor Really Operates

and
https://www.vwvortex.com/threads/vacuum-distributor-on-the-heater-controls-not-the-same-as-the-manual.2860977/
Vacuum distributor on the heater controls…

Next steps!

    Managed to find replacement NOS part (waiting on that to arrive.)
    try and fix my one, I noticed a few people have tried a few tricks and got it to stop leaking, but I am guessing I will have to get a replacement part.

Updated this problem to a few of the dedicated mk1 forums to see what others have done to do a fix (be nice to do the fix and have a spare)

All this issues ended up taking out the complete dashboard which actually will allow me to do some other work without breaking my back!
(https://live.staticflickr.com/65535/51188239641_da18e44881_z.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 20 May 2021, 19:33
Got my new vacuum pipe junction in today and connected it all up.

(https://live.staticflickr.com/65535/51185448767_def349f2ab_z.jpg)


Tested out each of the cooling/heating positions and everything is working as needed, I come to test out the MAX A/C positions as seen in this http://www.cabby-info.com/Files/HVACTesting.pdf and in photo below, this is the only option that allows your under the passenger dashboard recirculation vent flap to Close and its not closing. About 3 minutes later it really really slowly started to close - which to me is not right.(Tested the pipes to make sure the retracting the diaphragm, forcing the recirculation vent flap closed and that worked just fine so we know that is not the problem)

(https://live.staticflickr.com/65535/51187213820_449b159c5d_z.jpg)


I then noticed that the new vacuum pipe junction is not moving all the way down into the slot.
(https://live.staticflickr.com/65535/51187209770_e753ba07d1_z.jpg)

and I very gently moved it to as far as it could go into the slot
(https://live.staticflickr.com/65535/51186139656_f58a3cb416_z.jpg)

and as soon as I did that recirculation vent flap closed within 2 seconds - its working as it should!
(https://live.staticflickr.com/65535/51186360738_0d4c3a972a_z.jpg)

I repeated this process using the levers and again the top lever just doesn't move the vacuum pipe junction far enough down to get the MAX A/C position to work as required and thus the recirculation vent flap would not close. Moved the vacuum pipe junction down gently again and recirculation vent flap closed within 2 seconds.

So the big question is the new unit broken, the top lever bent, the unit it all connects to out of alignment, at this point I have no idea. Anyone got any ideas?

I took a pic of the vacuum unit apart to give everyone good idea what these look like apart
(https://live.staticflickr.com/65535/51186142651_3b870a572b_z.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 12 June 2021, 16:59
I managed to fix my heating/cooling issues, with simple fix, update on that and rebuilding of my fan motor too soon.

Well waiting on parts for my steering column, moved onto refurb of my steering wheel.

Treated the steering wheel to cleaning and treatment to wheel itself and then removed the center silver clip an painted it to match the OEM Red trim color.


Had really nice warm weather the last few days, so that helped this work.


Wheel as I got it

(https://live.staticflickr.com/65535/51242159346_554919aaac_z.jpg)


(https://live.staticflickr.com/65535/51242363358_194cb3410e_z.jpg)


Up close you can see little damage on surface

(https://live.staticflickr.com/65535/51243212750_470fb77125_z.jpg)


Part details for future reference

(https://live.staticflickr.com/65535/51242158846_b0a14e1cfe_z.jpg)


Time to prep for sanding and painting

(https://live.staticflickr.com/65535/51243212835_6f26b2ba09_z.jpg)


primer, had to do this a few times as primer to get it to point of smooth for red paint.

(https://live.staticflickr.com/65535/51241448112_b98905f782_z.jpg)


Few coats of red

(https://live.staticflickr.com/65535/51242362843_995c07414e_z.jpg)


Sanded down ready for final red paint

(https://live.staticflickr.com/65535/51241448167_87d40f26c6_z.jpg)


2 coats of Red and 2 coats of clear finish

(https://live.staticflickr.com/65535/51242160611_4520e10008_z.jpg)


dryed for 24 hours and then all ready

(https://live.staticflickr.com/65535/51242927349_844a932a68_z.jpg)


and installing on wheel!

(https://live.staticflickr.com/65535/51242928164_a5f4db0848_z.jpg)


(https://live.staticflickr.com/65535/51242159281_fb8ee66c54_z.jpg)


and all ready for installing in the vw cab again!

(https://live.staticflickr.com/65535/51241449762_502a1e4172_z.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 19 June 2021, 07:34
Heating/cooling not working in mk1 cabriolet.

After fixing my main heater unit controller, I finally was able to test out my heating/cooling system. If became clear that my fan/blower motor was not turning on, as I could not hear the fan turning.

I used this great document to get to my fan/blower motor out of my mk1.
http://cabby-info.com/Files/ReplacingTheBlowerMotor.pdf

Spec of my fan/blower motor:
vw blower fan # 171-820-015 or 021
Carbon Bushes measure 8mm x 9mm x 22mm

Now that I have the fan/blower motor out of the car, it become clear what my problem was very quickly.

As you can see one of my carbon bushes is been pushed and melted the holder itself, thus the carbon bush is not pressing up against the motor properly and thus not working.

(https://live.staticflickr.com/65535/51253629607_0c1b481a0f_z.jpg)

After some research (not much found the w.w.w) I managed to find solution to my problem.
As you can see from my other thread I brought this up in https://www.vwvortex.com/threads/blower-fan-motor-carbon-bushes-and-holder.9470480/#post-115093383 no many people have had this issue, usually they replace the whole fan/blower unit and as you can below with cost being $$$ I was not happy to spend some time to find a cheaper fix. Plus its actually harder now to find a replacement unit.

(https://live.staticflickr.com/65535/51255114564_28f9e8a4a5_z.jpg)

My fix:

   1. I found new carbon bushes.
   2. The carbon bushes holders from later blower fan motor from VW golf mk3/4 are the same setup and fit perfectly so using set from vw golf 4 gave me the holder I needed. Part # 1J1819021
   3. I added disconnects on cables so it's easier to service blower motor in the future, so no more disconnecting cable from inside the car.
   4. I gave the motor a really good clean too.
   
   I ordered another later model blower fan motor as additional spares for the future.
   
Here is how I fixed my fan/blower motor.

Once you have the motor out of your vehicle and on a table, you can start to take apart the fan blower motor.

(https://live.staticflickr.com/65535/51161062545_bd084035f7_z.jpg)

(https://live.staticflickr.com/65535/51160195503_7542d313f1_z.jpg)

As I planned to add quick connects to my cables, I cut the two cables to be able to remove the cabling to one side. FYI: To replace the cable is also expensive so be careful with that.

(https://live.staticflickr.com/65535/51255115279_59dfe5dca6_z.jpg)

Next up is to remove the carbon bushes holders. Both holders are held in place with springs, carefully remove these with precision pliers and not let the spring go from your pliers or it will spring out of sight into your room!

With the spring removed you can now pull the holder outwards and pull forward to remove from motor. Repeat this for both holders

Here you can see springs
(https://live.staticflickr.com/65535/51254370156_ff8bf8e0d1_z.jpg)

Now you have carbon bushes holder on table you can see clearly the problem I have with one of my broken holders and carbon bush bent.

(https://live.staticflickr.com/65535/51253640982_c83b2428ef_z.jpg)

(https://live.staticflickr.com/65535/51253629607_0c1b481a0f_z.jpg)

(https://live.staticflickr.com/65535/51257078774_c9d6ebb046_z.jpg)

So with sourcing new parts from later vw mk4 fan motor, you can see below the later holders in the unit before I took them off.

(https://live.staticflickr.com/65535/51254564203_ba201feaeb_z.jpg)

Mk4 unit looks like
(https://live.staticflickr.com/65535/51256331991_5622a70832_z.jpg)

(https://live.staticflickr.com/65535/51256529683_518076946d_z.jpg)

And now compare the original holders with carbon bushes to the ones from mk4 golf motor. The later model holders have a nice cable holder, so I plan to use both mk4 holders once cleaned up a little.

(https://live.staticflickr.com/65535/51255601292_324f3771f7_z.jpg)

Also going to use later mk4 spring too.. My originals seen better days!

(https://live.staticflickr.com/65535/51255115944_fdacd8100e_z.jpg)

So after some cleaning up of holders, I removed the original carbon bushes from my unit compared to mk4 and placed beside the holders so you can see
(https://live.staticflickr.com/65535/51254573123_b33a3a9eb2_z.jpg)

Carbon bushes

Top - from mk4
Middle - from mk1
Bottom - new carbon bushes.
(https://live.staticflickr.com/65535/51254572988_36f2a496ea_z.jpg)

Made sure my original carbon bushes fitted the mk4 holder and they do - happy days!
(https://live.staticflickr.com/65535/51255601422_9cd13468b7_z.jpg)

New carbon bushes
(https://live.staticflickr.com/65535/51255115064_a760b74d62_z.jpg)

Using the mk1 original carbon bushes as template, I used 80grit sand paper on wheel in power drill to get the shape I need
(https://live.staticflickr.com/65535/51254573603_f8f8c3a73b_z.jpg)

And placed into the mk4 holder
(https://live.staticflickr.com/65535/51254564003_d3d284d007_z.jpg)

Placed the carbon bushes holder back onto the motor, with mk4 springs. Using again my pliers to pull spring from inside to the other side to secure in place and then twisted cable end with carbon bushes copper together
(https://live.staticflickr.com/65535/51255411825_ae53acee50_z.jpg)

Now using a new cable tube, placed over and crimped to secure cables together
(https://live.staticflickr.com/65535/51254574143_8443f8bd2e_z.jpg)

(https://live.staticflickr.com/65535/51255115084_e995693b7f_z.jpg)

Repeated on the other side
(https://live.staticflickr.com/65535/51254573628_0b89bcf108_z.jpg)

At this point I wanted to check the motor worked

Click to watch the short video!
https://live.staticflickr.com/video/51166717673/12fd235b7c/1080p.mp4?s=eyJpIjo1MTE2NjcxNzY3MywiZSI6MTYyNDA4MzE0NSwicyI6IjkxNzMwYWVmOWQ2Y2M1MmEwNGY2ZjIxNTAzYTVlMjIzNjI5MzE4Y2UiLCJ2IjoxfQ

I then added quick connects onto the end of the cables
(https://live.staticflickr.com/65535/51255105459_a6db317d22_z.jpg)

(https://live.staticflickr.com/65535/51254369996_7eefc85b92_z.jpg)

(https://live.staticflickr.com/65535/51255116699_3efbaa3c83_z.jpg)

Now time to reinstall into the mk1 again.

Ran the cabling back through into hole and connected cable up inside
(https://live.staticflickr.com/65535/51255400495_4fe6b6c0fd_z.jpg)

(https://live.staticflickr.com/65535/51254370756_efe2a70fdd_z.jpg)

(https://live.staticflickr.com/65535/51253638727_0178a13115_z.jpg)

Then installed the fan blower motor
(https://live.staticflickr.com/65535/51254360151_9c5c036901_z.jpg)

(https://live.staticflickr.com/65535/51254369341_75a6e42528_z.jpg)

With the fan blower motor working and in the car, now time to test out my complete heating/cooling system.

Tested out the complete system on all the settings and noticed the Vacuum servo for air re circulation flap was not opening or closing, so I followed this amazing PDF - http://www.cabby-info.com/Files/HVACTesting.pdf and everything was working just perfect until I tested the vacuum distributor and bingo we have a leak.

Part #161820293B - another expensive part, not available from VW!

So some research and looks like there is a lot of good info on vwvortex - the best thread on how this unit works was found here:
https://www.vwvortex.com/threads/how-that-darned-vacuum-distributor-really-operates-a-detailed-analysis.2883746/?id=2883746&highlight=vacuum+distributor

And
https://www.vwvortex.com/threads/vacuum-distributor-on-the-heater-controls-not-the-same-as-the-manual.2860977/

So as outlined in earlier update recently waiting for parts to arrive, once they arrive I will update here with full details on fixing this part and actually test out system on all settings and then get actually get onto doing A/C servicing and coolant flush and refill.







Title: Re: US VW Cabriolet 85
Post by: Madone_si on 19 September 2021, 21:11
Fixing my dashboard issues!

So while I've been waiting for parts to turn up to finish up my HVAC system, I started to work on fixing few problems I have with the Dashboard.

Since I took the dashboard out to fix my HVAC issues I noticed the following issues on the dashboard. I believe most mk1's cab dashboard will have this issue, so thought I would write this up for others.

Overall the dashboard is in great condition on the visual side when in the car. When you flip it over and start looking at the underside its another matter.

Problems seen - most of the clips and metal structure have rush all over them. The four main clips that hold the dashboard to the main part of the cab body near the wind screen are usually like welded to the dashboard under structure "fiberboard". When you try to pull these off to clean up or remove, they will properly 99% of time rip the fiberboard too. In my case 3 of the 4 did this very thing, so I will show you how to fix that.

The main structure metal of underside of dashboard will over time just rust, most of it will be surface rust but the only way I found to protect that metal is to POR15 it. Its super painful to remove it from dashboard outer skin.

The inside area of fiberboard where the stereo of car goes, always ends up being damaged and in my case it too has screw holes and ripped, so will have to fix that and maybe add more structure in place to help support and secure stereo to dashboard.

The last area I can see being a common problem is the edging of the dashboard and in a lot of the areas of the edge of my dashboard you see parts of the outer cover of dashboard coming away from fiberboard, so will have to protect the edging and glue back the areas coming away.

Dashboard
(https://live.staticflickr.com/65535/51423788765_324ba49198_z.jpg)

Clips
(https://live.staticflickr.com/65535/51423789210_bda2ac1739_z.jpg)

Clip off dashboard with part of fiberboard :(
(https://live.staticflickr.com/65535/51423035503_642b383107_z.jpg)

I added some liquid glue to the area clips come off from, to protect the area but also to see clearly the damaged area.
(https://live.staticflickr.com/65535/51423537719_8b3c97a7a9_z.jpg)

Once I got all four main clips off, I put them in a small bucket and used this product to help remove the rust.

LOCTITE - Rust Dissolver
(https://live.staticflickr.com/65535/51422028207_b3ce06206f_z.jpg)

Leave for 24 hours
(https://live.staticflickr.com/65535/51422028082_ccc6c724cd_z.jpg)

After 24 hours
(https://live.staticflickr.com/65535/51422775116_b98571931a_z.jpg)

Now onto cleaning the clips up and removing the old fiberboard in the smaller clip side area.

Tools used to clean clips…
(https://live.staticflickr.com/65535/51423537609_b00e1aab68_z.jpg)


Each clip too about 10-15 minutes using pick and razor blade to get all fiberboard out.

What I did was put small screwdriver in the bigger clip part and then pulled and pushed using pick and razor blade to get parts out.

(https://live.staticflickr.com/65535/51422028847_1a7d8f0a8c_z.jpg)

And after doing that to all four… end results.

(https://live.staticflickr.com/65535/51423762350_c400cb1ab9_z.jpg)

I then used the wire wheel on each of them to get all crap of them and spray painted them with POR 15.
You will see the results on clips after I explain how I fixed the clip areas on underside of dashboard next.

Fixing the fiberboard on underside of mk1 Golf dashboard

As stated above I put glue on the 3 of 4 clip areas of fiberboard that was damaged by removing the clips.

First thing I did was go along and tape around each area of the dashboard, so any repair work I do is limited to that area only. I used blue painters tape, If I did this again I would use green painters tape, as some of the repair work bleed underneath the tape.

(https://live.staticflickr.com/65535/51422055157_ecce67fe33_z.jpg)

Using the free sample flooring you get from like Home-depot, I cut and glues together a 90 degree angle and place under the area broken until its cannot go any further inwards. This will give me a good base to fill in the whole broken area.

(https://live.staticflickr.com/65535/51422048862_5e985f77e3_z.jpg)

I then made sure I tapes this in place and made sure the underside was tapes well too

(https://live.staticflickr.com/65535/51423054703_14cd23887d_z.jpg)

I repeated this for the other three areas and then it was time fix these areas.

So asking others in this forum and other places… it seems most people have used Fiberglass to fix these areas in the past and it worked well. So I ordered a kit from online and here is what I did.

   1. I used just the fiberglass resin first. Let that set 1 hour and moved onto step 2.
   2. I removed my custom 90 degree supports
   3. I then fiber glassed over the clip areas on top and underside. (this was messy!! Is an understatement - always, always work in area with fresh air and use gloves when working with fiber glass and always wear a mask)
   4. Let fiber glass dry out for several hours, in my case I left overnight.
   5. Sanded down the fiber glass to shape I needed
   6. Added POR15 paint over the area.
   7. Add to clips back onto the underside of dashboard!
   
Here are some photos of above steps.

No.1 & 2 step
(https://live.staticflickr.com/65535/51423782015_12804d94cf_z.jpg)

(https://live.staticflickr.com/65535/51423548969_e1bbb7de1b_z.jpg)

No.3 Step
(https://live.staticflickr.com/65535/51423549199_8a83e0da74_z.jpg)

No.4 step
(https://live.staticflickr.com/65535/51423045408_cbb49a4e56_z.jpg)

No.5 Step
(https://live.staticflickr.com/65535/51422778611_6b771acee1_z.jpg)

No.6 step
Actually re-taped the area and then painted
(https://live.staticflickr.com/65535/51422782176_ce0ef65d2a_z.jpg)

No.7 step
All clips back on underside of dashboard
(https://live.staticflickr.com/65535/51423037593_dcbfc9f956_z.jpg)

The second to left clip was the one that was not damaged, but I ended up painting each area.

Close up of repaired area and clip on. Clips perfected went on and holding in place. You can see where paint bleed under the taped up area, this is why I recommend using green tape over blue tape. Yes I have OCD issues haha..
(https://live.staticflickr.com/65535/51422779466_ff3e65698a_z.jpg)

Fixing the dashboard edging
If you have not noticed in some of the photos, a lot of the dashboard edging is lifting up, so went ahead and repaired those areas.

Using 3M Scotch-Weld Super fast Instant Adhesive SF100, I add that to the edging and underneath areas of dashboard lifting and then using super small clamps to hold edging down this fixed all the areas on edging perfectly.

Waiting time on gluing is 5-10 minutes which is perfect.

(https://live.staticflickr.com/65535/51431825451_838a6d7bf3_z.jpg)

(https://live.staticflickr.com/65535/51431825796_c26feb8e96_z.jpg)

(https://live.staticflickr.com/65535/51432571124_6a6c3f58f9_z.jpg)

Idea of edging before and after

Before
(https://live.staticflickr.com/65535/51432571844_c2618ac28e_z.jpg)

After (adhesive you see on top, wipes off nicely with hot water on cloth.
(https://live.staticflickr.com/65535/51431825696_f4a405f708_z.jpg)

Fixing the area of fiberboard where stereo secures too.

The inside area of fiberboard where the stereo of car goes, always ends up being damaged and in my case it too has screw holes and ripped, so will have to fix that and maybe add more structure in place to help support and secure stereo to dashboard.

Fixed this area with fiber glass and I think later on I will secure a metal bracket in there too so stereo can slot into it. Will provide that update on that solution later on.

Just noticed another area I need to fix in this photo - see more edging of dash cover coming away!
(https://live.staticflickr.com/65535/51492548837_0f854ee4e7_z.jpg)

Fiberboard damaged
(https://live.staticflickr.com/65535/51493563258_5a71312323_z.jpg)

Taped up ready for fiber glassed applied
(https://live.staticflickr.com/65535/51493563223_ef28e2cc52_z.jpg)

Applying fiber glass - I added 3 layers.
(https://live.staticflickr.com/65535/51493562983_995aab9cee_z.jpg)

All done!
(https://live.staticflickr.com/65535/51493343516_4e0c4e20f3_z.jpg)

Next fix updates will cover;
Final stage of fixing dashboard - POR15 all metal structure and any last minute edge fixing!
Fixing my rear boot lock
Fixes to HVAC issues and service AC
Draining of engine coolant and service!

Little teaser…
(https://live.staticflickr.com/65535/51422048832_d30502f124_z.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 23 September 2021, 22:41
When I bought the cabriolet one of the areas not working was the rear boot lock. I was lucky that it was in the unlocked position so I could open and close it, but I wanted to find out why it was not working with original key.

The outside lock and seal cover was broken and missing so had to order new parts for that too.

Here is what I found.

Here was the situation of rear lock
(https://live.staticflickr.com/65535/51423565289_85dc5d0b1c_z.jpg)

So time to remove the lock, this has to be done from inside the back side of boot.
Most will have a cover in this area, mine was already off, the cover is only held In place with 6 clips, just pull them out.
(https://live.staticflickr.com/65535/51503576806_2ec1c2b260_z.jpg)

Then un-screw the two screws holding the lock in place. Notice there is metal bar attached to lock. Once you have screwed removed and can move lock backwards you can then turn and pull that metal bar out of the plastic clip. Note nearly 99% of time that small plastic clip will break so you will need to order a replacement for that.

(https://live.staticflickr.com/65535/51422799406_eb96282e31_z.jpg)

See plastic clip on the back of lock in this photo. I actually managed to get the metal  bar out without breaking my clip and then placed it down and clip broke! Typical….
(https://live.staticflickr.com/65535/51423768000_daf51fef7d_z.jpg)

So now you have the lock off the vw, time to take the lock apart and see what is wrong.
(https://live.staticflickr.com/65535/51423560994_2fd190b5b5_z.jpg)

There is metal pin at the back of lock - you need to pull out. The best way I did this was put the lock in a vise and then using vice grips pulled on pin. Took at few goes and it come out. Be careful not to lose the pin!!

As you can see in photo the grease was more like jelly…

Now to take the barrel of lock out of its cylinder, do this nice and easy as you don't want to have the lock pins spring out..
(https://live.staticflickr.com/65535/51423561259_824a762900_z.jpg)

Place the key back into the lock. This pulls or you hope all the lock pins down, I had to push down a few with small screw driver before the lock came out.
(https://live.staticflickr.com/65535/51422799346_fddb78a170_z.jpg)

(https://live.staticflickr.com/65535/51423561194_cbca1aa37d_z.jpg)

And lock out! You might not see it in photo but a few of pins are not properly sitting down and this is problem for lock to not work properly.. Time to investigate further
(https://live.staticflickr.com/65535/51423054238_ca960a44bf_z.jpg)

Now remove the key slowly, again making sure no pins spring out and get lost… I actually did this in a small plastic see through bag just in case. As you can see the grease is like jelly - the pins are clearly not moving up and down properly.
(https://live.staticflickr.com/65535/51423772350_ca559e3089_z.jpg)

Next I took each pin out of the lock and placed on clean piece of paper and mark against the lock positions, I knew where to put the pins back.

I then cleaned the lock thoroughly with WD-40 and then using air compressor, cleaned out all WD-40. I did this 3 or times leaving soaking times of about 15 minutes each time and the amount of dried up grease that came out was not good.

Sadly my photos of this part was lost on my camera, but I have another lock I am doing for someone else and will update this part of my thread with photos from that one soon ( I promise)

I managed to recover one photo of pins out of the lock cylinder after clean up.
(https://live.staticflickr.com/65535/51507743402_445bf3b85b.jpg)

With the lock clean and pins cleaned too, I greased up the lock and put all pins back and then put the key back into the lock cylinder and guess what? All the pins now are flush with cylinder. Time to test..

See grease applied to lock
(https://live.staticflickr.com/65535/51422031382_42d5decc2f_z.jpg)

And the original key now works in the lock! (video!)
https://www.youtube.com/shorts/IlxiJ8T6sOI

So now installed new lock cover and seal

Part 161827527 - this is the hatch lock seal ring - you have to install this first before you can put the lock back onto the car. This was completely missing on my car.

(https://live.staticflickr.com/65535/51503575661_51d398da4a_z.jpg)

Before installing!
(https://live.staticflickr.com/65535/51502777127_02ca4e1451_z.jpg)

Installed! Trick for install.. Add little water to inside lip, makes it easier to install
(https://live.staticflickr.com/65535/51504503700_d1ccd6a685_z.jpg)

Next installed the lock seal and cover - before (I actually had these as spares from another lock, so not sure if you can buy these individually)
(https://live.staticflickr.com/65535/51503502191_5240b8cf92_z.jpg)

And installed!
(https://live.staticflickr.com/65535/51423060798_89dfd8d216_z.jpg)

Now I just installed the lock back into the vw, place the metal bar into the clip on back of lock and then placed into position slowly - not to push out the new hatch seal in place and then install the two screws and place the cover back in place.

(https://live.staticflickr.com/65535/51504216064_dd78d6b430_z.jpg)

And another item fixed :)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 26 September 2021, 00:44
Teaser on next update.. rebuilding of air vent unit!

(https://live.staticflickr.com/65535/51218361898_a916eac3fb_z.jpg)
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 04 October 2021, 03:53
Refurb of HVAC engine bay fan motor big cover and Flap box.

I am sure most of our cabs HVAC venting system has a lot of old broken foam, allowing leaks in the system and so this update is refurbing the two main covers that allows the fan motor to push the air from engine bay area into the cabriolet on the passenger side (US spec cars).

Here is diagram of those two covers;
Red box = (4) is the flap box (171-820-551-A)
Blue Box = (5) is the big main cover (171-820-565)
New foam OEM: Seal 321 820 061 D (1)
(https://live.staticflickr.com/65535/51547938063_15eab61ce7_z.jpg)

Started with the Flap box refurb.
(https://live.staticflickr.com/65535/51218361898_a916eac3fb_z.jpg)

Started to remove the old foam, using few tools (primary a big screw driver and Stanley knife)
(https://live.staticflickr.com/65535/51524125161_b3676861ba_z.jpg)

Few minutes later all old foam is off
(https://live.staticflickr.com/65535/51525032650_e41cc32394_z.jpg)

Old foam, was very hard
(https://live.staticflickr.com/65535/51525032925_5335bc0088_z.jpg)

Moved onto dismantling the unit. Removed the middle foam. This was actually was in great condition, just very dirty. Will be able to reuse this one.
(https://live.staticflickr.com/65535/51524123231_ec98d4c13e_z.jpg)

Popped out the end cap, so can remove the flap inside the box.
(https://live.staticflickr.com/65535/51525014335_187ec925c2_z.jpg)

Disconnect the vacuum unit from the flap box side arm and pulled out of the unit (4 plastic clips holding in.)
(https://live.staticflickr.com/65535/51524333283_2d2ab268bb_z.jpg)

I then disconnected the inside bar to the center flap pin and pulled the flap out. All parts now apart!
(https://live.staticflickr.com/65535/51219218500_36dff29c60_z.jpg)

Moved onto the flap itself. It has thin layer of foam on both sides. Foam is actually worn away on both sides not sealing when in closed or open position.
(https://live.staticflickr.com/65535/51217433627_dc92bcf144_z.jpg)

I used a small scrapper to remove the old foam.
(https://live.staticflickr.com/65535/51219214960_5d948499dd_z.jpg)

Cleaned up the plastic with little car wash and water and then buying new foam, cut the foam to size
(foam size is Foam seal tape, 1/2" Wide x 1/16" thick high density)
(https://live.staticflickr.com/65535/51219213985_e82f30a6cb_z.jpg)

Foam installed on both sides.
(https://live.staticflickr.com/65535/51218166301_839105055b_z.jpg)

(https://live.staticflickr.com/65535/51218361863_54a4bc8ee8_z.jpg)

I noticed that the flap moves around when in place, so did a little mod, you can see the clamp is spread out a little
(https://live.staticflickr.com/65535/51218147081_0008a90427_z.jpg)

To secure that clamp more, I drilled out a hole and added a split pin to bring the clamp inwards again. Nice easy fix.
(https://live.staticflickr.com/65535/51219217085_ef1f43f118_z.jpg)

Add split pin through new hole
(https://live.staticflickr.com/65535/51218357693_9e5b6953d4_z.jpg)

(https://live.staticflickr.com/65535/51217431672_77d8bedc0b_z.jpg)

And on the other side of the split pin opened up the end of pins to bring in the clamp.
(https://live.staticflickr.com/65535/51218144681_66020f44ea_z.jpg)

Compare before and after.
(https://live.staticflickr.com/65535/51546987262_49f23ba69a.jpg)

Now moved onto protecting the vacuum unit. I actually tested it before I metal prepped, taped up and painted this unit. (I will show you how to test these units later in this update)
(https://live.staticflickr.com/65535/51524122101_c22ab6db83_z.jpg)

Sprayed the metal with POR15 prep and the painted with POR15.
(https://live.staticflickr.com/65535/51524811119_2a0aa0344f_z.jpg)

Add back onto the flap box
(https://live.staticflickr.com/65535/51523292972_d594e2ddd4_z.jpg)

The flap end cover actually is in great shape but the foam has seen better days.
(https://live.staticflickr.com/65535/51525014335_187ec925c2_z.jpg)

Stripped off the old foam and add new on.
(foam size is Foam seal tape, 1/2" Wide x 1/16" thick high density)
(https://live.staticflickr.com/65535/51523293252_2353f5346a_z.jpg)

I then installed the flap back into the flap box and put the end cap back on. I moved onto testing the vacuum unit just to make sure it works like before I painted it.

Using a pressure/vacuum meter, connected up pipe to the vacuum unit and set to pull vacuum
(https://live.staticflickr.com/65535/51217436802_9cc72bb416_z.jpg)

Set the pressure to 15in Hg.
If gauge holds steady at 15, then the servo is good, if not servo is faulty. I tested pressure for 5 minutes and it held vacuum.
Useful link for testing each vacuum units here: http://www.cabby-info.com/Files/HVACTesting.pdf
(https://live.staticflickr.com/65535/51217436252_9f95e7b56f_z.jpg)

One more mod to add to the Flap box. I noticed that the top side of the unit has big hole and that can allow any small animals or leaves get into the covers, so I add a mesh cover to mine.
(https://live.staticflickr.com/65535/51218148746_31d8021a64_z.jpg)

Trimmed down the mesh to size
(https://live.staticflickr.com/65535/51219236695_3912e88656_z.jpg)

Taped up around the mesh, so I can add instant 3M liquid glue.
(https://live.staticflickr.com/65535/51524131971_954bb1b5c4_z.jpg)

To hold the mesh down, I used one of my old power tool batteries to put pressure on mesh
(https://live.staticflickr.com/65535/51523313492_71c523a700_z.jpg)

I then taped up the middle part of mesh too, so I can add some water sealant to really hold mesh in place.
(https://live.staticflickr.com/65535/51525032165_fcde79581f_z.jpg)

Few minutes after applying the sealant I removed all the tape. Let the sealant dry out overnight.
(https://live.staticflickr.com/65535/51524353868_403b6158f4_z.jpg)

Then re-taped up the flap box where I did not want any paint to be exposed too and put Plastic Black paint on the edge of mesh.
(https://live.staticflickr.com/65535/51218379153_622f9b0e8c_z.jpg)

And the finished product!
(https://live.staticflickr.com/65535/51217454292_7864cbfd0c_z.jpg)

I added all new air pipes to the flap unit and then add the main underside new foam too.
(Foam size 1/2"W x 1/4"D)
(https://live.staticflickr.com/65535/51218146121_e8f43c7b34_z.jpg)

Finished flap box refurbed ready to put back into the cabriolet.
(https://live.staticflickr.com/65535/51218148446_4e5c6bb6fc_z.jpg)

(https://live.staticflickr.com/65535/51218912274_8bb153ba5d_z.jpg)

Fan Motor big cover refurb
The cover itself was just fine, just required a good clean inside and out and then remove the old foam and apply new foam, which foam size is 1/2" W x 1/4"D)
(https://live.staticflickr.com/65535/51546472307_92bcb63478_z.jpg)

(https://live.staticflickr.com/65535/51548195395_82a7017684_z.jpg)

(https://live.staticflickr.com/65535/51546470962_2be574909f_z.jpg)

Both units all done and ready to go back into the Cabriolet
(https://live.staticflickr.com/65535/51547271991_68e526bfc5_z.jpg)

Next up the unseen rust that prevents me from putting all my HVAC setup back in and dashboard!
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 23 October 2021, 20:51
Coolant Flush - VW cabriolet

Finally got around to doing the Coolant flush on cabriolet.

So few reasons I am doing this. 1. No idea previous owner last did this, 2. all the time I've had the car it's had a bad smell from the expansion tank area, 3. the coolant color is just pure black which cannot be good. So here we go.

   • My plan is to take out the radiator completely and flush and clean it inside and outside.
   • Inspect all hoses to see if require to be replaced.
   • Inspect thermostat and replace
   • Take out expansion tank and flush and clean.
   • Flush the system until clear water is appearing out of lower radiator, engine block hose and expansion tank.

Found all my part numbers here: https://volkswagen.7zap.com/en/rdw/golf+cabriolet/goc/1985-44/1/121-19000 (good diagram and what is what for cab)

There seems to be many great summaries and videos available, so please do your own research, but this is what I did.

Due to I have power steering and AC on my VW cabriolet the easy way for me to get lower and upper pipes off easily from radiator is to remove the fan shroud first. There is 4 screw bolts (2 on each side) to remove this, you will also need to disconnect fan cable and side clamp that holds fan cable securely. With fan shroud out of the way, you can then open the spring clips from hose with vice grips and pull hoses off top/bottom radiator. Undo the two top screws  bolts and you should be able to remove radiator. You can then flush the radiator thoroughly until clean. My radiator was full of black coolant god knows what else.. It was actually really bad. Took a good 20 minutes to flush out, starting with black color, then yellow until it was clear water.

The outside of the radiator had a lot of crap on it, so using a copper brush, cleaned both front and back sides of outside of radiator. Cleaned up well and saw no damaged to radiator and no leaks.

Moved on to checking all hoses, most of the smaller hoses looked to be replaced from original, but the upper and lower main hose to radiator need replacing, so put order in for them.

I actually found that I don't have thermostat installed, which makes for flushing a lot easier and less work as you have to undo the power steering pulley to get to the thermostat housing.

I spent a good 30 minutes flushing the old coolant out of the engine and hoses, using hose pipe method starting at top radiator hose into the engine block. I blocked up the lower hose. Lovely hard yellow stuff came out of the expansion tank, until turned clear. Then did the reserve with flushing through the expansion tank until clear water was coming out of upper and lower radiator hoses.

Next was to remove the expansion tank and clean it. This to me is the one place I feel a lot of crap just stays in the tank and then gets pushed around the whole coolant system. I was amazed at how much crap had stuck to the sides of the expansion tank. After few flushes and using flexi wire brush I actually managed to get 99% of all internal crap out. Of course the tank is not like new (has that yellow color to the plastic), but I've got a new one on order.

After cleaning everything individually, I put all back in place and filled up system with just water and then ran the engine and let the coolant system get up to temperature. Once the fan kicked in and off few times I then shut off the engine. I then disconnected the lower radiator hose, still coolant system was light yellow. Flushed the system again and again about 3-4 times. Each time the coolant system getting cleaner and cleaner until last time coolant was clear and then this was when I actually installed new OEM coolant.

As most know adding fresh coolant will add air into the system, so I have bleeding funnel that you add to the expansion tank so you can always have enough coolant and when systems gets up to temperature (remember to set heater to HOT and turn air on so blows into the car) the air will force it way to the highest point which will be expansion tank and in the funnel. I actually had a lot of air bubble up with-in the first 5 minutes and then about 30 minutes later smaller bubbles.

I took off the funnel and sealed the system with the expansion tank cap and took the VW for drive about 20 minutes. I then inspected whole system, no leaks, color is nice OEM Coolant color now and steady temp showing through the dash cluster. The Fan kicks perfectly.

The only thing I have to do now, is installed the new higher and lower pipes, new expansion tank, (maybe a new thermostat) once they arrive. In long term I will treat and paint the fan shroud with POR15, when I do most of the rest of the engine clean up and painting.

So here is coolant in the system.
(https://live.staticflickr.com/65535/51591218849_fe96ac6b41_z.jpg)

(https://live.staticflickr.com/65535/51591419950_38324f2cb2_z.jpg)

Made little video of steps I did and you can see the mess that comes out of radiator, expansion tank and system Vw Mk1 coolant flush

Undo screws bolts for Radiator shroud
(https://live.staticflickr.com/65535/51591185729_187a20d8f3_z.jpg)
(https://live.staticflickr.com/65535/51590847368_9ef0e7faee_z.jpg)

Fan cable disconnect
(https://live.staticflickr.com/65535/51589744627_da3d9a27f3_z.jpg)

Fan shroud removed
(https://live.staticflickr.com/65535/51590793943_76b4c54c5e_z.jpg)

Un-clip upper and lower hoses and remove radiator screw bolts
(https://live.staticflickr.com/65535/51591185739_2cf1066cf0_z.jpg)

(https://live.staticflickr.com/65535/51591218114_a6dab6097f_z.jpg)

Radiator out!
(https://live.staticflickr.com/65535/51589822312_7dd881245c_z.jpg)

Cleaning of radiator
(https://live.staticflickr.com/65535/51590846528_0519216aeb_z.jpg)

(https://live.staticflickr.com/65535/51590779923_63bab1d2fc_z.jpg)

What came off radiator on outside.
(https://live.staticflickr.com/65535/51591240299_36ff9049a3_z.jpg)

Then Flushed out radiator and this is the mess coming out of it first of all (Black!) and then rust color and did this several times before clear water came out
(https://live.staticflickr.com/65535/51622085802_200dd7b00a_z.jpg)

After black mess, this is what came out of radiator after filling up with water and moving radiator up, down, back and forward to try and loosen up anything inside.
(https://live.staticflickr.com/65535/51604327357_5f6976983d_z.jpg)

Expansion tank
(https://live.staticflickr.com/65535/51589751277_92f08fc83b_z.jpg)
(https://live.staticflickr.com/65535/51590575686_219731c0fd_z.jpg)
(https://live.staticflickr.com/65535/51590846963_fe3e097690_z.jpg)
(https://live.staticflickr.com/65535/51591422050_742c185f7a_z.jpg)

Cleaning
(https://live.staticflickr.com/65535/51589744072_129cefbe34_z.jpg)
(https://live.staticflickr.com/65535/51590527406_e4ffd2e226_z.jpg)
(https://live.staticflickr.com/65535/51590799428_32cf681b56_z.jpg)

Cleaned
(https://live.staticflickr.com/65535/51590581856_f620419603_z.jpg)

Flushing system with hose method, force water through top upper hole and then through expansion tank
(https://live.staticflickr.com/65535/51591219039_d2d9d3b8f5_z.jpg)

Look at the mess coming out of expansion tank
(https://live.staticflickr.com/65535/51605155181_56c5dd04b6_z.jpg)

Clean water now coming out of the expansion tank, after several flushing.
(https://live.staticflickr.com/65535/51605815539_119e01758d_z.jpg)

Now showing clear water in bleeding funnel.
(https://live.staticflickr.com/65535/51590868698_480fddf5b8_z.jpg)
(https://live.staticflickr.com/65535/51591239624_35d890bf0d_z.jpg)


The evidence of before, during and after flushing
(https://live.staticflickr.com/65535/51591227699_aa87454d7d_z.jpg)

Adding new coolant. Note all pre 96 vw's use G11 (Blue) coolant, so make sure you use the right coolant. I am using later coolant as I've done a complete flush of the complete system.
(https://live.staticflickr.com/65535/51591455800_01d2efe7f2_z.jpg)

(https://live.staticflickr.com/65535/51590846283_d2a0e31fd7_z.jpg)

(https://live.staticflickr.com/65535/51589696312_cb964c46af_z.jpg)

Coolant temperature just perfect
(https://live.staticflickr.com/65535/51591421935_d9b0ab5492_z.jpg)

And the before and after coolant color
(https://live.staticflickr.com/65535/51590794733_2ec1a73673.jpg)


And onto the area that is now stopping me from putting back in the dashboard and all the HVAC setup, I saw some paint bubbled up near front windscreen, dug a little at it and bingo load of rust and its gone all the way through and checked underneath and it needs fixing, so I am planning on pulling out the windscreen, getting this fixed, primed and painted and then new window rubber and window back. Update on that soon.

(https://live.staticflickr.com/65535/51601031226_5d1becb974_z.jpg)

From underneath, you can see a line of rust, this runs along the bottom of where the front windscreen is and is very common rust area over time on vw mk1's.
(https://live.staticflickr.com/65535/51601689264_d401358f77_z.jpg)
Title: Re: US VW Cabriolet 85
Post by: Mr_Orange on 19 December 2021, 13:18
Top work as always. Amazing attention to detail  :cool:
Title: Re: US VW Cabriolet 85
Post by: Madone_si on 04 January 2022, 01:01
Happy new year everyone!!

Well few change of plans for 2022, was planning on updating about upgrading engine to 20v from Audi TT 225HP, but that is going to be stored for now for another project and managed to get a complete setup of 16v engine, manual gearbox, with powering steering and AC setup, brakes, loom - so I can keep all that setup in cab as part of engine conversion. Happy days... I think long term this is much better engine for this kind of car anyhow.

Engine pic for excitement
(https://live.staticflickr.com/65535/51775042617_21c24e696f_c.jpg)

Start the dismantle of engine and rebuild in coming weeks.... question now is do I go OEM or mod engine?


Title: Re: US VW Cabriolet 85
Post by: Madone_si on 04 January 2022, 01:22
Top work as always. Amazing attention to detail  :cool:

Thank you for kind words..
Title: Re: US VW Cabriolet 85
Post by: Simeon on 22 February 2024, 13:46
How have you got on in the last couple of years? Be great to see some up to date pics  :smiley: