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Model specific boards => Golf mk2 => Golf mk2 gallery => Topic started by: Coakers on 04 September 2019, 17:42

Title: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 04 September 2019, 17:42
Well this a journey that started in April 2016. I've got threads on clubgti and retro rides too so I thought why not add mine here too. I was looking for other VAG sites since the demise of the ED38s website. So here goes, from the top.

I had a 1.8 auto which I adored but eventually wanting to buy a Gti was the next step up. Searching various old haunts saw that there were many 8 valves out there. Never saw many 16valves but the ones I did see were either very well maintained/restored or were on the verge of being scrapped. Guess which I picked...

(https://i.ibb.co/tXb7fzr/2257eed5ecfbb1f777919c93e4b0babe-1.jpg) (https://imgbb.com/)

(https://i.ibb.co/ky5Q0w1/dd40d07676557e5f8f8da7cb8012b1fb-1.jpg) (https://ibb.co/z5QGbBJ)

(https://i.ibb.co/Lz1vgjQ/bbb571b565d78d6fb1785b14fd52c665.jpg) (https://ibb.co/WWfsz8D)

(https://i.ibb.co/SPD63m5/b19080b847b121dea8cd5a84f28ee36b.png) (https://ibb.co/G0fd5Mn)

(https://i.ibb.co/4SfV5RZ/dd29fe13e31047c8d278a6ffc6dd5d3d.png) (https://ibb.co/94vrCH9)

(https://i.ibb.co/jGJWwC8/c3ae22e42e6f4c1464978e7bbde32a5b-1.jpg) (https://ibb.co/nfPn1Xw)

Questionable wiring.
(https://i.ibb.co/cwJPdH5/ea32bc7b0c94a116656ed0d0a7b4ddd4.jpg) (https://ibb.co/3v1wHqX)

Much greater horrors lie in wait.


Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 04 September 2019, 18:10
Discovered thanks to the mk2 owners club that someone had installed a mk1 campaign wheel which is a whopping 380mm which makes steering and finding the brake pedal with a manual rack quite a danger more than anything.

(https://i.ibb.co/T8JqBbm/1c48fdf335b30e4f653dbef43d61c7f9.jpg) (https://ibb.co/85G4Dd6)
When I got the car it had a rattle at the top end, the rattle eventually turned into a knock (more on that later) I've covered 3500 miles in 6 months. It came off the road with  151,000 miles. I got it for £900 with an mot would you believe. Did manage to have some fun though

(https://i.ibb.co/hy3YPw6/da8cb54caf5f285443a236a13f40fe38.jpg) (https://ibb.co/0cHsgv7)

(https://i.ibb.co/5hQ0Z6L/3e02f688f2ce2c7c01fe1a78ac6784ca.jpg) (https://ibb.co/tp0GR4D)

Had our one and only breakdown. (https://i.ibb.co/ThYcxtk/9da0b4a4ab5192dc3c88a9f25bddb926.jpg) (https://ibb.co/Sv5N4BP).

Heater matrix blew up, doing about 80, extremely hot water suddenly peppered me and my girlfriend through the vents. I think she said something along the lines of.. 'pull the f**k over before I get scalded alive' not good.
Managed to pull over without further incident.. Just. What hurt more was having to fork out £140 to the RAC for them to bypass the heater matrix which is a simple thing to do by the way. When I told the Rac guy where we were going he said 'in this??.. Your brave'



Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 04 September 2019, 18:17
I didn't do much apart from fit from fit period correct small bumpers (https://i.ibb.co/mbNhVQn/d8b7eb5fea625085026710c404cdd7a7.jpg) (https://ibb.co/wBcpFDn)

(this brings us to around Aug 2016) Looking back now I still have to remind myself why I bought such a neglected scrapper that was destined for to be parted out. The original colour.. Monza blue.

(https://i.ibb.co/z6rFjJy/904e66d3f848267583605b1c9bffc032-1.jpg) (https://ibb.co/rdm3TsC)

This is the scuttle, I noticed it as soon as the seller lifted the bonnet. He didn't even mention it had been resprayed (awfully) and monza blue just happened to be my favourite mk2 colour so call it fate I ran into this.



Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 04 September 2019, 18:35
Getting to more recently. Started looking for places to restore her, she's named Ellen by the way (due to the licence plate) planned on doing some of the work myself but lack of time, space and general expertise on such a build made me realise that I was delusional.

Took her to Deutsch Doctors down in Stoke (I'm in St Helens) who were very good and nice guys too. They had a hoard of mk1's and mk2's.

(https://i.ibb.co/f0kyfFs/a6c2cb36fc929f02d5de7ee83b712d20.png) (https://ibb.co/Ky2fdhJ)

(https://i.ibb.co/kXLwJqF/377a21e8d7de4cc72ddbc440dc969e0f.png) (https://ibb.co/SBkMcVp)

Only issue was distance so had a chance call into somewhere 10mins away. Quest Auto body in Orrell. These guys were high end. Very expensive stuff in there.

Meanwhile I originally wanted the current KR to be rebuilt but something came up in the form of this...

(https://i.ibb.co/C6xDZmc/43774af815fda84c2a83424bbc03b22a.jpg) (https://ibb.co/tzyFtQG)

(https://i.ibb.co/QMVQR5K/4531da21d4ac806dd434092a17eef510.jpg) (https://ibb.co/5L34y7R)

A Mk3 16V ABF engine but I've seen it running a few times because I've followed the owners build thread on cgti, it's had a top end rebuild and the only reason he's changing it out is because he's going with a Vr6t. So I know it's running well. Also I'm able to retain the mechanical fuel injection (k-jet) which is essential for me so it will look completely stock but with about 40-50bhp extra so I'm quite happy

(https://i.ibb.co/GRdCXr9/dbb44770c7434d73c7f5ff99a535ff33.jpg) (https://ibb.co/89mPJQb)
He even threw in an early 7 slat grill with a genuinely very uncommon 16v badge (the word 'rare' just makes me cringe nowadays) for a very good price.


Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 04 September 2019, 19:08
OK so here is where it starts getting interesting. (Dec 2016) The Strip.

(https://i.ibb.co/R2YqhTc/3a2c90d409e7c72c8ff31822890c7345.jpg) (https://ibb.co/SN5zQwB)

(https://i.ibb.co/9b7dy4p/f462848e9957b22c4a71cc9b5494e199.jpg) (https://ibb.co/v3SMLdc)

(https://i.ibb.co/jZZVwMB/e3d2989f23095e9cfeb5cbf1723e1393.jpg) (https://ibb.co/Xkky5sN)

(https://i.ibb.co/JjN1FZT/12b60bdb15e05492f8ba35c6380221f1.jpg) (https://ibb.co/chPBXq9)

(https://i.ibb.co/5rNCmSF/0294e87dba4eb670f123f4388a81ead5.jpg) (https://ibb.co/SthHbMr)

(https://i.ibb.co/BZDnmPH/1bb952a8f6ed84d1175ed781a8bec4fa.jpg) (https://ibb.co/wWHcTLZ)

(https://i.ibb.co/Q8jX1t8/be60ecfddf68a6101d025a03a6edc32f.jpg) (https://ibb.co/XykVvMy)

(https://i.ibb.co/JKG87vG/b6dd9c23d3fb8cde7de1e76815b1fea0.jpg) (https://ibb.co/L8cBtxc)

That's the first part done.

Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 04 September 2019, 19:21
This is an example of one of the former owners 'handywork' the heatsheild was cut through presumably to get to the dash bolts which were rusted on anyway. Whilst it was being stripped I had a text from the restorer which contained words such as 'deathtrap' and 'accident waiting to happen'. Most bushes were perished, crossmemeber was rusted to the point where the engine mount was not secure. And most bolts on the suspension set up were cross-threaded.

 (https://i.ibb.co/5nWfVGC/X9DucwKP.jpg) (https://ibb.co/MGD3LZK)

The metallic blue car there is a 60s ferrari. But can you guess which the car in the foreground is?

(https://i.ibb.co/y0dwT2K/usbYpcCl.jpg) (https://ibb.co/PxF7pkJ)

In the meantime while the car was being worked on I continued to collect parts. Most notably the thinner (84-87) side mouldings.
(https://i.ibb.co/DRXGMf3/6lq42aMH.jpg) (https://ibb.co/qrG0gYb)

(https://i.ibb.co/N3H96wf/7Ou1dlgT.jpg) (https://ibb.co/BPSyV8v)

Paint stripping next.

(https://i.ibb.co/vQWJFGs/Yw6fkVJH.jpg) (https://ibb.co/fnWCg58)

(https://i.ibb.co/ZHnbrMF/7KypoTKM.jpg) (https://ibb.co/N18GqyJ)

(https://i.ibb.co/Rgv9jd8/C3JB3xBi.jpg) (https://ibb.co/2FnyZHJ)

(https://i.ibb.co/1b50Tff/AkN0j87k.jpg) (https://ibb.co/qxfDpMM)

(https://i.ibb.co/nbZzdXx/GOZZUjgW.jpg) (https://ibb.co/zrjG93q)

And in etch primer

(https://i.ibb.co/TLHR1jT/EHwiINqV.jpg) (https://ibb.co/tXbczjh)

(https://i.ibb.co/JpLCZ8b/Y34CiD1q.jpg) (https://ibb.co/B6Dwkv7)

The wings and bonnet were being replaced, hence why they weren't stripped.



Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 04 September 2019, 19:38
Mar/Apr 2017

I hope you guys like welding.

(https://i.ibb.co/T0xc5Wt/35077352553-f2a2bed989-k.jpg) (https://ibb.co/xgthQF6)

(https://i.ibb.co/dPwYSrc/35077352313-c0b5979e4d-h.jpg) (https://ibb.co/5rgHd69)

(https://i.ibb.co/sskX9Bj/35047068204-b220d29106-h.jpg) (https://ibb.co/3SGPmJ1)

(https://i.ibb.co/LZ3ycPP/35077351623-e10e96bb3c-h.jpg) (https://ibb.co/5RP3S99)

(https://i.ibb.co/bKsXQZn/35047067694-a3d518acc7-h.jpg) (https://ibb.co/5RrLGyV)

(https://i.ibb.co/k30D0Wc/35077351423-3069257ca3-h.jpg) (https://ibb.co/28PMPfK)

(https://i.ibb.co/x3ZNVqb/35077350953-854693f595-h.jpg) (https://ibb.co/0Q5xPyL)

(https://i.ibb.co/WD5Jshp/35047065864-3a0786a845-h.jpg) (https://ibb.co/tZKr3GP)

(https://i.ibb.co/KXMmTr0/35077348753-d993efbc66-h.jpg) (https://ibb.co/hyPC3m7)

(https://i.ibb.co/ZThy9qd/35077348393-b26b6389b4-h.jpg) (https://ibb.co/ggDsYky)

(https://i.ibb.co/KmgCjHc/35886588475-47ee490afd-h.jpg) (https://ibb.co/st4Lvrp)

(https://i.ibb.co/TwzcYqm/35886588275-3bb9b72dee-h.jpg) (https://ibb.co/mRQJbF6)

(https://i.ibb.co/02PwS8j/35886587955-4e0b68ac9a-h.jpg) (https://ibb.co/W5STwqW)

(https://i.ibb.co/02mKQht/35047064354-23a023e39b-h.jpg) (https://ibb.co/r0F3v4s)

(https://i.ibb.co/2gVBQ69/35047063424-1be38458db-h.jpg) (https://ibb.co/PwX8nYL)

(https://i.ibb.co/wJM8YMR/35886586505-6d7e47795e-h.jpg) (https://ibb.co/8z6GX60)

(https://i.ibb.co/HVS4gLC/35047063104-62034f9d0e-h.jpg) (https://ibb.co/0c72JpK)

(https://i.ibb.co/f4Zqrf2/35886586365-05892a4b49-h.jpg) (https://ibb.co/XS6jF1b)

Now onto the other side.

(https://i.ibb.co/VQ5srdD/35047062434-9c31b86095-h.jpg) (https://ibb.co/D8TZsNk)

(https://i.ibb.co/rQmtXP9/35886585015-94092b253d-h.jpg) (https://ibb.co/vcHBM59)

(https://i.ibb.co/t3q2dCj/35886584915-4e43c0985a-h.jpg) (https://ibb.co/3kpFJh6)

(https://i.ibb.co/2SDvYbm/35047061354-c41a3d75ef-h.jpg) (https://ibb.co/nBH78WZ)

(https://i.ibb.co/M2q4Npr/35886584415-0bcc15289a-h.jpg) (https://ibb.co/xCV05GW)

(https://i.ibb.co/TwHG1gh/35047060404-0b14000696-h.jpg) (https://ibb.co/VLvGxqB)

(https://i.ibb.co/jy0FZGL/35077342913-ec83006607-h.jpg) (https://ibb.co/StYp70K)

(https://i.ibb.co/fvGpPgx/35047059504-90ccc82caa-h.jpg) (https://ibb.co/dgJ2zT5)

(https://i.ibb.co/NNq47QP/35047059334-5d1f50e33f-h.jpg) (https://ibb.co/kDTdMkf)

(https://i.ibb.co/FYdLh1J/35886582915-bbe4e04a3d-h.jpg) (https://ibb.co/SmZ46g0)

(https://i.ibb.co/sgH6GkJ/35886582785-46fc5e1d66-h.jpg) (https://ibb.co/WHtPwqp)

Phew... BUT WAIT THERE'S MORE  :laugh:
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 09 September 2019, 08:48
More welding, It was cheaper and easier to just replace the lower rear valance completely. Also in this updated update is underseal and suspension removal.... joy.

(https://i.ibb.co/2ZN1njm/35716752152-280e2f4746-b.jpg) (https://ibb.co/NTSdVLQ)

(https://i.ibb.co/xq6c19S/35498012510-7cbe8b241a-b.jpg) (https://ibb.co/PGgbcXZ)

Battery tray, particularly impressed with this one.

(https://i.ibb.co/PrZjk1J/35076776753-91518dd0f8-b.jpg) (https://ibb.co/hgR902r)

(https://i.ibb.co/4tfXYcL/35498007100-73dac17476-b.jpg) (https://ibb.co/JtdGyNT)

(https://i.ibb.co/yd8g1NM/35046375174-f6cf4f388a-b.jpg) (https://ibb.co/MZRP4gj)

This was the only part of the car where the corrosion shocked me. As it was particularly bad and in a crucial structural part of the car.

(https://i.ibb.co/TTJRw91/37781287124-60252a4af5-b.jpg) (https://ibb.co/W37FHm0)

(https://i.ibb.co/zP0qv00/37781281054-557cc61bbb-b.jpg) (https://ibb.co/wpx5mxx)

(https://i.ibb.co/2ssnjdg/38440838786-a3190f2c23-b.jpg) (https://ibb.co/YyyRthp)

(https://i.ibb.co/BrLgSF0/38440829286-784efc71a9-b.jpg) (https://ibb.co/jWhL1sn)

(https://i.ibb.co/4smYYck/24624212218-d06b1e8de9-b.jpg) (https://ibb.co/HNFxx0Z)

(https://i.ibb.co/VD1YNHZ/38440823456-a08abd35c0-b.jpg) (https://ibb.co/XpQx4yg)

And suspension/running gear removal.

(https://i.ibb.co/7RbNjbm/35498078210-4c84c0c2be-b.jpg) (https://ibb.co/z7NHQNv)

(https://i.ibb.co/VVNj9X4/35046423824-e90d4e9759-b.jpg) (https://ibb.co/Y2WRQvs)

(https://i.ibb.co/173Nq4V/35754647991-9f01a6c8c5-b.jpg) (https://ibb.co/wBTqW2H)

(https://i.ibb.co/9N7t6cc/35754645441-27c546c144-b.jpg) (https://ibb.co/wRfsVBB)

This was spring 2017.




Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 09 September 2019, 09:02
And a bit more welding. Nearly done though honest. The fuel filler bracket which has rotted out of 99% of mk2s ever.

(https://i.ibb.co/XXgYq3v/vgjJX5xE.jpg) (https://ibb.co/LSWN3J2)

(https://i.ibb.co/qjfBGCy/YN1sKly2.jpg) (https://ibb.co/6wxYh8n)

(https://i.ibb.co/pzgcq4G/Cbv3jwcX.jpg) (https://ibb.co/vPbp9Lg)

(https://i.ibb.co/VgMjVdH/E058kSBg.jpg) (https://ibb.co/CbV1BqJ)

(https://i.ibb.co/HHwK3B5/Pgvn2kN1.jpg) (https://ibb.co/MCwgQZF)

Next is to tackle the underseal. Eeesh.

(https://i.ibb.co/q1KcxTw/nZxv1XDx.jpg) (https://ibb.co/pXcMnYp)

(https://i.ibb.co/5cnrRhF/1L7lR5pw.jpg) (https://ibb.co/Thb4gML)

Left this for a bit.

Time for something a bit more exiting.. Colour.

(https://i.ibb.co/bKnFXGw/38496511841-52bfd12f4f-b.jpg) (https://ibb.co/jrFzDj0)

(https://i.ibb.co/hYhpmj1/24624230798-23d9f55932-b.jpg) (https://ibb.co/Bnd8CxK)

(https://i.ibb.co/3BfS9tc/24624230328-a145402e77-b.jpg) (https://ibb.co/f48rzmH)

(https://i.ibb.co/3BfS9tc/24624230328-a145402e77-b.jpg) (https://ibb.co/f48rzmH)

(https://i.ibb.co/RpBgwTN/24624228658-245136ed25-b.jpg) (https://ibb.co/SXd6Cwc)

(https://i.ibb.co/dQ4Z8r7/24624227698-9b4150ca5c-b.jpg) (https://ibb.co/br5tcP7)

(https://i.ibb.co/xG7KXB4/37609784945-9f0f8e3326-b.jpg) (https://ibb.co/ZKMRGFZ)

(https://i.ibb.co/3YMT7V9/24624223058-d5a0624984-b.jpg) (https://ibb.co/mFXRGdV)

Very much happiness, however things had to be taken down a notch. I began to do work on my own car to save money and because I wanted to more than anything. I'm definitely not a proficient welder even though I have been practicing so the plan was for them to do all the bodywork, paint it and then I could build it up at home, they were very reluctant to give me a final price to get the car in paint but I always paid on time from the beginning so I believe I was less likely to be scared off so when I asked a few weeks ago how much it would take to get in paint from where it is currently they said around £8k.. just to get it in paint headache headache.

I have put close to that amount into it so far in parts and labour so far so I thought It was unjustifiable. I really believed that I was passed the hard part so that was partly due to my reason of putting on hold.

I chose to put the car in storage in the autumn of 2017. And there it stayed pretty much untouched for around 8 months. I lost my mojo.
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 09 September 2019, 09:19
And here she is in storage.

(https://i.ibb.co/YyCvkfS/38073149294-d4495cc76b-b.jpg) (https://ibb.co/HxSmzGy)

Very sad sight.

I didn't do any work until summer 2018. It was never far from my thoughts and enough was enough. Time to pick myself up.

Started on the running gear at my grandads shed.

Pressed out the wishbone and rear beam bushes with this bearing/seal driver that I've had knocking around for a while.

(https://i.ibb.co/ThLjj5S/C8ylMg63.jpg) (https://ibb.co/F7VZZtM)

For the subframe, wishbones etc.
(https://i.ibb.co/B4XsDGf/TmWg1HAT.jpg) (https://ibb.co/8zW83bm)

(https://i.ibb.co/jkTQHvy/IMG-20180511-163419-411.jpg) (https://ibb.co/CKzYW5b)

(https://i.ibb.co/f2WN1Ry/IMG-20180511-163419-402.jpg) (https://ibb.co/FK1Yxvy)

(https://i.ibb.co/t2hT0Xy/IMG-20180511-163419-401.jpg) (https://ibb.co/09XR0tP)

(https://i.ibb.co/7gz9pbv/20180604-115844.jpg) (https://ibb.co/3fsJFk1)

POR 15's metal prep showing in full effect here. You can see the etching effect.

(https://i.ibb.co/3448Wv9/20180604-124353.jpg) (https://ibb.co/YPPK8XF)

That there is my grandad who was 92 at the time. Pressing in the wheel bearings into g60 hubs. He lives for mechanical engineering in all its forms. Hes built model steam engines, boats, mechanical clocks and maintained the neighbours clocks just for fun.. and that's just in his retirement years! He was also in the Lancashire Fusiliers during WW2, spending 2 years in India during that time.. legend.

My grandad sadly passed away in September 2018 (photo taken in June) He had been a constant source of encouragement and knowledge since I started this build so it has become much more personal to me now that it gets finished.

(https://i.ibb.co/FsgvXtc/p1h7999q.jpg) (https://ibb.co/KNFZDHB)

So this corner of the car will always be his.
(https://i.ibb.co/VHZ1Gkv/20180606-174542.jpg) (https://ibb.co/N1PvqGL)








Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 09 September 2019, 09:52
One of the things I've been itching to do was dissect the KR... because it sounded like it was about to spit every piston out of the block simultaneously. The restorer told me they were frightened of turning the ignition key when moving it in and out of the shop shortly before it was stripped!
So the dissection commenced, i had never done this before and found it immense fun. Especially when i discovered the offending item. Cast your eyes at the photos.

(https://i.ibb.co/LhKPV8x/kfMp90gn.jpg) (https://ibb.co/3YKsg7p)

(https://i.ibb.co/WFKwzP0/0mVxucJ2.jpg) (https://ibb.co/RPHm6BN)

Conrod bearing no.4
(https://i.ibb.co/CtvSqB0/Uikxkwbo.jpg) (https://ibb.co/mBtPmJz)

(https://i.ibb.co/LnhXWVD/SoX4VnEa.jpg) (https://ibb.co/Hnpfs5L)

How was it still running?

So the source of that was found. The pistons themselves had significant scouring also. The engine was undoubtedly toast.




Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 09 September 2019, 10:03
Back to the underseal.
One angle grinder will get very hot very quickly so I advise using two.


(https://i.ibb.co/TgWxPtp/20180608-152818.jpg) (https://ibb.co/wzcFp43)

(https://i.ibb.co/h239f8Y/IMG-20180615-154808-317.jpg) (https://ibb.co/zPqxJf6)

(https://i.ibb.co/Wzc2jMH/IMG-20180615-154808-308.jpg) (https://ibb.co/ZghM7Ff)

(https://i.ibb.co/J5npfwS/20180622-133516.jpg) (https://ibb.co/6gYt37q)

Highly rated stuff this.
(https://i.ibb.co/8bT4D58/20180517-212658.jpg) (https://ibb.co/7Q8NJWy)

(https://i.ibb.co/NZ8jcTD/20180622-135301.jpg) (https://ibb.co/m6LqfNZ)

The Bilt Hamber range. Hydrate 80 rust killer/converter. Electrolux high zinc primer. Dynax s50 cavity wax. Dynax UC underbody wax and Bilt Hambers seam sealer.

(https://i.ibb.co/7zrJJ0W/20180626-220732.jpg) (https://ibb.co/MhPDDJV)

(https://i.ibb.co/6bQ5Rpc/20180704-173700-01.jpg) (https://ibb.co/4MkxZDw)

(https://i.ibb.co/8gm1JDy/20180704-173632.jpg) (https://ibb.co/CKwRq5j)

This was by far the worst job on the car. Doing all this on your back is dire. Rotisserie next time.

I've also stripped and painted the subframe with POR15 around this time.

(https://i.ibb.co/k8tT548/20180701-093246.jpg) (https://ibb.co/G2qDnW2)

(https://i.ibb.co/HCJRK4d/20180701-164621.jpg) (https://ibb.co/3vJVTdz)


Heres a before and after on the subframe. The monza blue anti-roll bar has got to be worth at least a 15bhp increase right??

(https://i.ibb.co/Tgt1Svy/IMG-20180709-193419-203.jpg) (https://ibb.co/gRJdpjY)



Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: jv on 09 September 2019, 19:46
Serious level of work/commitment going on here - thanks for sharing :)
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Adam T7 on 09 September 2019, 21:51
Excellent read - thanks
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 10 September 2019, 18:15
Thanks guys  :smiley: lots more to cover yet.

After using the dynex s50 in the cavities it was the seam sealing next.

(https://i.ibb.co/KVnHTwh/20180717-011320.jpg) (https://ibb.co/5sZVbF4)

(https://i.ibb.co/ZGBg49c/20180717-011314.jpg) (https://ibb.co/bQsvwtN)

Before turning my attention to the engine bay.

All the rust issues were already dealt with so I didn't need to worry about uncovering anything. Ive primed it with Electrox, its different from other primers because it... 'produces a surface film containing over 90% metallic zinc, once cured the tightly packed zinc particles establish an electronically conductive pathway enabling cathodic protection of the underlying steel'... Fancy ey?

(https://i.ibb.co/pwSF2qV/IMG-20180709-032338-967.jpg) (https://ibb.co/xLNThZ9)

(https://i.ibb.co/QQPKCYF/IMG-20180709-032338-968.jpg) (https://ibb.co/7Cn1RrJ)

(https://i.ibb.co/FwmgFjF/20180717-011345.jpg) (https://ibb.co/zRQGz0z)

(https://i.ibb.co/xhPfz2K/20180718-215232.jpg) (https://ibb.co/ZdtYcfR)

(https://i.ibb.co/qJ6XHQr/20180718-215246.jpg) (https://ibb.co/MBdWz0C)

(https://i.ibb.co/0YP43K0/20180718-215252.jpg) (https://ibb.co/3St6Hvx)

Very happy with how it turned out. Considering it's a rattle can job.
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 10 September 2019, 18:32
Threw the subframe, servo and replacement master cylinder on and the front suspension. Felt very good to start putting things back together.

(https://i.ibb.co/N6htS5C/20180818-142514.jpg) (https://ibb.co/GvwnTyp)

Coilovers are AP.

(https://i.ibb.co/mCgMr0h/20180830-151849.jpg) (https://ibb.co/qMVPLCm)

(https://i.ibb.co/HHb6g8g/20180917-163302.jpg) (https://ibb.co/1mP12W2)

Then started making the brake lines. Never done it before and making a full set from scratch was very daunting. I opted for kunifer as it they have anti corrosion properties but kunifer was a lot less malleable than copper.
(https://i.ibb.co/Ks3DknP/20181013-194437.jpg) (https://ibb.co/z20FYdM)

(https://i.ibb.co/wWPGfNN/20181013-194429.jpg) (https://ibb.co/VSznsWW)

(https://i.ibb.co/qpMHR30/20181209-182253.jpg) (https://ibb.co/6FRK47v)

Got my flaring tool from Vintage 65 via ebay.

New compensating valve.
(https://i.ibb.co/LYzxZGZ/20181209-181506.jpg) (https://ibb.co/4KZ8VQV)

Then the big moment came of chucking the ABF in.

(https://i.ibb.co/qMb81xm/20181215-143920.jpg) (https://ibb.co/VWXGB3M)

 :laugh:
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Simeon on 11 September 2019, 11:35
Great work mate, love it, keep the updates coming

Please please please can you replace those rusty bolts you've used on the fuel tank though :laugh: I got a couple of stainless steel ones for pennies when I did mine
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 11 September 2019, 20:35
Haha will do mate I'll be replacing most of the bolts that are in poor condition before it gets mot'd, cheers for the interest, the comments do genuinely help with motivation.

Next up is the grill.

(https://i.ibb.co/FzZVrkJ/20181112-163627.jpg) (https://ibb.co/w4GskZC)
Sanding down.
(https://i.ibb.co/DfFpV3w/20181116-165601.jpg) (https://ibb.co/CKy21xV)

After stripping it I tried to remove the spotlight locating screws. 2 were rusted and the heads just stripped when i took a screwdriver to them. I had cut the back of the shroud to get them undone.

Then I had to mask the Gti stripe to paint it. What a pain that was.

(https://i.ibb.co/5B45Zz1/20181118-163040.jpg) (https://ibb.co/GcpVm1d)

But happy with the finished result
(https://i.ibb.co/qjbs7S3/20181125-084201.jpg) (https://ibb.co/9gRTcDk)

(https://i.ibb.co/mq7sb68/20181125-084142.jpg) (https://ibb.co/NjzhtZS)









Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 11 September 2019, 20:46
We are now in around Dec 2018.
I was getting concerned about rust creeping back. So I had to reprime the shell. It was just etch primer. Tbh this was largely unnecessary if it was staying at the unit but as the unit was 25 mins away from my house and working up motivation was getting harder. Also my fiancee was expecting our first child together in Jan so plans were hatched to get the car on the drive so that meant..

(https://i.ibb.co/qyZXtzz/20181215-121715.jpg) (https://ibb.co/mDx1Lmm)

(https://i.ibb.co/v4xh3nH/20181223-142738.jpg) (https://ibb.co/GQv9WS0)

(https://i.ibb.co/mJ5LD6Z/20181222-212223.jpg) (https://ibb.co/VVY7j2n)

And back home, for the first time in 2 years.
(https://i.ibb.co/s35cQtY/IMG-20190106-171240-100.jpg) (https://ibb.co/vzsfmDn)

Don't do what I did and use a scotchbrite wheel to strip filler and paint because I later found out I warped the panels. Live and learnt  :undecided:



Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 11 September 2019, 22:03
Turned my attention to the fuel pumps, or more specifically the fuel pump casings. The brackets for these are brittle and the screws that retain the main fuel pump rust away completely making them nigh on impossible to remove. 2 of mine luckily came out by turning the drill to anti-clock and they whizzed out. The third one... Just never.

I tried to dremel a slice in the head so I could use a flat headed screwdriver but the head was just basically mush. Then it just broke off completely.

Leaving the stem of the screw. Very disheartened I was.

(https://i.ibb.co/dB52R4f/20181220-115938.jpg) (https://ibb.co/zs4RzVm)

So I left it and bought another for £23.00. No you didn't read that wrong (usually these casings go for £100+) and it came with the accumulator and main fuel pump (which he said was knackard). The seller also said that his was leaking. Which I hope I've rectified by plastic welding the seam that goes around the diameter of the casing.

(https://i.ibb.co/02SFn3h/20181206-093604.jpg) (https://ibb.co/ZXPYfCW)

Furthermore the bracket that holds the Accumulator snapped when trying to remove it and unscrew the rusty bolt that holds it on. Soo I broke out the arildite and the miliput to fix it.. Ugly as sin I know but to utter some infamous words, it'll do.
(https://i.ibb.co/yfKbnQ0/20190205-090424-1.jpg) (https://ibb.co/h7rtRms)

Also a lick of paint never does any harm and a set of stainless steel (very expensive) fuel lines to finish the job.
(https://i.ibb.co/3vqfqXJ/20190220-172124.jpg) (https://ibb.co/NrP1Ph4)

(https://i.ibb.co/7W7R7MH/20190221-123914.jpg) (https://ibb.co/SnqdqY2)

(https://i.ibb.co/cxvmqFk/20190221-154906.jpg) (https://ibb.co/x3s4ZjX)

(https://i.ibb.co/C1Vtypj/20190221-144226.jpg) (https://ibb.co/NVW3qg0)

I may buy a new bosch fuel pump as I've read they have a habit of seizing up when left without use for extended periods.
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 11 September 2019, 22:12
We are now entering early this year (2019 if someone from the future is reading) I went and found a bargain and sourced a full genuine mk2 leather interior, It required a hefty road trip to Bedford to pick them up but well worth it. All for £230 inc door cards! The drivers side has got a lot of bolster wear but than can be sorted in time. I'm also thinking of dying it black but I need to look more into it as I'm not a huge fan of the grey leather but mk2 leather interiors crop up so infrequently now I had to have it at this price.

(https://i.ibb.co/84PSNBz/20190303-130525-1.jpg) (https://ibb.co/3YSL4sf)


These were up for sale for around 4 hours, at which point the seller said he was swamped with offers but I said I'd give him a deposit. They had been recently refurbished and he only wanted £300. It required another lengthy road trip but was well worth it.

(https://i.ibb.co/nr31Vm7/Screenshot-20190318-112311-Facebook-1.jpg) (https://ibb.co/8MzxRsr)

(https://i.ibb.co/nfGn0fR/Screenshot-20190318-135940-e-Bay.jpg) (https://ibb.co/rMjctMv)
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 17 September 2019, 13:12
Let's talk about bumpers shall we, or rather restoring them. For thousands of years mk2 golf owners have debated, argued and fought over the best way to restoring the fading textures to bumpers and arch trim. Well I saw Rye1991's thread a while back and he used this stuff

https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.co.uk%2Fulk%2Fitm%2F262589135785

Pro-XL textured bumper paint.

Didn't get many before pictures but all I did was clean the bumpers with white spirit, key them with scotchbrite pads, clean again with white spirit and dry with a MF towel. Oh and mask...

(https://i.ibb.co/b2CBcWP/20190314-174614.jpg) (https://ibb.co/wwPW50R)

(https://i.ibb.co/pbGY8C8/20190314-174609.jpg) (https://ibb.co/zQjqYKY)

That's the rear bumper after one coat compared to the untouched front bumper.

(https://i.ibb.co/BTTtHCF/20190320-074514.jpg) (https://ibb.co/CVVzpHD)
Close up showing textured effect.

I thought well I can't have nicely painted bumpers and just leave the faded GTI stripe. What a paint these were to mask up.

(https://i.ibb.co/KDkVC24/20190320-104349.jpg) (https://ibb.co/qCfmbNq)

But I was very happy with the finished result.

(https://i.ibb.co/m9ct8bg/20190320-125842.jpg) (https://ibb.co/tqJcXQF)

(https://i.ibb.co/tLrmPjz/20190320-125855.jpg) (https://ibb.co/fDw1G69)

Not perfect, there a scratches and dints in them but I think they'll look good on the car.
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 17 September 2019, 13:13
Not much to report for the time being, I've been buying parts that I need, bits and bobs really, I need some GENUINE 84-87 gti arches of anyone has a line on some. But in terms of jobs I've not been upto much except open a gigantic can of worms.

(https://i.ibb.co/BnTMbpw/IMG-20190418-154316.jpg) (https://ibb.co/414rzqJ)

You see where this is going.
(https://i.ibb.co/TwmS9nn/IMG-20190417-223530.jpg) (https://ibb.co/qDkfT44)

And after 47,000 years working my way up from 80 to 600 grit then switching to mop attachments on the dremel I've ended up with this.

(https://i.ibb.co/2qszxtw/IMG-20190418-154153.jpg) (https://ibb.co/5TnQm8d)

(https://i.ibb.co/WnsLQLb/IMG-20190424-001111-121.jpg) (https://ibb.co/p2nSgSt)

The third 'runner' is slightly duller than the rest as I tried a different finishing method but I'll go back and sort that and tidy a few other bits and bobs. They need to be thoroughly cleaned inside as undoubtedly aluminium swarf has ended up inside so you obviously don't want any of that getting sucked inside the engine.
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 19 September 2019, 23:55
Let's fast forward a little bit to this year. The car was sent to a recommended bodyshop called firefly speedshop.

They stripped it to metal...
(https://i.ibb.co/d0WJ9mL/IMG-20190612-WA0005.jpg) (https://ibb.co/5WMxDKn)

(https://i.ibb.co/BK3Mgst/IMG-20190612-WA0006.jpg) (https://ibb.co/gF9KDg3)

(https://i.ibb.co/sHXNvGN/IMG-20190612-WA0014.jpg) (https://ibb.co/vYMTxGT)

(https://i.ibb.co/2cmc3qZ/IMG-20190612-WA0015.jpg) (https://ibb.co/GCBCQ7H)

(https://i.ibb.co/hFR5Ck6/IMG-20190612-WA0009.jpg) (https://ibb.co/0yjNQk7)





Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 13 October 2019, 11:36
After a f**k ton of body work

(https://i.ibb.co/34QrW5C/IMG-20190917-WA0002.jpg) (https://ibb.co/sbzmQpV)

And then the moment I've been dreaming about for a very very long time. This is literally in the last 2 weeks (Oct 2019).

(https://i.ibb.co/LSN3yP2/IMG-20190917-WA0018.jpg) (https://ibb.co/jhJSY51)

(https://i.ibb.co/Rgjk9tD/IMG-20190917-WA0019.jpg) (https://ibb.co/Bfn5tvC)

(https://i.ibb.co/Fqkc8Wz/IMG-20190917-WA0015.jpg) (https://ibb.co/5xXCs9L)

(https://i.ibb.co/ctmdm5c/IMG-20190917-WA0016.jpg) (https://ibb.co/vmt8t5x)

(https://i.ibb.co/K0r45TQ/IMG-20190917-WA0017.jpg) (https://ibb.co/6nW9yjp)

(https://i.ibb.co/DwqNgMw/IMG-20191011-123915-653.jpg) (https://ibb.co/XFw9k5F)
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 17 October 2019, 16:09
And she's home, dropped off at 21.30 last night. Helped the guys fit the window regs and sunroof, missing a few bits from the sunroof but I can finally work on it now. Its only now shes back I'm reminded how much their is to do and how little time I've really got! :rotate:

(https://i.ibb.co/SQCgBVf/IMG-20191017-151855.jpg) (https://ibb.co/wJmq4pc)

(https://i.ibb.co/WzHjk0H/IMG-20191017-151847.jpg) (https://ibb.co/bv6DsF6)

And if you needed reminding what she looked like before..

(https://i.ibb.co/hRXfYQf/4e4b981a4daaadebef4b1291e03dd3bc.jpg) (https://ibb.co/XZy8Y08)

Same car, same location, but a bit of difference ..
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Simeon on 21 October 2019, 12:10
Lovely mate, looks gorgeous in the new paint.

Lots to do, but so much easier when you're putting parts back on and the end is in sight! :)
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Madone_si on 31 October 2019, 08:25
very nice..
Title: Re: Mk2 Golf Gti 16V ground up rebuild
Post by: Coakers on 03 November 2019, 22:36
Thanks for the kind words guys, i find myself daydreaming about driving it a lot now!
However since the cars return I've done next to nothing, swapped over the bonnet seal and a few other bits but thats all. Time being the primary factor as per usual.

I have also been building a new shed in the back yard as I have gathered a multitude of different tools and parts since starting this build there is no room for anything anymore plus my missus keeps sh!t machines (rabbits.. Not mk1 allegros) too so there is a lot of stuff knocking around.

(https://i.ibb.co/RNTvpPk/IMG-20191031-115604.jpg) (https://ibb.co/kJ2Hg0s)

I've just spent a couple of hundred quid on the last remaining parts that i need to properly put everything together on this car though. My missus is buying me 2.25'' trackslag exhaust system for my birthday :-) and that will be the last piece of the puzzle.

I'll start updating this regularly every sunday unless something significant happens like the first engine start.

Oh yes I filmed a very basic and poor (why i never shared it at the time!) walk around video of my car when it was in the storage unit in the depths of winter at around 23:30 at night. I do look back on them times of working on the car there with rose tinted glasses I must say. But its good to see a video format from what it looked like then to how it does now.

https://youtu.be/5WmUOtVh8vs