GolfGTIforum.co.uk

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)