Author Topic: Well I'm calling this extreme GTI 16V makeover LOL!  (Read 36524 times)

Offline clipperjay

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Well I'm calling this extreme GTI 16V makeover LOL!
« on: 25 October 2010, 16:21 »
Ok after selling the Rallye I thought I would not buy another golf, but this time I wanted my holy grail the II. Had to be an Atlas Grey 16V Gti 3doors on an H plate or J plate.
So it didn't take too long to find this one (15 years LOL ). I rang up and a young lady was selling hers which was just too much for her now as she was having a baby and bought a Passat.
They lived about 250 miles from me and I took a chance to see it in the dark.
It had been standing for about a year looking very sorry for itself, but got out my tools and battery started to check it over. She cranked ok, but no fire up. Anyways she told me a couple of lads were coming down tomorrow evening to make an offer so I don't like being pressurised into buying a non runner without MOT. She had plenty of history and old MOT's.   
I was worried for a few things the bumper was new, it had a broken gril and TBH if I didn't check it over I would have said YEP its had a front hit at some point. I took a chance as it essentially rust free on the chassis legs (straight) and no accident damage anywhere, so drove back the next night with a trailer.
Got home and it was a Saturday morning I started to check things out.

A few things bothered me the engine was dirty and rusty and the fact it would not turn over. So I started to strip back the block to see what was the issues.
The main issue was blocked fuel lines plus the fuel was just too old and bad.
At some point someone had ripped out the PAS completely and left the rack!
The plus side was the coilovers there were some FK's and not in bad condition.
The Capri Green bonnet painted matt for a chalk bonnet, this jarred me the most!
No headlights that worked
Water in the boot
Water in the passenger footwell.
No brakes.
Worn bolsters large hole on rear bench.
Alternator giving me low voltage.
six odd parking dincs
Small bubble rust started on door
All in all not too rusty for a H plater!
Here is what we started with.
















Offline Sam

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Re: Well I'm calling this extreme GTI 16V makeover LOL!
« Reply #1 on: 25 October 2010, 16:26 »
Good work mert. No rest for the wicked n all that!


The entire world is a Money Pit, you just have to pick yours.

Offline clipperjay

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Re: Well I'm calling this extreme GTI 16V makeover LOL!
« Reply #2 on: 25 October 2010, 16:28 »
The manifold, rocker came off and I checked the valves which were nice and shiny.
At some point the head had been overhauled as the guides and valves were way too clean for a 140K millage car. All was good and mechanically very sound!

The check list was long, but here is the list of parts bought so far!
Gaskets for rocker and manifold
Stainless steel bolts and washer
Bonnet
Visors
Carpet boot and sides.
Manifold Down pipes
Centre blank
Steering wheel
Scuttle ECU cover
Side Repeaters OEM
Crystal indicators
Kick plate + Rubber pedals
Steel wheels + Tyres
Braided Fuel lines
Injector seals + collets
Brake servo & Master Cylinder
Headlamps
Interior door handles
Expansion Tank
Water pump for washers!
Fogs lights with brackets
Heater washers system
Interior seats, golf ball, bushes. Door pin surrounds wiper arms
Power steering Pump & new pipes brackets alternator brackets.
Scuttle Panel & ECU cover
Bonnet Lifter handle
Central locking Solenoid Motor
Misc VHT paint Thinners, brake cleaner, dremel, Tape ETC.
Power steering Rack boots
Cam belt, Tensioner, alternator belt
Sunroof arms one side missing
PAS belt Alternator belt
Oil filter
Oil Synta silver
Fuel filter
Waxoil
Starter motor
280mm G60 Brake discs and pads
G60 calipers and splash shield
Corrado Brake hoses
Rear 226mm Mintex Discs & pads
New rear brake hose and splash shields
New Bearings full kit 
x2 Wishbones
x2 Tie rod ends
x2 Ball joints
Tyres
Leather brake cover
Alloy refurb
Parcel shelf straps
Alarm FOB
Heat shield Firewall
OFS Wheel Arch trim
Front mount
Heat shield firewalled.
Wire loom upgraded from Corrado
Interior Blower motor
Seat runner covers
Rear light gaskets
Wheel arch driver side
Twin Grill with spots
GTI 16V badge
New petrol tank straps with mounting brackets
New Exhaust rubbers and rubber hanging brackets
Fuel accumulator
Fuel filter pipes banjo, bolts, clips.
Complete new never fitted GTI rainbow interior included door cards.  :tongue:

I thought I bit off more than I could handle, but as long as the engine was good the rest was easy enough, but parts these days and scene tax on parts was going to kill me.
I was lucky enough to find a local kid breaking a Corrado on a J plate and updated mine as I went along.
A friend helped me out with the bonnet (Thanks Norm) he drove to Manchester from Liverpool and dropped it off to me in the south east!


Before:





After:









Offline clipperjay

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Re: Well I'm calling this extreme GTI 16V makeover LOL!
« Reply #3 on: 25 October 2010, 16:37 »
After fu*king around the new servo the corrado one, it just didn't fit! The angle was off by 20 degress to the left LOL. so bought another one which fitted! Teh master cylinder came off a G60 so had to cap off two pipe holes to make it work. :wink:
 









Offline clipperjay

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Re: Well I'm calling this extreme GTI 16V makeover LOL!
« Reply #4 on: 25 October 2010, 16:50 »
Took off the cross member and slam pannel for refurb cleaned up nice some good old fashion DIY restoration! Some parts had arrived!















Offline SoundillusioN

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Re: Well I'm calling this extreme GTI 16V makeover LOL!
« Reply #5 on: 25 October 2010, 16:54 »
nice one... got yourself a real project there and you seem to be working hard on it..... have you got a deadline set for when you want it done or are you just going to keep at a crazy pace till you're happy its finished..  its always good to see cars being saved... some people would just happily bin cars that need this much love!

Offline clipperjay

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Re: Well I'm calling this extreme GTI 16V makeover LOL!
« Reply #6 on: 25 October 2010, 16:55 »
So new grill arrived and put it all together!





Offline clipperjay

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Re: Well I'm calling this extreme GTI 16V makeover LOL!
« Reply #7 on: 25 October 2010, 17:02 »
nice one... got yourself a real project there and you seem to be working hard on it..... have you got a deadline set for when you want it done or are you just going to keep at a crazy pace till you're happy its finished..  its always good to see cars being saved... some people would just happily bin cars that need this much love!

I'm over my deadline due to cash requirements fella  :rolleyes:
Yeah I keep going until I'm happy I've only made two concessions
A new FAN, shroud and radiator. Cost about £300 which I can't justify at the moment!
A new paint job £2K
 
How much do you think I paid for this and how much do you think I spent on it  :laugh:

Offline clipperjay

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Re: Well I'm calling this extreme GTI 16V makeover LOL!
« Reply #8 on: 25 October 2010, 17:13 »
Next section PAS system like i've said there was none  :grin:
So lucky enough to get it off a corrado and pipes from another golf!
The only thing you must have stubby spanners to tighten up the rack unions and NEVER forget there is an O ring to stop the little f**k*rs from leaking! :laugh:
Bought the resivor and a little bracket has rusted to pieces and I decided to make one instead out of alu, as its obsolite from VAG.
Refurbed the Water pump as it was all out new gasket and thermostat!
The horn didn't work so got a second hand one and refurbed it as with the starter motor which failed in the end so just bought a new one in the end.
















Offline clipperjay

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Re: Well I'm calling this extreme GTI 16V makeover LOL!
« Reply #9 on: 25 October 2010, 18:02 »
Next job was no central locking was a simple one if you blew down the vac pipes all door locks opened except the drivers. But the pump was not working. Tested for voltages none present crossed a live wire to the pump and bingo it worked! So the switching point on the drivers solinoid was broken. Plus bellows had perished.
Replace it and all doors, petrol cap, boot locks and unlocks now!



Mint visors now in place as teh old ones where white LOL  :grin:

Rocker cover in VHT



New Injector O rings and seals


Cleaned up some rusted brackets and pipes


Started to clean up the block anti rust paint and some VHT to seal it over!


Taking shape before the manifold went back in!


New front mount and refurbed mount bracket Oil housing cleaned up and brand new oil filter!