GolfGTIforum.co.uk
Model specific boards => Golf mk2 => Golf mk2 gallery => Topic started by: jv on 11 December 2009, 12:16
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:)
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Thanks JV.
I bought my car about a year ago and it was always intended to a project. However the day before I was due to collect her the cylinder head gasket blew in my daily driver (Rover 200 who would have thought), so I was forced to press the Golf into service. Heres a picture of her as she was before I collected her.
(http://4.bp.blogspot.com/_BQpkIbqSeZE/SXsbPTf5TII/AAAAAAAAAAM/mO1AVis0ZlU/s200/1.JPG)
Specification:
Golf GTI 8v
Seat Wheels (sprayed black no primer)
Lowered (chopped springs :shocked:)
"Racing" seats (Ripspeed type recliners)
Jetta front end
Few ripspeed bits and pieces (ariel, gear knob, handbrake cover)
Single wiper (modified linkage)
Not a big fan of cars modified in this way but a really nice clean car to start a project.
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I've worked on old cars for a number of years and know from bitter experience that a easy job can turn into a nightmare with siezed on/ broken / rounded off bolts etc. so I refrained from doing anything major to the car while I was using it. Even though getting my Rover back on the road should have been my priority I still felt compelled to tinker.
Despite how much I hated the seats they stayed with me until the summer, one of the first jobs was to replace the wing mirrors with proper Golf ones. I changed the door locks, switched back to dual wipers, changed the gear knob and handbrake back to standard. Replaced the light up washer jets and silver ariel with plain back ones and eventually switched the Jetta front end back to standard. This is the car the day I took her off the road.
(http://4.bp.blogspot.com/_BQpkIbqSeZE/SshucvTraKI/AAAAAAAAAA0/l8coG3sNxEw/s320/Picture+(Small).jpg)
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By this time the decision was made to at least replace the g60 arches with standard ones although I had been toying (and have now decided) with going back to small bumpers. I already knew the tailgate was a bit nasty (see below) and upon removing the arches discovered that the nearside wheel arch wasn't much better. I also had a dent in the drivers side wing which I'd partially knocked out but was still stopping the grill sitting properly.
(http://3.bp.blogspot.com/_BQpkIbqSeZE/StDVMtP2PTI/AAAAAAAAABc/7PchHFfz15c/s200/P1010070)
Decisons are still to be made but my current list of jobs seems to be as follows:
Sort body work (both wings, deep scratch in the bonnet and tailgate).
1) Replace suspension
2) Replace discs and pads all round (on the limit)
3) More than likely replace hard brake linings (might do flexis as well)
4) Go back small bumpers
5) All the other jobs I cannot even think of yet.
6) Service and ready to re-MOT
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That brings me up to now. First job I decided was the nearside wing which looked like this:
(http://1.bp.blogspot.com/_BQpkIbqSeZE/SuIAn33RJdI/AAAAAAAAABs/zzz2n6axHPk/s200/P1010027+()
I had three maybe four choices with the wing. A)A new original one if available B)A second hand one, C) A pattern wing or D) repair the old one. The first option was too expensive and perhaps not possible. I didn't really have time to source a second hand wing and I've heard the fit with pattern wings isn't very good. This left me with trying a repair, which after all would be cheap and I could still consider my options again if it didn't work.
So after scrubbing the rust away with an angle grinder fitted with a twisted wire brush I was left with this:
(http://1.bp.blogspot.com/_BQpkIbqSeZE/SvWJTF99V9I/AAAAAAAAAB8/MjouSJ9EpLk/s200/P1010030+(Small).JPG)
I then cut the rust out and welded new metal in. I was a bit mean with cutting so ended up chasing the weld a bit. I welded using a series of tack welds to avoid distortion, changing sides and eventually joining them together. After I welded the new metal in I used a p40 flap disk in the angle grinder to flat the welds flush leaving me with this:
(http://3.bp.blogspot.com/_BQpkIbqSeZE/SwF3yZJqPBI/AAAAAAAAACM/hylqo4l1ipI/s200/P1010033+()
Next was a skim of body filler. My last experience of this was in my teens sticking it in great piles over rusted holes then half-arsed sanding it down. This time I used just a skim, light sanding with P40 grade sandpaper and a block, then a guide coat, sanding again until flat and then using P80 to smooth. This is my first effort doing it the right way and I'm pretty pleased with the result.
(http://1.bp.blogspot.com/_BQpkIbqSeZE/SyFTIZGskFI/AAAAAAAAACc/fcCpdcdMDGs/s200/P1010039)
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Just a quick update because I've finished repairing the dent on the driver side wing. This was kind of my second attempt because I drifted most of it out when I fitted the golf slam panel and grill. The pictures more or less speak for themselves and I got a chance to try my ebay panel beating set. Once I get some primer on I should have a better idea whether i've done a dent enough job.
(http://1.bp.blogspot.com/_BQpkIbqSeZE/SyUwBnZrSOI/AAAAAAAAACk/AB1Tluze4bg/s200/P1010046+(Medium).JPG)
(http://1.bp.blogspot.com/_BQpkIbqSeZE/SyUwBzPyi4I/AAAAAAAAACs/hJnWqj-osKc/s200/P1010051+(Medium).JPG)
(http://2.bp.blogspot.com/_BQpkIbqSeZE/SyUwCBgy-7I/AAAAAAAAAC0/qaQbFHUgi_U/s200/P1010053+(Medium).JPG)
(http://2.bp.blogspot.com/_BQpkIbqSeZE/SyUwCRxFTXI/AAAAAAAAAC8/3rC67XVEnno/s200/P1010055+(Medium).JPG)
(http://1.bp.blogspot.com/_BQpkIbqSeZE/Syex-Qi6eHI/AAAAAAAAADE/20XbdE2rvlg/s200/P1010030+(Medium).JPG)
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An update to show the repairs to the tailgate. This isn't anything different in terms of the type work to what I've already carriied out so I'll let the pictures tell the story.
(http://4.bp.blogspot.com/_BQpkIbqSeZE/S2sgXof4VkI/AAAAAAAAADs/NZL0IRChVQU/s320/P1010090.JPG)
(http://2.bp.blogspot.com/_BQpkIbqSeZE/S2sgX5Idt6I/AAAAAAAAAD0/xPznxfmnc7o/s320/P1010091.JPG)
(http://2.bp.blogspot.com/_BQpkIbqSeZE/S2sgYaePjPI/AAAAAAAAAD8/_DlFfuFxDSE/s320/P1010092.JPG)
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I cant believe its been this long since i updated. Nothing much happened for a while and since the new year the works started and i haven't taken the time to take photos. The tailgate is on with a new decal and the damaged wiring has been repaired. New springs fitted rather than the chopped ones, small rear bumper and rear arches. New discs and pads on the front. I'll get a photo up as soon as I can.
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(http://i1131.photobucket.com/albums/m550/acooling/070.jpg)
This shows the front with the wings back on still sporting the high build primer. I've fitted a front panel inline with my small bumper plans.
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(http://i1131.photobucket.com/albums/m550/acooling/072.jpg)
This shows the rear with repaired tailgate and small bumper. You can just see the new arch trim, sadly theyre a pattern part so the fit could be better.
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Here is a picture of the chopped spring next to its replacement. Not entirely sure how it passed its MOT if it was like this there was no preload whatsoever I actually took the strut apart without spring compressors.
(http://img593.imageshack.us/img593/2572/032vz.jpg)
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I've painted the front of the car and to be honest its not good. Im not even going to take a picture until ive done something about it. Most of it will be hidden by the arches and its better than dents and rust but I still expected it to turn out better.
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Im doing really badly with the photographs. MOT was yesterday and it was a fail, despite having rebuilt the front calipers, replace the flexies and hard lines it seems the back needed similar attention. :grin:
On top of this I needed a new CV boot, rear wheel bearing and exhaust centre section. I dont fancy tackling it my self its a bit hard getting under the car with it being on grass. Further update to follow once I get a price for the work.
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It has an MOT!!!! £330 lighter and the owrks done and if this wasn't a Mk2 Golf then this would be then end of the project thread however as all owners know this is only the start of the work. The battery light is on constantly and that has to be a priority fix I also need a couple of arches for the front as the pattern ones I bought are dire so I never bothered fitting them. Then a few other bits and pieces to fix inside. I've added a nice mobile phone shot of it pre-mot and also what aI believe is the culpret for the alternator problem.
(http://i1131.photobucket.com/albums/m550/acooling/SP_A0021.jpg)
(http://i1131.photobucket.com/albums/m550/acooling/SP_A0026.jpg)
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Well got a new brush/ regulator unit and it still didn't fix the problem although the alternator is now kicking out over 14v instead of the 13.7 or so it was doing before. The battery has started to die overnight and I've ckecked to parasitic drain which isn't huge so it looks like the battery has bought the farm.
Some of the other jobs to do:
Wing mirror adjusters need nuts.
Oil and filter change
Small coolant leak somewhere probably to be expected given I froze the engine last year.
Getting a bit sick of the backbox, stainless steel universal type way to loud. The centre pipe was welded at the last MOT so I suspect that will probably give way shortly.
Speedo is bouncing around - new cable time.
Sort out the shocking job i've made of the paintwork.
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I've changed the speedo cable but it still vibrates a bit. Oil and filter are changed and i've identified the coolant leak as coming from the heater matrix. I've started to strip the air box apart and will upload photos as soon as I find the cable for my camera.
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Found a cable for my camera. So I can upload some obligatory heater matrix pics replacement pictres. It really is a fatherless son of a job I'm afraid so say. Nothing technical just a right arse on and I still need to replace the ducting but at least its in.
One of the dash pulled apart.
(http://i1131.photobucket.com/albums/m550/acooling/Picture005.jpg)
And one of the offending heater matrix itself. I think this died when I froze the engine last year.
(http://i1131.photobucket.com/albums/m550/acooling/Picture006.jpg)
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Thought I'd take the opportunity to post a picture of the front calipers I rebuilt before the MOT last june. New seals from Bigg Red and a new piston from Brakesint after I somehow managed to snap the old one. Despite these, new disks pads hoses and hard lines I still spent a fortune getting it MOT'd.
(http://i1131.photobucket.com/albums/m550/acooling/Picture002.jpg)
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Hot air at last no ducting so it blows everywhere but I really think a working heater is such the in thing this time of year. :laugh:
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Couple more picture updated Ive started to get the dash back together and rewired the stereo so it has an ignition live now. Also started to get the centre console ready for the VDO gauges. Still far more work to do than I have time. I've noticed a rumbling noise when cornering hard so either a wheel bearing or a CV joint is on its way out. It really is constant maintainence with these cars.
(http://i1131.photobucket.com/albums/m550/acooling/IMG_0047.jpg)
(http://i1131.photobucket.com/albums/m550/acooling/IMG_0048.jpg)
All the other jobs are still need doing but at least Ive fixed the heater matrix in time for the warm weather. :sad:
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And through laziness I havent updated my project thread for over a year. The car stayed on the road until June when the MOT ran out. By this stage I'd started to be tempted by a larger engine conversion and decided to upgrade my brakes to 16v spec.
So I bought some SEAT Ibiza hubs, stripped them and binned the ABS gubbins. Rust was removed using electrolysis.
(http://i1131.photobucket.com/albums/m550/acooling/photo0081.jpg) (http://s1131.photobucket.com/user/acooling/media/photo0081.jpg.html)
The hubs were then reassembled using new bearings.
(http://i1131.photobucket.com/albums/m550/acooling/photo0094.jpg) (http://s1131.photobucket.com/user/acooling/media/photo0094.jpg.html)
I used electrolysis on a pair of caliper as well replaced the seals and also the pistons and placed back on the car. Unfortunately I became drawn to the state of the suspension.
(http://i1131.photobucket.com/albums/m550/acooling/photo0110.jpg) (http://s1131.photobucket.com/user/acooling/media/photo0110.jpg.html)
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So set about rebuilding the suspension. The chopped springs had been replaced with a second hand set for the last MOT and ideally I'd like to replace the whole lot with something decent but for now it would just have to be new dampers, bumpstops and topmounts.
(http://i1131.photobucket.com/albums/m550/acooling/photo0113.jpg) (http://s1131.photobucket.com/user/acooling/media/photo0113.jpg.html)
I ordered for Eurocarparts which lists suspension components for the year of your car. Due to this and a bad description I ended up ordering inserts. I'd never do this again I'm not sure if they were any cheaper but the work involved in getting the old rusy shock bodies to this stage isnt worth any saving.
(http://i1131.photobucket.com/albums/m550/acooling/photo0118.jpg) (http://s1131.photobucket.com/user/acooling/media/photo0118.jpg.html)
In addition I also noticed that the control arm bushes were in a terrible state. Oh well MOT might have to wait a bit longer.
(http://i1131.photobucket.com/albums/m550/acooling/photo0117.jpg) (http://s1131.photobucket.com/user/acooling/media/photo0117.jpg.html)
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Unfortunately in removing the wishbones I snapped the n/s/f bolt in the captive nut on the subframe. By now my plans had changed from a 2 litre bottom end to an ABF so I decided to remove the rear engine subframe so I had better access to get the bolt out.
(http://i1131.photobucket.com/albums/m550/acooling/photo0128.jpg) (http://s1131.photobucket.com/user/acooling/media/photo0128.jpg.html)
I had the option of attempting to drill the bolt out (it was just below flush) or cutting the subframe. Whilst it seems extreme I went with the second option. I was too concerned the required 10.5mm drill would foul the outer bolt hole and it was going to be difficult to pilot drill as smaller drill bits simply wouldnt reach. I cut an access hole in the side of the subframe and proceeded to saw the old captive nut off, not the easiest of tasks. With a bit of grinding with the dremel I was able to weld a new nut in.
(http://i1131.photobucket.com/albums/m550/acooling/photo0133.jpg) (http://s1131.photobucket.com/user/acooling/media/photo0133.jpg.html)
The flaps around the access hole were closed and then the whole lot was welded up painted and refitted.
(http://i1131.photobucket.com/albums/m550/acooling/photo0137.jpg) (http://s1131.photobucket.com/user/acooling/media/photo0137.jpg.html)
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Some of the pictures are slightly out of sequence to make more sense. During the wet / colder weather I started the ABF loom. My car is CE1 and my approach was to make the ABF loom match what was already there. Dash sensor wiring will therefore be the original and I used some plugs from a donor loom to match it under the rain tray.
(http://i1131.photobucket.com/albums/m550/acooling/photo0131.jpg) (http://s1131.photobucket.com/user/acooling/media/photo0131.jpg.html)
The ABF ecu is considerably larger than the digifant 2 one so getting it to secure in the rain tray in an OEM manner is a challenge for another day. Apparently a SEAT toledo bracket is an option however i've wired the TCI into my loom so I really need a solution thats as like the original as possible.
(http://i1131.photobucket.com/albums/m550/acooling/photo0130.jpg) (http://s1131.photobucket.com/user/acooling/media/photo0130.jpg.html)
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Fairly productive week and bank holiday weekend. My engine arrived and I took the opportunity to weld up a rust hole in the bulkhead before it went in. This wasn't the easiest of tasks since my cheap mig welder kept blowing holes.
First step before fitting the engine was to fit a new clutch and the flywheel from the original engine as I'm using the 020 gearbox.
(http://i1131.photobucket.com/albums/m550/acooling/image.jpg) (http://s1131.photobucket.com/user/acooling/media/image.jpg.html)
The front of the car was held on with the bare minimum of bolts after I pulled the old engine out so once I'd fitted the gearbox the front crossmember was dropped and the engine and gearbox pushed into the bay. You might be able to see I have fitted a 16v style engine mount, if your really eagle eyed you'll spot its the wrong way round
(http://i1131.photobucket.com/albums/m550/acooling/image-1.jpg) (http://s1131.photobucket.com/user/acooling/media/image-1.jpg.html)
Then using a combination of blocks of wood, jacks and levers it was lifted into position.
(http://i1131.photobucket.com/albums/m550/acooling/image-2.jpg) (http://s1131.photobucket.com/user/acooling/media/image-2.jpg.html)
Its by no means finished but the engine bay now looks like this but i,ve moved the engine mount the right way round and bolted it in and started to fit a few of the ancillaries.
(http://i1131.photobucket.com/albums/m550/acooling/image-3.jpg) (http://s1131.photobucket.com/user/acooling/media/image-3.jpg.html)
The ISV is the original from the PB engine. It doesnt fit, the body of its too fat so it doesnt sit right against the manifold and you cant make the connection.
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Then once again I got really lazy and stopped taking photos. I still have the car, and its still not on the road.
I moved house in September and work stalled until I got the car into a council garage in November and then slowly started work again. By this time the ABF was in and running in a manner of speaking.
I'll update the few photos I have as soon as I can and I'm aiming for an MOT in September.