GolfGTIforum.co.uk
Model specific boards => Golf mk2 => Topic started by: jezza16v on 26 May 2009, 17:27
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Hi all, took the rear bumper off at the weekend and had a bit of a rekky..... :sick: Should have stayed in bed.
What should I do with this lot then? It's a real sod because this is the only rust I can find on the car.
It was all botched in with filler and grey stripe.
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_4971.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_4972.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_4973.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_4974.jpg)
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kin'ell :shocked:
splash some filler in there, rub it down, quick spray of black
sell the f'ker on :grin:
kidding. Ive done some painting here and there. Recently did my back pannel rust scab removal. Wasnt as bad as this though. I'd send that in to a specialist if it was worth it?
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Asses the rest of the car, sills, inner wings, floor ect.. before even starting on that little lot, anything other than welding in a new panel, will be a bodge... and wont last more than a few months...
Tom
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had to do all that on mine, just grind out what u can, treat it, then either weld some bits in or fibreglass and filler mix, depends how lazy your feeling, then sand it down and spray :cool:
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Take it someone has already had a go at putting a rear panel on that then!
The panels arent that expensive from vw (but dont know if they are still available now)
I got quoted £300 to have one painted and fitted to my last mk2
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Take it someone has already had a go at putting a rear panel on that then!
I think you're right about that, probably much earlier in its life, there's none of the usual stickers on the inside and the backside is clear of underseal. The colour coat has only been put on 'where you can see it above the bumper and right at the bottom. Thankfully there's no buckling in the boot floor or the chassis legs and the rest of it is excellent underneath. I think I'll pop the lights back on and run it down to a bodyshop tomorrow and see what they say. I think it might just be worth £300, any more and it'll be the 'frybert fix'. :undecided:
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I would say that someone has in the past fitted another panel, it is fixable but won't be cheap.
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I guess I'm going to need one of these? Anyone used panels from Beevers?
http://bap.dominohosting.biz/members/bap/bapdb01.nsf/Plookup2/91-23-543VOLKSWAGENGOLF-JETTA09-83-02-92!EditDocument&Ret=ALL
I can see how the main lower section comes off, well it almost is off and there's only a few spot welds holding it along the boot floor line, but I can't figure how it comes apart around the lights?......Has anyone done this?
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The genuine repair panel i had included the rear light mounts
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I guess I'm going to need one of these? Anyone used panels from Beevers?
http://bap.dominohosting.biz/members/bap/bapdb01.nsf/Plookup2/91-23-543VOLKSWAGENGOLF-JETTA09-83-02-92!EditDocument&Ret=ALL
I can see how the main lower section comes off, well it almost is off and there's only a few spot welds holding it along the boot floor line, but I can't figure how it comes apart around the lights?......Has anyone done this?
It is all spot welded in from memory.
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Ive just had a look on etka, for the complete panel including the light mounts its £144.50 +vat
For just the lower part its £51.90 +vat
Looking at that i would want to replace the complete panel with light mounts if it were me
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Ive just had a look on etka, for the complete panel including the light mounts its £144.50 +vat
Checked with local VW dealer today......the part has not been available since 2007!
Beevers it is then! I'm bidding on a mig welder off ebay, I'm going to have a crack at it myself I think, how hard can it be?.............. :laugh:
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Just a reminder to anyone witha pre 88 model to check their rear ends( :huh:) as this rot is common on mk2's.
(I think it was a fault with the rear wash system/fitment, but I could be wrong)
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Just a reminder to anyone witha pre 88 model to check their rear ends( :huh:) as this rot is common on mk2's.
(I think it was a fault with the rear wash system/fitment, but I could be wrong)
This one is Jan 91 so mostly hidden by the big bumper, at least with a small bumper I guess you could see the rust starting before it gets too bad?
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Just got the new rear panel delivered today.........hmmmm pattern part....not sure which pattern? :rolleyes:
The rear tow eye doesn't fit though the slot.....? The exhaust cut out is for a single pipe.....? And its generally very poorly fabricated. Going to need a lot of fettling to make it look like a mk2 rear end........and LH front wing delivered instead of RH? Hey- ho WTF. :laugh:
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Just got the new rear panel delivered today.........hmmmm pattern part....not sure which pattern? :rolleyes:
The rear tow eye doesn't fit though the slot.....? The exhaust cut out is for a single pipe.....? And its generally very poorly fabricated. Going to need a lot of fettling to make it look like a mk2 rear end........and LH front wing delivered instead of RH? Hey- ho WTF. :laugh:
Might it not just be easier to find a scrapper in good nick at the back in the same colour, and get the bit you want cut off? I wouldn't fancy messing around trying to fit a badly shaped part, especially if it's poor quality.
I think about half the pattern parts I've got so far have been a poor fit, and I've just ended up going to VW/a scrapyard for the same part anyway. The last one was a number plate light that didn't even look close to being able to fit under the tailgate plinth.
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Just got the new rear panel delivered today.........hmmmm pattern part....not sure which pattern? :rolleyes:
The rear tow eye doesn't fit though the slot.....? The exhaust cut out is for a single pipe.....? And its generally very poorly fabricated. Going to need a lot of fettling to make it look like a mk2 rear end........and LH front wing delivered instead of RH? Hey- ho WTF. :laugh:
Might it not just be easier to find a scrapper in good nick at the back in the same colour, and get the bit you want cut off? I wouldn't fancy messing around trying to fit a badly shaped part, especially if it's poor quality.
I think about half the pattern parts I've got so far have been a poor fit, and I've just ended up going to VW/a scrapyard for the same part anyway. The last one was a number plate light that didn't even look close to being able to fit under the tailgate plinth.
You're probably right, gonna take ages to beat that LH wing to fit the RH side.............. :laugh: :laugh:
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Even the O/E panel had to be modified to accept twin exhaust, and the tow eye hole is easier to enlarge, than to make smaller!
One size fits all...
Tom
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Even the O/E panel had to be modified to accept twin exhaust, and the tow eye hole is easier to enlarge, than to make smaller!
One size fits all...
Tom
I'm not bitter, honest. Just can't wait to get on to it this weekend and get it back on the road........I guess as I'm unlikely to be towing anything I could just cut the towing eye off.......? I had a look at the one thats on there, I think its OEM & its had the exhaust part enlarged to suit. But the tow eye hole is unmodded.
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the later models have a recess in the valance that you chop out for twin exhausts, this is mine before I cut it out:
(http://vwtech.no-ip.info/images/golf/golfrear2.jpg)
after:
(http://vwtech.no-ip.info/images/golf/golftwin2.jpg)
the earlier models didnt have this it was all smooth and just had a cutout for a single pipe, as even the GTI had a single pipe exhaust.
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Yes its pretty much like that.......
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_4992.jpg)
Its a bit of a lash up around the lights though.........
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_4993-1.jpg)
Sort of looks like it might fit anyway.....
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_4994.jpg)
I guess we can't expect VW to supply the parts forever.
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yep thats fine, just need to trim out the extra section. doesnt look pretty round the lights but a bit of seam sealer should sort that. never know it might look almost the same on the factory pannel once scaped out :grin:
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Just done this....... :smiley:
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5007.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5011.jpg)
Didn't take much getting off.....Just have to get the new one to fit now. :rolleyes:
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Good progress. Ill be keeping an eye on this thread :smiley:
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yeah looks like a good project
i would PM JV for a project page for this topic so it don't get lost :wink: :wink:
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Update. Spent all morning getting the new panel to fit. I think its just about there now. Going to need to make up some small pieces to extend the edges of the existing metal where it has rusted away, that should be fun. I've just won a gasless mig on ebay so hope to pick taht up today or tomorrow. Hopefully we'll get it back on the road soon. I'm probably going to have to 'plug' weld the panel as I don't have access to a spot welder. I need another clamp as well.
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5025.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5026.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5027.jpg)
Even looks OK with the seal fitted and hatch down........why paint? a few self tappers, filler, touch up the edges & polish....job done! :laugh:
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5028.jpg)
Looks like a golf again now. :smiley:
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good work :afro:
so would you reccommend that panel? i need to do this job on mine :sick:
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Well I don't think I would recommend it if there was another choice. I'd have paid twice as much for a genuine part but they're not available from VW anymore so the only other option would be to cut one off a scrapper, but whether you would be able to get it off in a fair state is another matter? This panel is a very good fit on the lower section below the bumper line (like you really need it there?) but around the lights its a pig and I reckon that its been fabricated incorrectly as regards the light mountings but I don't have the skill to unpick the spot welds and refabricate it. I'm going to need a lot of weld sealer to make it look OK. I suppose if you're willing to 'have a go' and not afraid to bend and fettle then the job will end up OK, but you must be pretty fearless. :undecided: If your skilled in this field then I reckon you could make the new panel work a treat but it would take considerable time & effort. Also, because the panel that came off was a replacement (genuine VW as it happens) even that had been fettled to fit, so i'm unfettling some earlier fettling, if you see what I mean? I never planned on doing this when I bought the car, it just turned out that way, sort of 'I've started so now I must finish approach'. Fortunately its not my daily.
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Good progress.
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I had a pair of wings from Beevers and an actual beever from a river would have fit better, they are in my back yard waiting to be made into something useful and I got the last 2 wings gen from VW :) They have a pas side one left I think!
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I had a pair of wings from Beevers and an actual beever from a river would have fit better, they are in my back yard waiting to be made into something useful and I got the last 2 wings gen from VW :) They have a pas side one left I think!
how much are the gen wings? i need a pass one :smiley:
Dan
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not fricking cheap. but they fit bang on.
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I had a pair of wings from Beevers and an actual beever from a river would have fit better, they are in my back yard waiting to be made into something useful and I got the last 2 wings gen from VW :) They have a pas side one left I think!
Oh dread, I have a driver's side front wing to fit from Beevers :undecided:
Thw VW ones are about £75 + vat.
Where else can you get them? I've read that the Hadrian ones are the same as Beevers & that would figure as my rear panel had a Hadrian label on it. The wing I got just said 'made in Taiwan'.........not very VW really.
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If you can, fit only genuine wings.. even then you'll find that the O/S wing doesnt fit as well as the N/S! this is because the small closing panel spot welded at the rear of the wing, is a few millimetres out of line, probably due to the original tooling being worn on the production line, but still your best bet, by far
Tom
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Been on this since 8am, managed to weld in some new bits that were missing, cut them out of and old slam panel and the old back panel so at least I have something to weld to now. (genuine VW parts at least :laugh:)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5035.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5036.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5037.jpg)
And now the bu**er is welded on, no close-ups cos my welding is sh*te :embarassed:, (but rock solid), I'm damn good at grinding now though.
Used a 90amp gass-less mig, probably quite good in the right hands. Just need to finish off a couple of welds but ran out of wire.
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5038.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5039.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5040.jpg)
Its going to need some filler and a lot of seam sealer/ underseal/waxoyl to stop it getting rot again. I don't think VW ever considered repair when they designed the back end. Doing this will teach me to check out the back end properly next time I buy a mk2, and if that label isn't there I think I'll just walk away....... :rolleyes:
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Getting the corners right was a pig but didn't need much filler in the end and despite my whinging about the Beevers panel there is actually very little filler on it at all, just where the welds buckled it a bit. Most of the filler on the corners is from a previous repair and its not very thick at all. I used the red primer as an indicator coat so I could see when the filler was exposed.
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5041.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5042.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5044.jpg)
Main grey primer on, just have to wait 24 hrs to rub down and get the top coat on. I'm going to use plain gloss black just to get a good thick cover over the whole panel and then use the LA9V I got mixed at Halfords (expensive) as a finishing coat, then laquer. Will have to blend around the sides to the rear plastic arches. Fortunately no paint damage above the coach line so I can blend into that. I'll be getting some anti chip paint on to all the hidden edges and seams below the bumper line.
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5046.jpg)
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Good work mate!
Nick
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Very brave of you to take something like this on. If this aint your day job, I am impressed!
Good to see you are getting the prep work correct, now go that extra mile on finishing.
Excellent work! :cool:
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Very brave of you to take something like this on. If this aint your day job, I am impressed!
Thanks, my day job is in structural design, but I've always been a dabbler with cars, mind you I'm normally limited on bodywork to what I can do with filler and a spray can, just thought I should give welding a bash this time. I had a professional welder friend look at it and his comment was.............. 'You need lessons mate'...... :laugh:
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They all say that!
And then run away when you ask them to do it for ya :laugh:.
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Just wanted to say well done. Saw this thread a while back - looked in the boot of my new mk 2 straight away - no label! Sh*te! Signs of rust along seam but not too bad. Been emptying rust killer / proofer the whole mularky on it. I think it'll be OK - hope so. Might float now as well. Just got a gasless welder myself and take heart you're not the worst!
Rich
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Got the wiring loom back in, just thought I'd check the lights for fit....Bu**er......Left too low, right too high and on the pi**.........more work required :angry:
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5047.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5048.jpg)
Pinted below the bumper line with a thick coat of Hammerite anti chip, great stuff & seam sealer added inside & out.
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5049.jpg)
Then covered all over in solid black, just to get a good shine so I could see the 'lines' and check for flaws, a few small ones but WTF!
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5051.jpg)
Cut back with 1200 w&d and paste then........top coat and laquer........not too bad at all :smiley:
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5054.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5055.jpg)
Not a bad match at all, thanks Halfords.....just one 300ml can gave a very good cover over eveything above the bumper line and the very bottom of the panel which is visible. Hard to get a good finish on the laquer, had to cut it back with 1200 and paste again but the finish is good and the blend around the side not too bad, not perfect but acceptable all things considered.
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5057.jpg)
I have to say thanks to phil88 for the inspiration gained from his project, I'd have scrapped it if I hadn't seen his perseverence.
Some more boring sealing work to do underneath to make it last another 18 years, will get pics of the fully finished job, hopefully next weekend........Phew
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credit to you mate well done you should be proud....
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very good effort mate!
While your at it...
Check the petrol filler area. Remove the black rubber overspill guard thing. It just pulls out.
Poke a screw driver around the top area. garanteed rotten :lipsrsealed:
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very good effort mate!
While your at it...
Check the petrol filler area. Remove the black rubber overspill guard thing. It just pulls out.
Poke a screw driver around the top area. garanteed rotten :lipsrsealed:
Thanks for the tip on that, I just had a look, had to remove a big circlip first, unbelievable caked on crud in there :shocked: (and bl**dy sharp), cleaned it all out, hard to see but had a good 'poke & feel'. Some of the underseal has split and peeled and there is some surface rust but no holes thankfully. A thorough Kurust and Waxoyl treatment should sort it.........A good tip for everyone on here I think........unless you have a sensitive disposition. :wink:
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Fu**ing Yay!........... :grin: Its finished and back on the road at last after the best part of 2 months in the garage.
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5065.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5066.jpg)
(http://i60.photobucket.com/albums/h30/jezza16v/IMG_5067.jpg)
Still not 100% happy with o/s rear light fit, but no leaks at all now and due to the lack of huge holes in the back is much quieter now........like its a different car.
Thanks to all for your interest and encouraging comments. :grin: :grin: :grin: :grin:
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Mate, that looks superb!
Nick
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well done! i bet noone will notice the lights being a smidge out unless you pointed it out to them
however you have convinced me to repair my panel rather than replace :grin:
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Mate, that looks superb!
Nick
+1
Excellent job :afro:
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You should hire him to do yours Jay!
nick
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Tempted! only I can't have the car off the road for 2 months :laugh:
I'll PM him and see if we can do something together, welding in a new panel makes more sense than bashing the old one straight and filling it, sanding painting etc..
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Awesome job! :cool: You are a shining example to us all!
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Been following this from the beginning, well impressed!
Shows what can be done when you put your mind to it! :) Nice one!
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Tempted! only I can't have the car off the road for 2 months :laugh:
welding in a new panel makes more sense than bashing the old one straight and filling it, sanding painting etc..
Well, the 2 months was just a day at the weekends, + time waiting for panel, getting welder, welding wire etc, etc if I were on it full time I guess I could have done it in a week.......ish. Also a very steep learning curve.
If your existing panel isn't rusty, I would do the 'bash it straight & fill it'. There was a pattern rear panel on ebay a week back, the guy claimed it was the 'last one anywhere', not sure if its gone though.....A professional could probably do a reasonable job with it considering what I've managed.
Why not post some pics of your damage, its surprising what will knock out...?
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Pics here mate:
http://www.golfgtiforum.co.uk/index.php?topic=120103.msg1069427#msg1069427
It probably will be easier knocking it out, I'll book some time off when the payout comes through.
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Great job jezza, just shows what can be achieved when you set you mind to it..
Back in the good old days of "bonus" I could strip, remove the damged panel, refit a new one, seal and paint... all in one day! obviously it helped having a genuine panel and all the kit needed at hand, especailly a spot welder :evil:
I fitted one those pattern rear panels a couple of years ago, and remember having to drill the spot welds that attached the R/H rear lamp bucket as it was about 5mm out of alignment, other than that, I found the panel to be a pretty good fit
Jay, the dent in your rear panel is very easily repairable, as long as the seems are corrosion free, there is no point in breaking into them to replace the panel, using a large block of wood, and a few gentle taps with a sledge hammer would see most of the damage taken care of! Whether you knock the dent out, or replace the panel, you'll still end up filling and painting..
Thom
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Whether you knock the dent out, or replace the panel, you'll still end up filling and painting..
Thom
Good point :afro:
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That's a job for 'dent doctor'. :laugh:
Seriously, if it were mine I'd knock it out and fill it rather than disrupt the original weld structure, or better still if you're getting some cash get a good old panel beater on to it. There are some awkward parts you can't get to from behind, like behind the center badge and a couple of other spots towards each light, but you could cut the obstructions out neatly to get to the outer panel and weld them back afterwards. As said, you'll need quite a bit of filler either way but at least you'll have good ol' Wolfsberg metal behind it rather than Taiwanese ****.