Simeon - "Golf G60 rebuild"

[Simeon]

Collection of parts pre cleaning;



Etch primed;





Not particularly exciting I know, but when these parts are done I'll do the rear beam then start bolting the subframe back together. Bit of welding and be back on the road in no time 

[Simeon]

Rocker cover in first couple of coats of paint;



The BIG news .... I'm now reshelling it into another of my mk2s that I was breaking. The underside of the other shell looks like this





The only bit of rust on the underside;



The new shell is a '91 16v gti .. if anyone needs any parts get in touch

[Simeon]

Some progress over the last few days. Shell is fully stripped now, just need to get rid of some parts as they're piling up! Shot blasted the two front cross-members today and got some paint on them. Going to do the rear beam tomorrow









Rust!

[Simeon]

Today was spent mostly sandblasting the rear beam .. talk about boring and never ending! Anyway, got there in the end and stuck some etch primer on this eve so it's now looking a lot better. Front crossmembers got another coat of paint too .. really looking forward to getting all this stuff bolted up to the new shell! Couple of pics;

[Simeon]

Painted rear beam this evening, pretty pleased with how it came out, though I'm beginning to think that the car is going to look better underneath than on top 

[Simeon]

Right, been a bit busy at work so not got much done, but stripped the engine a little today, mostly to get the flywheel off so I can drop it off tomorrow to get it lightened 

Whipped 'box off;





Put it up on the engine stand;



Started stripping it down;

[Simeon]

Not really much of an update, but have moved the engine to my work as there is a lot more space there and it's a lot cleaner. Planning to strip the last of the ancillaries off then clean the block up for some paint Not going to get much done next week as my daily needs a new clutch

[Simeon]

Right, well the clutch was a bastard of a job, won't be doing one of those again in a hurry. On the upside it works now and the engine hasn't fallen out yet

Little bit of progress on the jig to roll the shell onto its side. Cheated a little bit as I've used two outboard engine stands from work.

One of the stands;



Removed the wood and chopped the front uprights off;



Clamped in position;



One welded up and finished





The other one is done too now and have started on the crossmember to be bolted on the front of the car .. more to follow.

[Simeon]

Bit more done today;

Finished both stands;



Started on the crossmember to bolt to the car. Offered it up and marked the holes;



Drilled the pilot holes;



Followed by 10mm holes;



Tacked the nuts on one side;



And fully welded;



Bolted in place and marked up to cut to correct length;



Chopped down and clamped in place for tacking together;



Tacked;



Fully welded up;



Front one done also;



So, getting there

[Simeon]

Right, got a bit into it and forgot to take any pics along the way, but have taken a couple of where I've got to now. I've drilled the holes in the stands (which sounds easy, but was a actually a bit of a ballache) and welded the tube on. Still need to tidy the welds up as welder was spitting at me a bit today, but hopefully it should all be finished tomorrow afternoon