US VW Cabriolet 85

[jv]

Stunning work as always sir! Those door cards came out so well 

[Madone_si]

Stunning work as always sir! Those door cards came out so well 

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

[Madone_si]

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!


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.

[Madone_si]

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...


Cut bad foam out


I ordered high density foam, cut foam and glues three layers together. I use 3M 74 Foam glue.
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Start shaping the foam.. I use Carving knife - works perfect to cut foam.


Then moved onto using my air tool sander 1.5" diameter end.


Then using cheese greater for final shaping (this one is not taken from my kitchen... not sure cheese and foam go well?!)


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:




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


Then installed the back new seat cover.


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


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

[Madone_si]

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.



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.



parts cut out of new bolster to make them perfect match to originals.


pulled the base foam together to make sure all fitted properly - very happy with results


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.



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.


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;




Paint!


and painted...


and the end result on the car
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and the front grill off! thinking should I upgrade my lights or not?


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!!



The GTI one will now become Art in my office!


and the car is all covered up again..

[Madone_si]

Did a few things....

Install of new euro lip


The right securing parts - what some people use on left...



Jack vw up a little... makes life easier when using tools to get securing parts in to hold lip in place


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.


and all done.


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.


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!!)


First primer coats x2


Then onto the correct RED color paint.




While waiting for the paint to finish I cleaned up the grill itself..



I actually left the grill parts painted overnight and then put back together in the morning


All back together again


and installed again on the car, overall I am really happy with the it.

[Madone_si]

Additional changes on outside

Adding the CL rear arch covers;

All new parts and correct parts to hold arch in place;



installed!




now do I paint the side mirrors black or leave them white?



and what car looked like when I first got it.

[Madone_si]

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
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.


Rear arch cover clip arrived, now drive the cab without if flapping around!!


Rear badges needed taking off and applying new stickers to make them new again!


New stickers for badges;


Broken in door handle clip


New parts arrived, ordered from Europe... these are hard items to find for sure


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)


I am on the hunt for BBS RS Wheels too 15" 4x100.

Thanks Simon

[Madone_si]

Managed to complete the rear badge refurb



Take you time as each letter and VW symbol are individual - use small long length pliers to pull off and place on badge lettering





Painted the Cabriolet badge white



And installed





another job done.

Still waiting on my final leather to turn up so can cut and do my Recaro seats.

[Madone_si]

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


and now finished


and the Real Recaro covers and new handles


New supports (originals ones where ok, will be selling the originals ones)


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.




and finally my new shoes turned up - brand new custom lips, restored centers, new caps, bolts. Very happy with the staggered setup


and I might of just sourced and bought a RS3 engine and gearbox!