Mk1 Golf Driver project....

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Postby Globbits » Tue Mar 22, 2011 11:50 pm

Wires are easy. It's making sure they go to the right place that isn't :)
Krustybarn quotes:
It'll be fine
F*&k off it will! (in front of 8-yr old "assistant")
No Carl. Seriously No!
We're gonna need a ton of filler
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Postby regcheeseman » Tue Apr 19, 2011 11:27 pm

I've been tidying bits and messing with wiring some more.
Fitted a extra small battery behind the centre console, it charge's off the main battery doesn't discharge when the main battery does.
I also had to add a circuit for the tail gate popper with a hidden switch as an emergency entry.
The auxiliary battery runs the alarm and the popper - should the main battery go flat because I left the light on then you can still get into the boot to access the battery.

I also found the lower sections of the dash wouldn't fit because of the crossovers so I ripped the guts out of them and re-made them a little smaller.
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Also I had to sort some piping out for the heater matrix, the control valve is moved into the car and the pipes have been dropped down the bulkhead and out of sight. (the stupid joys of smoothing an engine bay)
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It's taken three attempts to get this far and they aren't finished yet. (edit - I later found out they still weren't right but they'll do)

Finally found the little plastic clip from the heater and could fit the lower dash section and centre console.
You can see the new heater pipework fitted, I wrapped it I heatshrink to hide and disguise it a bit

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The red stripe of tape is there because I've wired the two gauges up with a twin core shielded cable, one core red and one blue.

I've tested everything and it seems like my heater fan setup has only one speed, but it transpires that it's a duff switch and all three speeds are available. It's not quite as powerful as the standard fan but it's quieter.

So moving on, I dragged the seats out of the loft, they were clean when they went up and because I'm a tw@t I never covered them up.
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They soon looked like this.
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Now where do I get hog ring pliers from and should I be looking at replacement leather covers? How much and where from?
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Postby Brooky » Wed Apr 20, 2011 8:27 pm

Hog ring pliers from Frost Restoration Tools (www.frost.co.uk). No idea on the seat covers front!

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Postby Muppet » Thu Apr 21, 2011 5:55 am

Seat Covers

Talk to FlameHairedWarrior or Dylan88 as they had new ones maid and blokey
in holsworthy way done a Pukka Job

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Postby regcheeseman » Fri Apr 22, 2011 10:59 pm

Bored of all the fun progress I decided to do some.....
return to the flatting! Deep Joy.

I still had bonnet, passenger door and tailgate to do, very light mist from a rattle can and then start with 1500 grade wetndry.
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I bought three Fiat fitment wheels with brand new tyres on ebay - the wheels are unfitted too, the seller had one stolen from his drive which is why there are three.
Anyway I'll take the tyres off and probably weigh them in.

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And today's fun

With the golf pushed out of the garage I washed it, then set about it with the G3 and various sponges on the polisher, I did the bonnet, door and tailgate. then washed it again. That means it's been washed more times in one day than the Military spec Polo has in in 9 months of ownership/daily use

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Talk to FlameHairedWarrior or Dylan88 as they had new ones maid and blokey
in holsworthy way done a Pukka Job


Another mate mentioned a bloke in Holsworthy but thought he had stopped or moved away? I've PM'ed the above.
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Postby regcheeseman » Wed Apr 27, 2011 11:12 pm

Trimmed my tailgate with some vinyl from ebay
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Then got to work rebuild and clocking the hot and cold side of the turbo.
I toyed with all sorts of methods then used a bit of acetate with concentric circle to mark up the new positions for the locating dowels for vane assembly and housing.
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I made up a tool from a washer to tighten the nozzle
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Assembled the vane assembly
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And fitted the outer housing
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The cold side is now in the wrong place but it's only located by a circlip, which was soon shifted
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Postby regcheeseman » Sat Apr 30, 2011 10:57 pm

Meanwhile....

took my wheels to the welder which I hate doing, as I used to work as a welder. the trainee welded them badly and welded up the holes for the valves - :evil:

four hours of grinding to get the wheels ready for paint....
A decent slop of rustbuster....
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Consider I have black G60 style centres which I refuse to paint, how should I finish the wheels?
I'm thinking white dishes or a lime green pinstripe.

Any other ideas.....

even had a bit left for my inlet manifold.
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painted my window channels again, so I could fit the door glass only to find that I have 3.5 seals when I should have 4. I know I've got more as I had a full set....

tried to clean the mirror mount to paint and broke one :x

painted wiper arms, fuel cap (it was chrome)

Fitted my delocked door handle only to discover the arm inside is too long and missing the lever on the lock so I had to get some front door mechs and swap the bits about, but they work and look fine....

It's come on leaps and bounds the last week.
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Postby SiC » Sun May 01, 2011 3:00 pm

nice work dude 8)
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Postby regcheeseman » Mon May 02, 2011 10:39 pm

Cheers Si,

I've been down to Andy's and bought some seats - they'll need a clean.
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half leather mk1 scirocco tombstones :D
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Postby regcheeseman » Sat May 07, 2011 11:00 pm

Had a massive session today :D

Missus took the kids off all day and I got busy....

Having stripped an old GTI rear bench (monkey - want some red striped cloth?) I had to chop it about to fit the foam from the stripped 'rocco rear bench.
It was pretty rusty, it needed repair plates welding in and some new 'wings' welding on. Took about 3 hours to get the rust brushed of and the welding done.

Then I turned my attention to the side stripes with the help of a soft wire brush in a bench grinder, at first it was hard work so I attacked it with a gas torch - the paint gave up then! Still took a while to do all 8.

Then attention turned to cleaning some centre caps for paint
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Which option should I chose

Having done the one half of the rear seat frame work I had to strip and clean the other half for paint.
Wire brushed my injectors
Then I got painting...
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Having done my painting attention turned to the doors, ever suffered from cracked door cappings? My drivers side was ok but the othr was split in three places, so I cut some strips of grainy leather effect vinyl and glued it on, well chuffed with the final result.
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Check out the chrome Wolfsburg fittings - my stray into the world of the scene.

That done, I got some black trim dye and set about the seats - looks fine but I ran out.
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Postby regcheeseman » Sat May 14, 2011 8:57 pm

today I've been putting some satin black celly onto my side stripes and come near the end of the gun and I thought I'd add loads of thinner to the cup to get a level finish and ended up with a mix of about 80% thinners.

Inspection of the trims showed they were spot on so it was not required but then I remembered that one of my wheels had a rough dry spot, and also the finish was slightly mottled because my nozzle was too small - so I started on the wheel.

Then I remembered that the wheels were coated in epoxy mastic primer and as a 2 part finish the celly/thinners mix might not level/gloss it up as expected. However as Magnus says "I've started so i'll finish", and I continued to coat the wheel face.
I then went and cleaned the gun and tidied up a bit.

Eventually I went back to the wheel and my suspicions were correct, it hadn't glossed up at all, but instead was now flatter than a witches tit.
A nice uniform matt that matches the wheel centres perfect and looks so much better with the added bonus of never needing the brake dust cleaned off.

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left hand wheel is as it was, right hand is with reaction.
Now I have to ruin the other three equally.
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Postby regcheeseman » Tue May 17, 2011 8:22 pm

More progress has been made, waistline trim straightened, de-dented, primered, flatted and then given a coat of satin
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Then I ruined the other three rims and liking it so much did the inlet manifold too.

The golf was washed, machine polished with a soft sponge and t-cut, then polished by hand with t-cut then buffed then washed again. No pictures as she's on the low key. ;)

Last night I finally rebuilt my 90A alt, the rings were dressed, new bearings fitted and a new bearing cup and brush pack courtesy of Caddyboi were fitted. Fitted together with a coat of satin and a bit of matt black.
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Lovely - and another box of 'tings to do' is emptied :D
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Postby regcheeseman » Thu May 26, 2011 9:59 pm

remember those rare expensive mk1 'rocco tombstones?

wrecked 'em ;)
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I've done similar to the rest of the seats...

Also been doing some more painting tonight, all the bits cleaned up on the weekend, spare wheel, injector lines, swapped the rear flexis for the braided that have been on the shelf for 2 years, connected up handbrake and started to rough out the exhaust.

the tyres turned up and they sit pretty nice....
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When I took the front wheels off, the calipers I stripped and painted ages ago were starting to show spots of rust so I bought some paint of ebay.
The seller had cooker paint cheapish or caliper paint for a few quid more but it looked like the same stuff but with added tax for automotive use.
When the cooker paint turned up it was labelled as caliper paint suitable for automotive use!
I put three coats on with a brush.
I also stripped and old manky starter motor and repainted it
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Postby regcheeseman » Fri May 27, 2011 9:56 pm

Had to push the Golf out into the sun, the calipers are on, maybe a bit 'barry' but I like them
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My boy was straight in it, cool kid.
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And the rear end just gets better with fat rubber to beef it up
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Engine going in next week :D
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Postby regcheeseman » Sun Jun 12, 2011 9:36 pm

Well it's taken about a week to make some engine/ gearbox mounts, a fair few have ended up in the bin, but I'm finally sorted.

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I had to make a new hard water pipe as well as that has gone missing???? was a minter too, they are normally rotten. :(

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Built up the vane operating mechanism on the turbo and concocted a messy manifold to fit the pressure and oil temp senders, I've since decided it was rubbish and got some decent fittings from local hose specialist - he was very helpful and gave me a good price.

North Devon Hose and Hydraulic - Thanks very much.

Back [playing with the motor fitment, I then realised 4th gear was tricky and 2nd was a no-go, I had to dog-leg the shift arm and then grind in some clearance.
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Fine now.

Finally, to end on a high note, As the starter is now fitted and wired, I couldn't resist thumbing the button, and - after a false start when I remembered that I forgot to remember to fit an earth lead from engine to chassis - it cranked over quite happily.

Now to bolt up a few more bits, add some fluids and try for real.
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