Golf 1.6 Driver NEW NEWS

This is the project i started at the begining of this year

been a busy boy i tell thee

































got some new bits through -






removed part of the scuttle/rain tray, what a pig



also got all the wiring out the right side of the engine bay



slow but sure

here we go again had some pretty full on progress with the golf

first up clean all the rust off the front slam panel/headlight panel and respray with hammerite.





then to the top of the slam panel, done semi smooth, going to use LMR chromed bolts for bonnet catch which is also getting a polishing



Then i decided to work on the new door i had, old one had big dent the whole lengh of the door also filled all the wholes (welded) and smoothed with filler



next step was to mod the boot hatch, lots of work here, weld up all the holes for numberplate lights, lock and fixings for grab handle, then fill, weld plate over for wide short look, more filling and smoothing (still needs more



finally removed some seam sealer from passenger inner wing to prepare for smoothing the bay, what a pig.



will update again as soon as i have done more

got the engine out finally



put it on my engine stand ready for overhaulin



final primer spray ready for 400 grit wet and dry flatting on rear quarter and passenger door





cleaned up rear engine mount ready for painting



cleaned up starter motor, bit of paint



dreaded peirburg, gonna be swapped for weber yey



what my garage looks like - a touch messy





Right we will start small then work up

got some more pressies today YEY



rocker cover strips will clean up a treat



The big one, engine got a good stripping down









a box of crap i took off, yes that is an eight valve GTi exhaust manifold in there



more bits that came off



couldn't resist cleaning some bits up

inlet manifold



rover cover



sorry really got into this car now

decided to clean up gearbox mount, front engine mount bracket, gear linkage bracket







in the process done this



Complete gear linkage repair kit



New water pump and stat, bling



smoothed off water pipe, no studs for silly clips







well i can say i properly ache now, complaint over.

got more new stuff today.



And on to the main event, had a proper bash at smoothing the bay, injuries down to stupid stupid metal work.
first I removed the brake setup and remainder of the rain tray.



Next up was to use twisted wire wheel and get rid of rust and paint around the holes ready to weld them up.





after that i moved over to the inner wind, i plated this over, font section first, spent ages trying to get it the right shape.



Then after that was welded in I got out the fibreglass, lighter than filler. covered the front of the turret and the plate i welded in, also filled some of the deeper holes in the bulkhead.





then i got the filler out and slapped it on willy nilly.





started to smooth the filler off.



Then i finished off the plating of the inner wing



then more fibreglass.









i know there are loads of imperfections, thats what is killing me, but looking better all the time.

Between waiting for filler or fibreglass to dry i thought i would make a start refurbing the gear selector arrangment, stripping and painting parts, fitting new bushes, rubbers etc







I also decided to strip and paint the front cross member and the fron engine mount bracket





I also thought it would be a good idea to make the alternator look a bit better.

from this











pretty happy with the final result

first re-painted fan cowling



pulled suspension off



looked like this



and the bushes wernt all that either



I have been having an absolute nightmare with the driveshaft nut on the nearside axle, but with plenty of hammers and a big chisel..............



removed the whole of the front subframe too



this is going to get the refurb treatment too.

and finally here is how the bay looks at the minute, plenty more hours left in her



completely refurbed front cross member, new bushes in there too



also overhauled the front subframe and steering rack. BEFORE



AFTER

new steering rack gaitors, tierod ends and mounts.



The end result



Wasn't really happy with the nearside inner arch so i rubbed it back down again, also started on the off side inner arch, decided to plate the chassis rail in stead of filling with fibre glass.

BEFORE



AFTER



hers a close up of the off side wing, bit of work still needed



And i managed to get the engine loom out of the way completely, PAIN IN THE A**E. needs a diet i think

wow you have been busy!! wil look wicked when your done!

thank you for you comments everyone

spent more time on the driver, spent most of the evening getting rid of the tar in the engine bay

nightmare !!!! Here is the result though



made this big hole in the floor



by removing this, changed the ball and cup on the gear lever



also overhauled the 9 inch servo i got through today, painted it and bolted the new MS to it



I done a bit more on the smooth bay but to be honest looks the same as before

cheerz all

Blimey you have been a busy boy Nice work m8 I'm really intertested to see how this project turns out. Keep the pics of your progress coming, I luv to see this sort of shit

Nice work! I love the space you have in your garage! Looks like you could almost get another whole car off to the side! I need a decent garage, Mine is really small!

I can't wait to see how it all pans out, nice!

Very impressive, I love being able to see the process as it developes and the amount of work you are putting in. Be great to see it when it is done.

Sweet looks like a How-to refurb a Mk2.. Sure Dan will be along soon too!

Wow, you have been busy dude. I'm sure all the hard work and the bleeding will all be worth it in the end. Rock on.

If your not bleeding the jobs not finished in my experience.

Theres doing a job! and theres doing a job properly!!! hats off to ya buddy great to see this scale of "lookin after ya motors"....

dam... tht how things are done properly man

Wicked..looks awsome..take it your going for the minimal look:)
really cool to see pics of the progress..gives other ideas too!

well gals and guys been a couple of weeks and its slow going.

I have decided not to show anymore pictures of the engine bay, want more of a WOW when you see complete pics.

been working on refurbing bits more than anything, i have also had a quote for the engine work, basically going to have the rods and pistons balanced, the crank dynamically balanced along with a lightened flywheel. block will be honed and new rings. new bearings and seals. going to have it done when i get back off holiday this weekend, off to french france for a few days snowboarding.

refurbed the gear lever housing, once dry its ready to go back in the car



Here is the block, its mostly stripped down but i didnt have a multipoint socket head to undo the crank shaft pulley bolt.



and the box of goodies that will get the 'treatment'



Also had a friend at audi push the old wheel bearings out, grinded the rust off and painted the hub carrier



And lastly fitted wishbones and lower strut brace on the front subframe, decided to keep the standard bushes to retain a bit of comfort, they are brand new so should still be tight



cheers for looking peeps

also having PIPER make a cam for me, power band will be 5k - 7.5k HA HA HA on a carb'd 8 valve

they said it should stil retain a decent idle

cool

till next time

hey ya'all

back from the brink of death in the alps.

right, dropped engine of to T&L engineering

fantastic price, having flywheel lightened and balanced, rods balanced, pistons balanced, crank balanced with flywheel and clutch, all new bearings and seals, brand new sachs clutch and it all rebuilt for £700, bargin, i got qouted £2490 to do this somewhere else, guess they didn want to do it.

also cleaned up the old brake fluid res.

cleaned down gearbox ready to paint. got the paint out started to paint the gearbox all was going fine, picked up the tin of paint gave a little shake, silver paint everywhere. RUBBISH

sorry no pics guys will update with photo's soon

EditiononeG60 wrote:

hey ya'all

back from the brink of death in the alps.

right, dropped engine of to T&L engineering

fantastic price, having flywheel lightened and balanced, rods balanced, pistons balanced, crank balanced with flywheel and clutch, all new bearings and seals, brand new sachs clutch and it all rebuilt for £700, bargin, i got qouted £2490 to do this somewhere else, guess they didn want to do it.

also cleaned up the old brake fluid res.

cleaned down gearbox ready to paint. got the paint out started to paint the gearbox all was going fine, picked up the tin of paint gave a little shake, silver paint everywhere. RUBBISH

sorry no pics guys will update with photo's soon

Hey thats really good, let me know how their work turns out! I want to eventualy get the loons motor balanced so I can rev it a bit higher to make full use of the DCOE's.
Looking good so far!

Right spent alot of time claening the god dam gearbox and repainting it in silver

quite pleased with it, also got a new seal from vw for the gear link shaft



Then started on the 16v brake setup, stripped them down and ground off all the s**t and painted in a nice shade of blue

its actually darker than in the pics, removed the piston too



sent my bearing carriers to my mate at audi to get new bearings and hubs pressed in, when they are back i will build it all back up on the front subframe

also had another delivery from the posty, starting to know them by first name now.

new cam covers, new rear bushes, new copper brake pipe, new 3/16th ends for brakes, new water flange on the front of the bloock, new rear bearings and a tool to make the ends of the brake pipe



cheers all

wicked, cant wait to see the finished project!

Right been doing loads on the bay, and its starting to look the nuts, will be finished end of next week i think. I will post some pics up then.

But as wel as that i have been building the front subframe up ready to bolt back to the front of the car when the bay is done.

hubs are bolted to the wishbones, disc's are on and caliper carriers bolted on, as you can see i have also changed to studs instead of bolts, just to different.







hope you like also have a bit of a surprise that will be revealed soonish

its really starting to take shape now m8 wicked stuff i like the blue brakes they do look V

Awesome work, I am just so impressed by how every part is being set-up with quality and precision, nice work and thanks again for documenting it.

well picked the block up from the machinists today and got to work on it, Barry at T & L said he was impressed at the condition of the bores, pistons etc. everything came up like brand new inside.



after i painted the block with heat resistant engine laquer i started to bolt some of the goodies i've been stocking up on





new sach clutch kit, balanced along with crank and flywheel.



and a box of all the old rings, scrapper ring, big end shells etc



cheers for looking

another update 1st april 08

excelant. So he ballanced and blue printed the engine? If so how is the work. I must say judging by the bores it looks top rate.

Constantly amazed at the level of detail on this..

And do I see a Lower Brace bar too?

vwdeviant wrote:

Constantly amazed at the level of detail on this..

And do I see a Lower Brace bar too?

you do see a lower brace my friend, hopefully the handling will make up for the lack of grunt, should be fun to drive

looner wrote:

excelant. So he ballanced and blue printed the engine? If so how is the work. I must say judging by the bores it looks top rate.

The bottom end has all been balanced and rebuilt using brand new piston rings, crank seals, big end shells etc

the rods all weight within 0.01 gram of each other and the same with the pistons and gudgeon pins, the crank has been balanced and then attached to the clutch and flywheel and all balanced together. It should be a sweet high revving engine

cheers guys

Wicked son! Nice to know someone who actualy understands about how important it is to balance the drive train as well. I want to eventualy get my 1.3 done in the same way. Becuase once the twin 40's go on its going to want to rev high. What are you going to be doing on fuel delivery side! I have to say once again, brilliant work bro!