1980 B1 Passat Project

[Peter Jones]

OK. I know I've already got oo many projects on but Jodie was determined to save this Passat.

It's a B1 "Facelift" or "Update" model. Parts are going to be nearly impossible to find, there can't be too many of these in Australia.

It's taken a bit hit in LHR 1/4 but I've found a '74 1/4 that should do the trick.

High comp 1600, massive exhaust!

We collected it yesterday and started on the interior and cleaning the engine bay.

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320580-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320584-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320585-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320586-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320606-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320607-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320608-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320614-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320619-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320642-1.jpg

[Peter Jones]

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320621-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320622-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320624-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320626-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320628-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320635-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320687-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320694-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320716-1.jpg

I had these seat covers lying around, relax, they're not permanent! :-) They'll keep the seats nice while I'm working on it.

[VR6child]

lol those seat rails and mechanism things looks exactly like the one from my golf which is 14 years newer.

[GoLfMan]

great to see that your saving a rare Dub :) looking forward to seeing it back on the road again!

[Peter Jones]

Anybody know what these back brakes are?

The pads are DB-1104.

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320609-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320610-1.jpg

Back to the world of fun that is my driveway!

I'll pop up some more pics later on.

Pete

[GOLFBALLS]

Awsome Pete! There was an orange '74 Passat coupe at Pickles here a few weeks ago with a hit in the rear drivers side. We thought about nabbing it but decided to put our minimal cash towards the mk1 Golf rescuing!
Dunno who bought it...

[Peter Jones]

Just figured out the brakes. The caliper is off the rear of a Nissan Pulsar of all things. I'll have to take a closer look at how it all mounts up.


Pete

[DVR68U]

looks good , whats the motor like power wise?
cheers brenton

[Peter Jones]

Here's the text from the e-bay listing. The motor details are vague. It has heaps of compression. I Haven't been able to properly drive it yet because the panel grabs that rear tyre and robs a lot of horse power.


Selling this car AS IS and the buyer is kindly asked to organise it's transportation.

This car is the hard-to-find facelift model of the b1 passat. It was imported new from Germany by an elderly man from Wangaratta, who held onto it for a number of years until it was acquired by some neighbours (A lady owner, if that makes a difference).

Being a B1 passat enthusiast and owner of many, I spotted this and drove for 4 hours each way from Melbourne to buy it and bring it back down.

It was originally a diesel and still has the original diesel gearbox, which has been maintained. It has an ultra-lightened flywheel too.

The engine was purchased by me from a private seller and engineer (and another B1 passat enthusiast) who completely restored and blueprinted the engine using the best parts possible including GT
flat-top pistons, 'Scat' brand valves etc. each little part was of very high quality and designed for performance. I have dyno readings showing this engine reaching 139 hp (this engine originally came with 75 hp
or 85 hp with the twin-barrel carby). It's the same engine used in the golfs and audi 80's/foxes and will fit into nearly any 4 vw/audi without modification to mounts etc.

currently fitted with a reco-ed 32/36 twin throat weber carby, it was used as a daily driver by my mum for the last 5 years while i was overseas. it is EXTREMELY fuel efficient, but can be tweaked for
performance if need be. It has never been thrashed. In fact there was never enough time or money to fully tune it for performace etc. The matched dizzy and electronic ignition system it came with was stolen before the
engine went into the car.

It has slightly lowered springs, a heavy duty sway bar and it might even be the only B1 with FOUR WHEEL DISC BRAKES! the front ones are big and use easy-to-find nissan pads. I have four alloys to
throw in on the deal too. the car has the tachometer out of the passat 'TS'.

I can't even remember all of the other engine stuff, but has many other little things such as a custom oil sump, extractors, etc. It has a 2" exhaust, 'turbo' muffler and 3" tip. Produces a deep note.

Engine still starts, but have recently taken battery out. It's a good quality AC DECO european battery, which will come with the car of course.

About 5 months ago, it was hit in the driver's side rear panel, just before I returned from overseas and my folks allowed it to run out of rego. It was a reliable daily driver and obviously unique.

I had it resprayed in Jaguar british racing green, however this may no longer be much of a selling point, due to the car's BAD POINTS:

- the smashed panel
- body/paintwork not perfect: chips, dents
- basically every door lock has been damaged by attempted theives
- the steering wheel, which was once a nice piece, is deteriorating
- the dash is utterly cracked, as is common with EVERY single example of a B1 (can be replaced with a later audi model dash, I believe)
- interior tatty. I also just gave away the sound system it one had.

All in all, this car would suit and enthusiast/collector, someone wanting to utilise the 'hot' engine in the car (forgot to mention the 'hot' cam and heavy duty valve springs), someone wanting a unique project,
somone wanting to just rip out the interior and race this around a track or outback.

It has rally lights hidden behind the grill, a rear louvre, a rare and valueable spoiler, which is interchangeable with most cars.

can probably roll/tow it home. prob just need a crow bar to bend read fender up a bit higher and shove on one of the spare wheels.

I have decided to have no reserve on this item, as I am grateful enough that it is going to someone who cares.

[DVR68U]

yeah i saw it up on ebay , maybe you should put in a nice(slower) motor so you can use that one in one of your mk1's lol

[Peter Jones]

The engine bay 'before' shot.
http://www.vwwatercooled.com.au/forums/images/imported/2008/12/SANY0004-1.jpg

It's a lot cleaner now.

Pete

[gtimk5]

Good one Pete, another project for you mate.
Loving the Holden air cleaner!!!
Cheers and good luck with it,
Andrew :)

[Jarred]

that's pretty cool Pete.

I'll have to come have a geez in the new year.

What are the plans for it? I'm geussing Jodie wants to daily this?

[SeanyQ]

Awesome car! Can't wait to see what it looks like once you've finished. :)

[Peter Jones]

Plans are to make it a daily driver for Jodie.

Mars Red is the go. Will sort out that 1/4 panel these holidays.

Engine bay is a bit cleaner now.

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320722-1.jpg

Pete

[Golf Loon]

Engine bay is a bit cleaner now.

And redder, obviously :)

[Peter Jones]

More red to come!:nana:

You don't have any UK contacts that could track down some tail lights for me by any chance?


Pete

[Golf Houso]

Nice work there Peter, does it handle like a boat under a king tide? The one I had did, it was well umm ... fun particulalry around round-abouts with the rear end skidding out :eek:

[Peter Jones]

Nice work there Peter, does it handle like a boat under a king tide? The one I had did, it was well umm ... fun particulalry around round-abouts with the rear end skidding out :eek:

Can't drive it 'till I get that guard off the tyre. I'll probably need to replace the shocks they seem a bit tired.

(I did drive it round the corner in the photos when we unloaded it from the tow truck. The tyre was dragging all the way. It's not safe to unload a truck out the front of my house and the driveway is out of the question.)

Pete

[phaeton]

Cool Resto Peter :D

Its about time someone saved a Passat.

[Golf Loon]

More red to come!:nana:

You don't have any UK contacts that could track down some tail lights for me by any chance?


Pete

Probably more passats left in Oz than in UK.

That crazy bloke with 100 vws in a field near Goulburn would probably have some. Volksapart? He is often in the trading post?

There are pics in here of his place. I went there once.

[Mischa]

Plans are to make it a daily driver for Jodie.

Mars Red is the go. Will sort out that 1/4 panel these holidays.

Engine bay is a bit cleaner now.

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320722-1.jpg

Pete

lol looks like an mk1 engine bay thats been put in a tumble drier :)

[posscakes]

hey good to see another old passat rescued. have fun finding parts though they are hard to find. if you cant find passat wrecks try audi 5+5 they share passat parts also.

[Peter Jones]

Went and got another 1/4 panel and inner guard yesterday. It's off a 74, there's a few minor differences but I can work around those.

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320733-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320735-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320842-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320847-1.jpg

Very scenic wreckers yard this one!
I was a bit worried about the impending rain.
http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320797-1.jpg

Pete

[GoLfMan]

ahhh ye olde 9 inch grinder at work aye :)
awesome Pete :D

[Peter Jones]

Got into some of the wiring yesterday.

What an oddball!

Mostly it's the same as a '77 Golf.

The ignition switch was stuffed and wouldn't power up the "ON" circuits. The RACV had wired IGN power from the RHS headlight parker circuit to make get it home and the owners had left it that way. This meant that you needed to have the parkers on to run the car.:duh: I pulled the switch aaprt and was able to adjust the contacts and get it going properly. GAP has new ones, I'll get one on the next order.

The dash blower fan had siezed leading to various parts of the loom having a melt down including the pin in the back of the fusebox and one of the 3 way connectors under the dash. I had a spare blower so I bench tested it and re-lubed its bearings before installing it. There's still some wiring to fix but if I hot wire the switch I get all 3 speeds working properly now.

The fuse box had some of the fuse connectors soldered together for some strange reason. Probably to provide more current to the siezed dash fan.:duh: I removed all of that nonsense and cleaned all the fuse terminals.

The car still had all of it's glowplug circuitry all in place including the relay and holder. I've removed most of that wiring now.

Also removed driving lights and associated wiring cables and switches as well as the dodgy horn relay setup. I'll re-do a relay setup if needed.

The engine fan wiring is spectacular! There's a relay on there wired in such a way that once the fan comes on it stays on - Forever! (or at least until the battery goes flat!) Why don't people just replace the temp switch?

Pete

[Peter Jones]

More gremlins sorted. Got the oil pressure switch working and cleaned up a heap of other wiring.

This is the main lead from the alternator to the battery. I guess someone had hacked an ammeter into circuit and later taken it out. This is what I found under the tape. Nice Huh?

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320899-1.jpg

How old is this ignition module? 6 digit phone number?! Still works. It uses a photo interupter setup in the dizzy. - Old Skool!

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320900-1.jpg

Messy!

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320901-1.jpg

Fan relay wired by moron.

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320902-1.jpg

Pete

[posscakes]

our passat's are related i think cause they share the same double headlight setup at the front not those ugly square things. my one is still diesel though. i would offer to share my light cover spares though my one is a station wagon so the tail lights are this triangular setup much different from yours. I watch this thread with much interest though.

[jnrm3]

hey very nice project you have have there, if you need more parts i saw a complete and very original one at center road wreckers it looked a little bit older though.

cheers
steve

[Jarred]

Cool Pete.

I'm back from holidays now, any time I can come round for a Geez?

[Peter Jones]

Cool Pete.

I'm back from holidays now, any time I can come round for a Geez?

Yeah, I'm on holidays 'till the 5th. Give me a call sometime.

Pete

[greasykitchen]

Cool project you got there. Is it rear wheel drive?

Is it wise to have the fuel filter between the pump and the carby? Any beetle owner (the old beetles I mean) will tell you that it's a recipe for fire if the filter gets blocked. There again beetles are quite prone to catch fire, but isn't the principle the same. Just a thought anyway :)

[Peter Jones]

Cool project you got there. Is it rear wheel drive?

Is it wise to have the fuel filter between the pump and the carby? Any beetle owner (the old beetles I mean) will tell you that it's a recipe for fire if the filter gets blocked. There again beetles are quite prone to catch fire, but isn't the principle the same. Just a thought anyway :)

Thanks, the car is front wheel drive.The rear end is same setup as current Polo!

That filter is going, I've got an electric pump looking for a new home and I'll relocate the filter to before the pump, probably under the car somewhere. All of the fuel hoses and clamps will get replaced as I work my way through the engine bay.

There's a lot of things in this car that aren't terribly well thought out (to say the least) that fuel filter is high on the list.

Pete

[phaeton]

Thanks, the car is front wheel drive.The rear end is same setup as current Polo!

Pete

Shows us how modern they were back then :D

[greasykitchen]

Thanks, the car is front wheel drive.The rear end is same setup as current Polo!

That filter is going, I've got an electric pump looking for a new home and I'll relocate the filter to before the pump, probably under the car somewhere. All of the fuel hoses and clamps will get replaced as I work my way through the engine bay.

There's a lot of things in this car that aren't terribly well thought out (to say the least) that fuel filter is high on the list.

Pete

Of course you've got it all sorted.:duh: I guess it's not too much of a problem if you can't even drive it yet :biggrin:

And as it's not a transverse engine I thought it might be rear wheel drive, but my knowledge is limited. Can't believe the rear end is the same as a modern Polo - was it advanced or is the Polo living in the past?

Cheers

[mollins]

The car still had all of it's glowplug circuitry all in place including the relay and holder. I've removed most of that wiring now.


have you still got this???

mike

ps. keep up the good work

[Peter Jones]

have you still got this???

mike

ps. keep up the good work

Yep. The base is still in the car, I haven't fully extracted it from the loom yet.

Pete

[Peter Jones]

Pumped the back guard out the other night so it clears the tyre now.

Plan is to remove the outer skin, trial fit the new 1/4 and bring the inner guard out to meet it. I think I can get away without replacing the inner guard at this stage. I'll see how it looks once the skin is off.

Pete

[migolf]

If you are still looking for parts for the passat,try the northern rivers area of new south wales lots of wreckers in the area and they seem to have lots of older european cars

[vinderliker]

Well Pete, it looks good. The shots of the engine bay are interesting, especially the placement of the battery and the brake servo and master cylinder, it is totally opposite to what is on mine, brakes left battery right side. I'll try to get some photos. I would love the steering wheel as it looks similar to the TS models. I also love the rear spoiler, I want one of those as well. I am chasing up a list of stuff for mine, via a few places. In the interior I want to get the centre console, gear and handbrake boots, new under dash and glovebox. At the moment I'm concentrating on getting the electric fuel pump re-located to where it should be, new shocks (current ones leaking), springs(rear end is sagging), new radiator, heater switch and cable and new tyres. It is a work in progress bit by bit when I can afford it, mainly trying to make and keep reliable as well as respraying the rear end which is badly crazed, and some other interior and exterior cosmetic issues. I also want the mags repaired and polished So far with the 1.8, the Holley 32/36, K&N filter and the 2 1/4 inch exhaust it goes like a rocket. Before the exhaust got done it was dynoed at the wheels at 66kw, with the exhaust have noticed a big increase in power.

[Golf Loon]

Update this Pete.

[Peter Jones]

The next thing to do is start on the body work. I'm waiting on my carport to be built so I can get everything undercover.

It's currently wearing the BBS wheels off our old e30 BMW but apart from that not much has changed.

We finally have tail lights for it after a 6 month global hunt, it was looking like mission impossible there for a while.

There's also a lot of little bits and pieces accumulating on the shelf for it and there's some bits for it in the stuff that 's just arrived from the US.

Once the carport is up I'll be hooking into the rear 1/4. I'll write it up when it happens.

I suspect I'm going to have to replace the rear beam. It looks like one rear wheel has a lot of camber. It's the wheel that was hit and the run out checks out OK. An earlier Passat one should fit and let me get rid of the Nissan rear brakes too. I'll have to get under there with a straight edge and see what's bent.

The carport will have to get it's own thread:biggrin:

Pete

[Peter Jones]

Some progress today. With a bit of luck I'll get it attached tomorrow.

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1330619-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1330620-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1330621-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1330623-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1330624-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1330625-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1330626-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1330627-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1330628-1.jpg

[roccodingo]

No holding you back on this Pete, new panel fit up looks pretty good.

Has the rear door been bashed also ??

[Peter Jones]

Yep, there's another door to go on there tomorrow too.

There's still a bit of trimming to do on that new panel, I haven't finished dressing it yet and there's that dent to knock out too.

I now know that there's a lot more spot welds in a '76 Passat than there is in an 80 model! I was drilling for ages!

More pics tomorrow!

Pete

[gldgti]

you really are one for all of us to look up to pete - inspiring stuff! magic!

[Peter Jones]

The inner guard took a fair whack.

The idea is to trial fit the new skin up and bring the inner guard out to meet it.

Lots of adventures with clecos (skin pins) tomorrow.

Pete

[Jarred]

wohoo pete. Good to see you're finally getting stuck in!

[Peter Jones]

Progress slowed today. The inner guard is defeating me at the moment.

Got the fuel tank out because it's a bit too close to where I'll be welding.

Fitted and adjusted the new door which took a bit of stuffing about. Passat's don't have the greatest range of adjustments.

I won't get much done next weekend due to Phillip Island, but the weekend after that should see it done.

Then it's on to painting which should be an adventure.

Need to get this on the road before DOVW.

Pete

[Golf Loon]

Nice writeup Pete as usual.

I actually have a Passat roof in the garage at the mo that someone kindly chopped off for me. Stage 2 of that is to graft it into the scirocco and get rid of the sunroof. That will be an adventure!

I was surprised at how similar the roofs and angles were and how small the roof section is once removed.

[Peter Jones]

After staring at the new panel for hours trying to figure out how to tackle it I realised this was probably beyond me and called for help.

Dennis is an old friend of mine and is one of those old skool metal smiths that are rarely found these days. He took some time off fixing Ferrari 360s to get me back on track.

The bottom corner of the guard had a rust pinhole in it, when I cleaned it up with a wire brush the panel started to disapear. It was mostly rust held together by a layer of paint. Dennis said he just have to put a 'piece' in there. Before I knew it he had fabricated a new corner to the guard!

Watch and learn.

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040639-2.jpg

Most of the morning Dennis spent straightening out the inner guard. I hadn't even got it close.
Here it's been etch primed and painted before the outer skin gets attached.

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040640-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040641-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040643-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040645-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040647-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040648-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040650-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040652-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040654-2.jpg

[Peter Jones]

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040657-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040658-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040659-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040663-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040664-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040665-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040666-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040668-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040670-2.jpg

This is where I've left it tonight, just a bit of etch primer and high fill on it to keep it from rusting. I've seam sealer'd the interior joins and the inner lip on the guard.

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040671-2.jpg
Pete

[Preen59]

Very nice! People with talents in sheet metal just amaze me.. I'm bloody hopeless with the stuff! haha. :rolleyes:

[gldgti]

pete, i think we should invent some kind of forum award and give it to you. every time you post up in one of your resto threads i feel like you've been reading my thoughts and then go about answering all my questions with a writeup on something new and cool.

all i can say is thanks - the pictures tell a thousand words :-)

[16v_kid]

pete, very nice work.

and done properly.

really impressed mate.


keep it up.


Gordan.


:banana::banana:

[Peter Jones]

Very nice! People with talents in sheet metal just amaze me.. I'm bloody hopeless with the stuff! haha. :rolleyes:

Yeah Dennis is freak. I've seen him make panels from photographs. When I first met him he was making panels for a Schwimmwagen. Crazy skills. Biggest hammer collection on earth!

Pete

[Golf Loon]

Another sweet writeup Pete.

And man enough to call in a pro for a particularly tough job.

Car looks pretty good now.

[phaeton]

Yeah looks great :D

[Jarred]

Amazing work.

The welds are so straight! Amazing.

Give me a holler when you want a hand sanding :)

ooh, and the carport looks good too! :D

[vinderliker]

Fantastic work. Slotted disk brake rear end! Tell me more please. Bridgestone Adrenalins as well? Love the rims, a bit easier to clean than mine as the meshing/cross hatching is finer and yours look in great condition.
James

[GoLfMan]

awesome Pete! :)

I'll try and get over for next weekend and give you a hand

[Satanstoenail]

I'm not usually a huge early Passat fan, but I love the look of this one for some reason. Are you keeping the green?

Also that welding job = :bowdown:

[Peter Jones]

The green paint is horribly applied and not a VW colour.

Frank, (short for Frankenstein), as the car is now known, will be repainted in Mars Red. It was originally silver.

We've decided to push on and get it painted before it get roadworthied.

It's been a long time since I painted a car, should make for another amusing chapter in the saga.

Pete

[Water Boy]

Run it Rat-look Pete :banana:

[Peter Jones]

Run it Rat-look Pete :banana:

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/NoRats2_Full-2.jpg

Pete

[Gipson]

red again pete! those paint shops do other colours too mate:wasntme::biggrin:

haha no its looking good i like the early passats, nice weld on that rear quarter too. once thats on is all the body work fine?

[Satanstoenail]

The green paint is horribly applied and not a VW colour.

Oak Green is a VW colour though! :wasntme:

I'm sure the red will look cool, I just like the dark green on it for some reason.

[Peter Jones]

Bit more progress. We checked out the Passats down at Centre road and picked up another rear door which is dead straight. The other one I had on there was repairable but this was a better option.

http://www.vwwatercooled.com.au/forums/images/imported/2009/08/P1040682-2.jpg

There's a heap of rust under the side strips which is taking a bit to treat. Most of the car is pretty good though, Just a little more welding to do and a whole lot of sanding.

On another note there's another one of these on UK ebay at the moment.
http://cgi.ebay.com.au/ws/eBayISAPI.dll?ViewItem&item=270449106044&ssPageName=STRK:MEWAX:IT

Oh, and thanks to Jarred and Golfman for popping by and lending a hand.
Pete

[Jarred]

Good pick up with the door. Save alot of swearing and mucking about I think.

I have a feeling this'll be painted in no time!

[GoLfMan]

looking good Pete :) sorry I wasnt much help, was/am feeling like crap!

[Peter Jones]

All the welding is finally done. Today I repaired minor pinhole perforations in he driver's door and front RHS 1/4, major rust in the bottom corners of the windscreen and filled in both the antenna hole in the roof :duh:and the one in the guard.

There's still a heap of cleaning and sanding to do but I'm hoping to get it in undercoat next weekend.

Here's some pics, my arms are to tired from sanding to type much more. :)

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040683-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040684-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040685-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040686-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040687-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040688-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040689-2.jpg

[Peter Jones]

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040690-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040691-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040692-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040693-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040694-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040700-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040701-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040702-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/09/P1040703-2.jpg

[Jarred]

another big weekend for you by the looks of it Pete, good to see you're making some major progress.

I'll try pop round next saturday arvo to lend a hand again. :)

[WABIT]

looks great pete, you give a lot of inspiration mate, theres not alot of blokes who'd tackle a job this big at home so well done

dom

[roccodingo]

Maybe something you can try Pete seeing you have gone to this extent.
To inhibit the corrosion in the windscreen lower corners, try lead wiping a small amount of body lead where the rubber seal will sit, then paint and fit screen in the usual way. the lead filler then serves as a rust barrier ( similar to galvanising ) if and when the windscreen seal allows moisture in that area.

Had this up my sleeve for ages, but yet to try its effectiveness.

Great to see the progress, need a size 10 up my a** to get me motivated here right now...

[Peter Jones]

Cheers Grant, I'm going to use drip check sealant to do the same thing. I've already re-done the gutters and the rear boot gutter.

The reason this rusted so badly was due to the previous paint job. They'd sealed the bottom edge of the rubber in with paint so the only place the water could go was under the paint.

The drain holes were blocked by a colony of ants which wasn't helping matters either.

Pete

[gldgti]

The drain holes were blocked by a colony of ants which wasn't helping matters either.

Pete

6-legged terrors strike again....

love your work pete, its looking very promising!

you're getting me inspired :-)

[JimmyACT]

Great project Pete. Inspriring stuff. I have a soft spot for old Passats. I am a newbie here but owned a few of these older Passats and a couple of Audi Foxes in the past.

I don't have one of these cars now but do have a few parts left over. I am in Canberra. I'll have to dig them out from under the house to see exactly what's there as it's been a while. Plus I moved house 18 months ago and some stuff was tossed. I wrecked a wagon at one point as I needed bits for my own wagon (back in the mid 90's). They may not interest you but I think I have an instrument cluster (not everything was working from memory), "restored" Passat LS badge, rear drums, external mirrors, alternator I think, maybe a Solex single barrel carby, handbrake cable, brake bits, maybe hubs and struts if not chucked, maybe front discs, etc.. I think that there is a box full of stuff as well as some loose stuff. Hopefully it survived the move.

As I am new here, I may not yet have private messaging privileges. If you are interested in finding out more about these bits, just post back here if you can't private message me yet.

Cheers,
James

[Peter Jones]

Thanks Jimmy, I've sent you a PM.

Pete

[Yevvy]

man i love old passats. have driven a b2 coupe when i was a kid (i swear i was legal age ;)) and it was a dream. it was finished in british racing green and the colour suited the car really well.

[vinderliker]

Anything left over can you give me a yell as well!




Great project Pete. Inspriring stuff. I have a soft spot for old Passats. I am a newbie here but owned a few of these older Passats and a couple of Audi Foxes in the past.

I don't have one of these cars now but do have a few parts left over. I am in Canberra. I'll have to dig them out from under the house to see exactly what's there as it's been a while. Plus I moved house 18 months ago and some stuff was tossed. I wrecked a wagon at one point as I needed bits for my own wagon (back in the mid 90's). They may not interest you but I think I have an instrument cluster (not everything was working from memory), "restored" Passat LS badge, rear drums, external mirrors, alternator I think, maybe a Solex single barrel carby, handbrake cable, brake bits, maybe hubs and struts if not chucked, maybe front discs, etc.. I think that there is a box full of stuff as well as some loose stuff. Hopefully it survived the move.

As I am new here, I may not yet have private messaging privileges. If you are interested in finding out more about these bits, just post back here if you can't private message me yet.

Cheers,
James

[JimmyACT]

Anything left over can you give me a yell as well!

No worries. We are both in Canberra so that helps. I may not have that much stuff after all. Hopefully I'll get a chance to dig it out on the weekend and will know for sure.
James

[76Passat]

Hey Peter I have a 1980 B1 wagon I want to get rid of if you're interested in parts - unfortunately I'm in Brisbane. It's in the complete cars for sale forum. I've put a price on it but I really just wanted to keep the scrap metal junkies away from it - I'd consider smaller offers if the car or the parts are going to a good home. It looks like it might be in slightly better condition than yours was before all your hard work (great job by the way). I've got to get rid of the thing cause I'm out of space.

I think I might be the only B1 owner up here in Bris. Only seen one other (a two door with 4 round headlights, probably '78 model, silver) up at Noosa earlier this year, and no others in about the past seven years....

[Peter Jones]

Some more progress, got it undercoated.

It's highlighted a couple of faults I missed, but nothing major.

Hopefully we might get some colour on it next weekend.

Enjoy!

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040788-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040789-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040792-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040799-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040810-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040814-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040818-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040820-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040825-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040827-1.jpg

[tassie_euro_mk1]

Excellent work Pete. Its sweet that your restoring the old passat :) They're becoming rare and your particular model is the only one ive seen in Aus so far.

I like the twin healights they have, something I wish our 76er passat has instead of the square lights.

:cool46: Keep it up

[GoLfMan]

nice work Pete :)

your giving me inspiration to finish mine now!

[Jarred]

Nice one Pete, good to see you finally got some time to get some more work done!

[vinderliker]

I'm just jealous:), yours will really put the Little Beastie to shame:(

[hiho]

The Passat is looking great Pete, nice to see the green (and orange) go!

[gldgti]

wonderful stuff pete - just great!

[16v_kid]

Great stuff Pete,

What sort of colour will it be?

[Jarred]

Great stuff Pete,

What sort of colour will it be?

Mars Red, naturally.

[16v_kid]

Mars Red, naturally.

nicee:bowdown:

[Peter Jones]

Did all the colour change tricky bits today.

Wet sanding tomorrow and first top coat if the weather holds up.

Don't know if I'll get it done before DOVW now.

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040848-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040861-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040876-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040893-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040899-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040903-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040911-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040914-1.jpg

[Preen59]

Looks good Pete.

You've got bigger balls than me.. I reckon i'd do a better job with a brush than a spray gun! haha.

[Peter Jones]

Looks good Pete.

You've got bigger balls than me.. I reckon i'd do a better job with a brush than a spray gun! haha.

Don't assume that I know what I'm doing:rolleyes:

If I did I probably wouldn't have started.

It takes a special blend of ignorance and optimism to start these projects.

Masochism is what makes you finish.

Pete

[gldgti]

pete you crazy cat, well done.

[Peter Jones]

It's all rubbed back and ready for top coat now but the weather is no good to spray. It's currently cold, wet and windy:duh:.

Hopefully next weekend will be warm. I've the weekend plus Monday and Cup Day to work on this, swap a MK1 gearbox (hopefully) and race at Sandown :)

Pete

[Golf Loon]

Good Colour and Nice work.
DOVW you can do it, its 3 weeks still isnt it?

[Peter Jones]

Still might make it, just depends on the weather.

If I can get it mostly back together I'll take it down on the trailer.

DOVW is 15 November.

Pete

[WABIT]

looking great pete! great color choice too! cant wait to see this when its done.....

dom

[Jarred]

hopefully i'll be able to give you a hand next sat arvo! doing what ever I can, as I'd love to see it at DOVW!



It takes a special blend of ignorance and optimism to start these projects.


and quoted...

[GoLfMan]

awesome progress Pete :) getting me all ramped up to paint my thing (finally!)

[Peter Jones]

The sun's come out to play. Two coats on and going for a third now. Pics later.

Pete

[Peter Jones]

It's all red now. The paint went on well. There's a couple of little areas I missed in the prep but we'll just live with them now :rolleyes:

We'll colour sand during the week and aim to buff the red next weekend. If the weather's OK then the clear can go on.

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040934-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040938-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040947-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040957-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040972-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040975-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040986-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040992-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040996-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/10/P1040998-1.jpg

Pete

[Preen59]

Really looks good Pete.. Ignorance is bliss right? hahahaha. :emo_baghead:

Nice looking colour. Those panels you put in look good from the pics. You've done a noice job on that. :)

[Jarred]

well done pete. I figured you'd be painting today, turned out to be pretty nice weather.

how come you are doing a clear coat?? with a good buff i don't think you'll need it for extra shine, unless it's meant to be a two part system? (base + clear)

[Peter Jones]

well done pete. I figured you'd be painting today, turned out to be pretty nice weather.

how come you are doing a clear coat?? with a good buff i don't think you'll need it for extra shine, unless it's meant to be a two part system? (base + clear)

'cos it's red! (UV protection)

Pete

[ajbull88]

Hi, I have been watching the progress, you have done an awesome job of the 1/4 panel and the paint, all in your carport. It just goes to show what can be done at home if your willing to give it a go. Your sure to be an inspiration to a lot of others who want to restore or even repaint there cars on a budget.

[greasykitchen]

I'm gonna echo other comments and add that it's a very impressive effort and transformation. :bowdown: How are the mechanicals? Anything needing attention?

[ajbull88]

Hi,
Not telling you how to paint.........But I'd recommend not to buff before clear coat. I'd ultra fine (wet) the red with 1000 wet & dry and then clear it.
If you wet sand and then buff it, it will be too smooth for the clear to bind too. The clear coat will bring a fantastic shine over the 1000 wet & dry and once the clear is hard you can ultra fine the clear with 1500 or 2000 wet & dry and then buff it to glass.
I paint cars at my work, and I think your done a fantastic job, just a suggestion.

[Peter Jones]

How are the mechanicals? Anything needing attention?

Motor's great, brakes suck - will probably replace the lot. Has Nissan rear brakes and Cortina front brakes.

Pete

[Peter Jones]

Hi,
Not telling you how to paint.........But I'd recommend not to buff before clear coat. I'd ultra fine (wet) the red with 1000 wet & dry and then clear it.
If you wet sand and then buff it, it will be too smooth for the clear to bind too. The clear coat will bring a fantastic shine over the 1000 wet & dry and once the clear is hard you can ultra fine the clear with 1500 or 2000 wet & dry and then buff it to glass.
I paint cars at my work, and I think your done a fantastic job, just a suggestion.

Interesting comment. I'm open to any suggestions. So far I'm just taking the advice of the paint shop. Their recommendation was to colour sand with 1500, buff then clear coat. Once the clear is dry I was to do as you suggested, 1500, then buff.

I need to go and buy more thinners and the buffing compund etc in any case. I'll challenge their advice and see what they say.

One thing I'm unsure of is how to clean the buffing compound off before I clear coat (if I head down that path).

Pete

[Jarred]

prep wash like you'd normally Do I guess? after removing bulk excess with a clean rag.

[Preen59]

prep wash like you'd normally Do I guess? after removing bulk excess with a clean rag.

That would have been my suggestion.


You know.. Considering i know so much about painting.. :rolleyes:

[gldgti]

my pa and i have used turps.... :-)

i know heaps about painting too :wasntme:

[Geoffrey Hale]

Great work Pete.......Geoff

[Peter Jones]

Ok I went and picked up some supplies and had a good long chat with someone a little more familiar with acrylic.

He suggests that what I was told is more applicable to sprayng with 2pac which is what my local shop always paint with themselves.

Barry "has been spraying acryilc for 20+ years " and seemed a very sensible fellow.

So, while I still remember this, I'll try and write it all down verbatim.



Rub back red with 1000
wash car off properly with lots of clean water.
respray with 1 more coat of red
mix remainder of red paint in with the clear
spray all 4 litres of clear.
wait a month before sanding and buffing the clear.


The additional coat of red is to fill in any minor scratches and any rub throughs.


Red paint tends to clog the paper so you can end up scratching the surface which is why you need the additional coat after wet sanding.

You don't buff between the red and the clear as there's too much risk of not being able to clean it all off properly.

"Green" or uncured clear is hard to sand and polish well, the longer you leave it before sanding and buffing the better it will look long term.

If you sand/buff it within a couple of days of spraying it will go dull within 6 months.

You need a heap of clear on the car (4L) as you'll and up sanding about 2.5 litres back off the car to get it shiny.


All of this actually means less work for us to get done before DOVW as we won't be buffing at all for some time.


With regard to the plastic bumpers, I got all the stuff to do it. Black stuff which goes on with the spray gun and and aerosol pack of primer.



The less paint the better
The primer is very thin and only one coat should be used.
The top coat should be applied as thin as possible

Lambswool pad on the polisher is fine when the time comes to polish the clear coat, you clean it by running a screwdriver or similar against it while it's spinning. (Away from the car obviously)

I'll add more to this if I remember any more.

Pete

[Jarred]

Sounds good to me Pete. I'll try pop round sat arvo, have a gander at the progress!

[Golf Houso]

Ok I went and picked up some supplies and had a good long chat with someone a little more familiar with acrylic.

He suggests that what I was told is more applicable to sprayng with 2pac which is what my local shop always paint with themselves.

Barry "has been spraying acryilc for 20+ years " and seemed a very sensible fellow.

So, while I still remember this, I'll try and write it all down verbatim.



Rub back red with 1000
wash car off properly with lots of clean water.
respray with 1 more coat of red
mix remainder of red paint in with the clear
spray all 4 litres of clear.
wait a month before sanding and buffing the clear.


The additional coat of red is to fill in any minor scratches and any rub throughs.


Red paint tends to clog the paper so you can end up scratching the surface which is why you need the additional coat after wet sanding.

You don't buff between the red and the clear as there's too much risk of not being able to clean it all off properly.

"Green" or uncured clear is hard to sand and polish well, the longer you leave it before sanding and buffing the better it will look long term.

If you sand/buff it within a couple of days of spraying it will go dull within 6 months.

You need a heap of clear on the car (4L) as you'll and up sanding about 2.5 litres back off the car to get it shiny.


All of this actually means less work for us to get done before DOVW as we won't be buffing at all for some time.


With regard to the plastic bumpers, I got all the stuff to do it. Black stuff which goes on with the spray gun and and aerosol pack of primer.



The less paint the better
The primer is very thin and only one coat should be used.
The top coat should be applied as thin as possible

Lambswool pad on the polisher is fine when the time comes to polish the clear coat, you clean it by running a screwdriver or similar against it while it's spinning. (Away from the car obviously)

I'll add more to this if I remember any more.

Pete

Can we get this post stickied? Its pure gold!

[Peter Jones]

Got the colour rubbed back today, if the weather holds we'll be spraying the clear tomorrow.

Pete

[Preen59]

:bigok:

..............

[Peter Jones]

2/3 of the way through the clear now. A few kamikaze bugs have decided to immortalise themselves in the clear, but no biggies so far.

Pete

[Peter Jones]

Exhausted now, I was spraying that clear for hours today.

Did the bumpers too.

Put a few bits back on already.

Entered it in DOVW! Next weekend's gonna be busy! 3 cars to prep.

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050089-1.jpg
http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050091-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050096-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050097-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050099-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050110-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050113-1.jpg

Oh, did I mention that the headlights are a common part that you can still buy new?

It's an unusual setup, the outers are low beam and parkers only and the inners are the high beam.

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050117-1.jpg

Front grill has a silver paint strip that needed re-doing.

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050119-1.jpg

I'm not going to bother making anything work for DOVW, just enough so I can drive it off the trailer.

Pete

[Preen59]

Looking good, Pete. Really good. :cool:

[greasykitchen]

Good to see the progress.

And I spy a beetle in the background :D

[Preen59]

And I spy a beetle in the background :D

Me too.. 1500?

[Jarred]

Me too.. 1500?

36HP! all the way. hopefully it'll be ready for next years DOVW aye Pete?!

Passats looking good!

[Peter Jones]

That beetle's been in the background for way too long :)

The pan is done and we have most of the bits now, it's a '59, semaphores, big back window, "snow flake" tail lights and 36 glorious horsepower.

Pete

[hiho]

Beautiful work Pete, well done!

[Peter Jones]

Getting there, trying to get a least a few small things done each nidght after work.

Got the grills and front bumper in tonight.

Installed a NOS Driver's door handle and re-keyed a S/H one to match for the passenger side.

Converted a RHR door handle to LHR.

Door handles are all the Chrome type but there's a mixture of "push in" and "push down" handles because of the mix of late and early doors. Took a bit to come up with a complete set.

Already had a stockpile of new handle gaskets to go on.

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050225-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050226-1.jpg

There's still a chrome trim to go on that bumper yet.

Pete

[Preen59]

Wow. Just wow. That looks sooooo nice. :bowdown:

[gldgti]

:bowdown:

looks real nice pete. marvallous!

[Peter Jones]

Real busy weekend, I've fogotten half the stuff we did.



Screen in
Bled brakes
Bonnet on
Boot on
Gutter trim on
Bumper trim on
all door handles fitted
Rain tray guard painted and fitted
MK2 wheels put on.
wiper motor lubed up and back in.
Fuel tank back in
New underbody fuel lines. (Had to make a reducer too)
tail lights in.
Door rubbers back in
Boot rubbers back in
Boot wiring re-instated
replace one rounded brake bleeder nipple
repair/replace damage chrome trim on passenger window.
Fitted NOS mirrors
Fitted sun visors and mirror.
Most of the door cards are back in.
re-wired engine fan and tested
Put fuel in tank and started car.
Assembled console
Fitted interior light
New bonnet cable
Red seat covers
Cleaned and fitted coolant recovery tank
Cut a piece of carpet for rear deck.
Vacuumed
Amouralled
Boot badges painted and fitted
And I clipped the dog too.

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050227-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050228-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050229-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050231-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050232-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050233-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1050234-2.jpg

I'll probably sort out a few other minor bits and pieces but that's mostly it before DOVW.

Pete

[GoLfMan]

that looks tops Pete. Sorry I couldnt help today :(

[Peter Jones]

That's cool . We actually roped in our door to door hairdresser to assist with the boot and bonnet fitting. (I got a haircut too!)

Pete

[Preen59]

Wow.. That looks really nice Pete! :cool:

[greasykitchen]

Beautiful! And a custom rear badge too! Doin' it in style. :cool:

[Peter Jones]

Beautiful! And a custom rear badge too! Doin' it in style. :cool:

We've got a box of different badges for this car. Is was a diesel originally so there's a Passat GLD badge as well as Passat GLS and a few dasher badges.

The DOVW entry form needs a rego number to tell the cars apart so we're using a set of US plates just for fun, the Dasher badge seemed to go with the theme.

(For those of you who don't know, the B1 Passat was marketed in the US as a Dasher.)

The fuel injection bit doesn't apply of course but so what!:banana:

Pete

[16v_kid]

Pete, great stuff!

did you cut it yet? (cut N polish?)

[mikinoz]

The fuel injection bit doesn't apply of course but so what!:banana:

Pete

I was about to ask, because you slipped that one past me in your hit list from the weekend! :emo_baghead:

[Peter Jones]

Pete, great stuff!

did you cut it yet? (cut N polish?)

Nope, too soon. We're going to wait a month before cutting and polishing.

Pete

[16v_kid]

Nope, too soon. We're going to wait a month before cutting and polishing.

Pete

I just brought a car, fiat 124bc, the guy had it for 23 years. He painted it 20 years ago and never cut and polished it.

Now i brought it, and cut n polished it, properly but. Took me 5 days. You should see the finish on it!! looks like new!

so i reckon, the longer you wait the better.

[Jarred]

looking good in person Pete, should be right smart once its all back together and polished nicely.

need to do something about that tail pipe though!

[VW VR6]

Great job ... great post ... and great CAR

[nick1234]

Mate,

this is such a gorgeous car! I adore people that save cars like this one - a real classic! It must have been a lot of fun restoring it! I've done some work on my Golf Mk2 today but I am just not as gifted as you are! Sad to see that you are moving it to Washington state! :0)

[Peter Jones]

need to do something about that tail pipe though!

Yeah, the whole exhaust system needs to go!

Might just paint that one silver for DOVW.

Pete

[velly_16v_cab]

wow pete this car looks great.
you have really done a great job! cant wait to see it on the weekend :banana:

[DubSteve]

Fantastic work there Pete! Like everyone says I can't wait to see this car on the weekend, will be great to see this in person!!!

[Peter Jones]

Got the boot lock in last night.

Doesn't sound like much but we had to drive to Springvale and pick up the lock from the previous owner at the Red Rooster store he manages.

Even the boot lock has a story!

We've got a couple of NOS ones but they're for earlier models, again this lock is a one year only part!

Gaskets for the lock are of course impossible to find so we dropped in to Bunnings with the lock on our way home and scoured the plumbing aisles. We came up trumps with a suitable washer from a tap body.

Pete

[vinderliker]

I know how you feel about scarce parts for these rare beasties.

[cram]

looks a treat - i love the shape of these

[Peter Jones]

Bit of progress, Jodie's been wet sanding the clear, this week we started on the polishing.

http://www.vwwatercooled.com.au/forums/images/imported/2010/01/P1050824-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/01/P1050825-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/01/P1050832-2.jpg

Just waiting on some brake bits from O/S to arrive before I get stuck back into the mechanicals.

Pete

[Peter Jones]

Here's a few Photos from Day of the Volkswagen I've been meaning to add to the thread.

http://www.vwwatercooled.com.au/forums/images/imported/2010/01/P1050239-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/01/P1050244-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/01/P1050333-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/01/P1050392-2.jpg

Pete

[16v_kid]

Is it lowered a tad or is it just me..

[Peter Jones]

Not by me, probably just old age sag.

Pete

[gldgti]

wow, lady in red :-)

looking great pete. truely beaut!

[mikinoz]

Sort of off topic, but the plastic bars on the mk1 look fantastic.

Where is the secret hiding place for such good quality plastic bumpers? I'll but them new if needs be, those ones are awesome.

Oh, and the passat is ok too! :)

[Jarred]

looks a treat with the polishing Pete! Much better than my wetsanding atleast :emo_baghead:

[Peter Jones]

Sort of off topic, but the plastic bars on the mk1 look fantastic.

Where is the secret hiding place for such good quality plastic bumpers? I'll but them new if needs be, those ones are awesome.

Oh, and the passat is ok too! :)

Amateur plastic welding, bumper spray and a new chrome strip. Really helps with the appearance of the car.

Pete

[vinderliker]

Brilliant Pete. I wish mine looked so good.

[Peter Jones]

Frank got to go to SEDF.

There was even a cousin to keep him company.

http://www.vwwatercooled.com.au/forums/images/imported/2010/02/P1050919-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/02/P1050921-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/02/P1050927-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/02/P1060005-1.jpg

The car got a fair amount of interest and we met some other passat owners, by the sounds of it there's a few more of these out there in backyards and garages that will be saved. :)

Pete

[Peter Jones]

Getting back into this again.

Needs brakes for registration.

The wheel of choice is off an Audi 80 , 14x6 Ronal, but they're 4 x 108 so I'm doing a PCD conversion along with the brake upgrade.

Being a one off model things are likely to get interesting under there, the car already has Nissan and Ford brakes on it :duh:

Backs are first as I've got shocks to go into the rear at the same time and re drilling the rears is easier.

The rear brakes should have been MK1 drums I guess but they're currently Nissan and soon to be MK3 Discs.

Here's a drilled and tapped disc.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340160-1.jpg

Making up the jig to transfer the new PCD took me most of the morning it's hub and bolt centric. This is the template sitting on a disc.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340161-1.jpg

Cleaned up the surface rust with a spot of bead blasting.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340162-1.jpg

Cleaned some callipers too.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340164-1.jpg

Backing plates are going to need some panel beating! Think the donor car got dragged without it's wheels at the wreckers

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340166-1.jpg

Passat handbrake cables are quite different to Golf ones, it SHOULD be easier to adapt to the MK3 setup. [fingers crossed]

Pete

[Preen59]

Nice work there, Pete. Good stuff! :)

[Jarred]

Glad to see Frank is finally getting some loving!

[Peter Jones]

Yeah, it's been to two shows on a trailer now, bout time it got self propelled!

Pete

[Peter Jones]

Bit more progress today.

Picked up a new set of strut inserts.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070231-1.jpg

Already had a set of NOS De Carbon units for the rear.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070232-1.jpg

That's one of the KYBs I extracted from the car in the top of the photo.

Only got the rear ones swapped out today as part of the rear brake re-conversion.

[Peter Jones]

I sad re-conversion - here's what I was faced with. Nissan Pulsar rear discs!

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070233-1.jpg

So I put some MK3 discs on re-drilled to suit 4 x 108 Audi Ronals.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070237-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070240-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070241-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070244-1.jpg

The hand brake cable will be interesting, I'm off to the wreckers tomorrow for inspiration and a crawl about under some Audis.

[Peter Jones]

Wouldn't be much fun without some wheels on there so we cleaned up a pair of the Ronals and did some tyre swapping.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070248-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070252-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070253-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070254-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070255-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070256-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070263-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070264-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1070265-1.jpg

I've got the centre caps for those, just waiting for the paint to harden. :)

[Preen59]

Good work there, Pete. The new wheels look nice. :)

[Peter Jones]

Cheers Chris, still a little bit of work there yet.

I'm not happy 'bout the bolt length, I'll have to scrounge up a set of BMW ones which are a bit longer.

Handbrake cable will be fun, Passats are nothing like Golfs. There's a Yoke in the centre of the car that pulls a cable that runs between the rear wheels sort of a Y arrangement.

I might have to manufacture a custom cable - hooray! I can do it but it'll take a few hours to turn up ends for the bowden sheathes and crimp in a new inner cable.

Converting the front brakes to 4 x 108 will be the challenge. There's quite a few complications and approaches there.

Pete

[Jarred]

Looks like I wasn't the only one working late into the night tonight!

Looks tops with the wheels,

and MASSIVE thanks today for your help as well!

[Peter Jones]

Time now to finish off the handbrake cable tomorrow and pull the front suspension apart.

Needs struts, strut bearings, wheel bearings and all new brakes!

Think I'll use the brakes I just pulled off white.

Pete

[Peter Jones]

OK as promised I got into the handbrake cable conversion today.

These are the ingredients.



Original cable removed from car.
Cable set from some sort of Audi I found at the wreckers.
cable swaging tool.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340193-2.jpg

After much careful measuring I cut down the disc ends of the Audi sheaths. I'd already cut the handbrake ends off the inner and pulled he inners out of the outers.

The two end pieces just above the sheaths are the chassis ends of the original cable. I just pulled them off the original sheath. They're lightly crimped to the sheath so I drove a 10mm drift into them to open them back up again to go onto the Audi cables.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340195-1.jpg

and here they are on the ends of the Audi cables. Lightly crimped with a bench vice.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340196-2.jpg

Inners and cotton reels assembled.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340197-1.jpg

Here it is after the test fit. I used a temporary clamp to gauge the length and keep it all together .

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340198-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340200-2.jpg

I trimmed the cables either side of the temporary camp and swaged in a lap splice.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340201-2.jpg

Assembled cable.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340202-2.jpg

Some shots now of how it fits in the car.
This is the yoke to the handbrake lever. You can see that the rod running to the handbrake lever had been lengthened to make the drum cables longer to work with the Nissan brakes .

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340203-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340204-2.jpg

[Peter Jones]

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340205-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340207-2.jpg

All fits nicely inside the wheel. :)

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340208-2.jpg

[Peter Jones]

Another item that needed attention was the traverse suspension arm under the rear. The big impact that took out the guard obvioulsy bent the thing.

Here it is beside it's replacement from an earlier passat.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340210-2.jpg

That can't have been too good for the rear tracking.

[Peter Jones]

With all of that done I pulled the front struts to get started on those.

Here's some pics.

Awesome Cortina brake conversion (Not!)

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340212-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340213-1.jpg

But "How do you make them fit?" I hear you say..

Easy just slot the mounting holes! It'll be right if you use really big washers too!

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340215-2.jpg

The other side was even more professional.

Both sides had bend thinned down to clear too. Some precision angle grinding going on here!

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340218-1.jpg

Ever wonder what a Passat strut looks like?

Wierd huh? Takes the bigger wheel bearings of the MK2/3 size.

Strut and spring much longer than Golf.

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340216-1.jpg

Mmmm Cross drilled solid 239mm goodness...

http://www.vwwatercooled.com.au/forums/images/imported/2010/04/P1340219-2.jpg

[Peter Jones]

OK. It's been a while. There were some tricky bits to sort out.

Springs are signature red now.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070411-1.jpg

In the course of figuring out stuff I pulled a CV and discovered it was smashed internally , here's the one that went back in.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070412-1.jpg

Strut with new Pedders insert, new wheel bearing and freshly converted 4x108 drive flange. Bump stop and cap are MK1 Golf.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070414-1.jpg

New strut bearing going in , they're the same as MK1 Golf.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070416-1.jpg

Re assembled struts with redrilled 239mm vented discs. These were off White (Wreck to Race car thread).

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070425-1.jpg

[Peter Jones]

Ball joints on these are quite different to Golf. The mounting holes are slotted to allow camber adjustment as the strut is in one piece with the hub.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070426-1.jpg

Trouble is if you don't do the nuts up properly this happens

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070433-1.jpg

This one was really bad and they'd butchered the ball joint too to try and keep the bolt in the undamaged part of the slot.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070435-1.jpg

Welding was in order, They're not heat treated and just pressed steel so welding is fine.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070436-1.jpg

Bit of filing and grinding and mandatory rattle can painting and good as new.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070438-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070437-1.jpg

You can see where this ball joint had been moving around. Would have made for some interesting steering.

Compared to the new one it's clearly worn away around the bolt hole.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070428-1.jpg

There were a mixture of bolts in there of assorted sizes and grades, I'll have to pop down the bolt bar on the weekend and grab some new ones.

[Peter Jones]

With work on the suspension halted until I can get some new ball joint bolts it's time to take a look at the cooling system.

We've never really run it for more than a few moments at a time and the temperature climbs pretty quickly.

The radiator is mechanically stuffed, all the brazed joints are broken and leaking. I've got a newer plastic header one to go in.

As we pulled the hoses off we discovered they were crunchy. They feel like they're lined with cornflakes. Looks like someone's used one of those radiator sealat products and it's coated the insides of the cooling system. Whole system will have to go.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070456-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070455-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070453-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070452-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070451-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070450-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070449-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070448-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070447-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070446-1.jpg

[Peter Jones]

A couple of other photos I forgot to work into the storey line.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070445-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070444-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070443-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070442-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070441-1.jpg

We found these retro Audi wheels the other day, they're also 4x108 so we're going to clean them up as a second set.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070440-1.jpg

Pete

[DubSteve]

Nice work mr Jones definately looking good :)

[gldgti]

Good work pete - I have a Passat radiator taking up room here that I dont want. Its from a diesel and is also a thicker, more dense core. Its yours if you want it. If you're coming to nat's PM me and i'll bring it along, or maybe one of your VIC buddies will take it home for ya???

[Jarred]

Looking good Pete! How far off roadworthy and rego now?

[Peter Jones]

Brakes went on today.

See the holes in the ball joint plate and A Arm? that's how you adjust the camber. You need VW tool 40-200 to move the ball joint back and forth in it's slots. I had to make one.

How's the offset between the ball joint and the base of the strut? Interesting geometry.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070468-1.jpg

VW tool 40-200 (PJ variant :))

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070465-1.jpg

Audi 80 brakes - well seasoned from racing at Phillip Island and Sandown. Need new brake hoses , these are VW at one end and Ford at the other. There's a pair on the way from GAP along with all new radiator hoses.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070466-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070464-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070463-1.jpg

[Peter Jones]

Replaced most of the engine mounts today too.

Removed the last remains of the air-conditioning system.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070469-1.jpg

Snub mount was stuffed. The bracket is different to the earlier passats as the engine bay is longer.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070470-1.jpg

New mounts either side of an old one. Much easier to replace than Golf ones. The engine sits up a bit higher in the bay now.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070471-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070472-1.jpg

One of the bolts holding the front mount bracket had been snapped off in the block. Right angle drill comes in handy here.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070474-1.jpg

As the drill bit broke through it snatched the bolt and wound it nearly all the way out for me. I was able to unscrew it with pliers from this point.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070476-1.jpg

How's that for straight shooting? Not bad considering the access issues. No thread damage what so ever. A lucky save.
http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070479-1.jpg

Mount back in place.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070477-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070480-1.jpg

[Peter Jones]

Some OEM NOS wheel locks to keep those Audi Ronals safely attached.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070482-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070481-1.jpg

[Peter Jones]

Looking good Pete! How far off roadworthy and rego now?


Not too far away now, just got to fix the plumbing and the wiring.

[16v_kid]

Good work Pete!

[roccodingo]

Interesting to see VW was welding the front hub assemblies back in the day ( as opposed to the forgings the Mk1's use) making me think about producing lowered front hub assemblies for the Mk1....

Other trick with the drilling studs out Pete is to use a LH drill bit and reverse drill, comes out the same side from which your drilling ;)

Can you PM me the heads up on those wheel locks bud , interested in a good few sets for the increasingly rare wheels here...

[Peter Jones]

Can you PM me the heads up on those wheel locks bud , interested in a good few sets for the increasingly rare wheels here...

Just got lucky on eBay I'm afraid. They do seem to be a genuine thing though. MK3 era. Try hunting down part number 535 698 137 They're M12 x 1.5 x 23.5 "Set of wheelbolts, anti-theft."

Pete

[Jace]

How's that for straight shooting? Not bad considering the access issues. No thread damage what so ever. A lucky save.
http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070479-1.jpg


Damn I could use aim like that!

Wanna come drill a few sheared bolts out for me? :D :rolleyes:

I love the work you're doing.

[Peter Jones]

More progress and a whole bunch of new stuff into the car this weekend.

VW Australia's very last B1 Radiator mount.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070487-1.jpg

Recent diesel radiator

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070499-1.jpg

New water pump

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070497-1.jpg

and housing

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070496-1.jpg

a bunch o stuff.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070484-1.jpg

Didn't get round to putting these in yet. They're the inner tie rod ends, a rare find off US eBay.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070485-1.jpg

These are an even scarcer item, the tiny clips that hold the chrome trim surrounding the windows.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070493-1.jpg

[Peter Jones]

Got the front brake hoses in too, one of them was a bit stubborn to undo.

Brakes bleed up OK and the pedal feels good, but I'll probably do a MK3 booster conversion after I've driven it.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070489-2.jpg

These callipers are going in the bin now!

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070490-2.jpg

[Peter Jones]

I was going to fit this new heater valve too but ended up using a Golf one as the orientation of this one was all wrong. Must have been setup for a LHD car I think.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070491-2.jpg

[Peter Jones]

The entire cooling system was pretty horrific, I kept finding worsre and worse stuff.

Here's some.

This is a spark plug that was used to block one of the lines.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070505-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070495-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070494-2.jpg

[Peter Jones]

and a few engine bay shots of it going back together.

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070502-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070501-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070500-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070498-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/05/P1070486-2.jpg

After all of this I got all the lights working too.

Next is to finish up restoring the engine fan and get it back in there.

[Jarred]

great work Pete! light at the end of the tunnel must be getting brighter!

[Peter Jones]

Cooling system all sorted now and it's back on its wheels.

Seems to drive OK, issues with the cluster and dash blower.

I think I'd best put a MK3 booster in there, the 18mm m/c isn't going to cut it. Otherwise though the brakes seem to work.

Pete

[Jace]

Loving this rebuild. As with all your builds you're doing a damn good job making an old car newer.

Is that a Uniflow air filter? Standard Solex carb. (same inlet size as Golfs)?

Great job. Keep it up.
But I suppose you don't really need anybody cheering you on to get a job finished. :)

[Peter Jones]

Is that a Uniflow air filter? Standard Solex carb. (same inlet size as Golfs)?

That's a Ramflo filter sitting atop a Weber DCD carb.

Thanks for the kind words :)

Pete

[Peter Jones]

Righto, knocked over the booster conversion today.

I'm not going to write up a "How to mod a MK3 booster for one of only 3 remaining B1 facelift Passats thread" You can read about it here instead. :)

The usual suspect.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340240-2.jpg

Master cylinder off, and looks like it's long overdue, the booster is full of brake fluid!

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340242-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340243-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340249-2.jpg

Heaps came out when I drained it.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340251-2.jpg

[Peter Jones]

It's worth pointing out here that Passats are a bit different here and this model in particular.

The transverse rod that actuates the brakes runs inside the firewall here's a few pics of the mechanism.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340245-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340246-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340247-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340248-2.jpg

Much the same end as the MK1 Golf booster really.

[Peter Jones]

Firewall cleared off.

I trial fitted the MK3 (Seat Cordoba) booster about now and it fitted up fine despite being a bit bigger in diameter.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340252-2.jpg

Here's a Seat Cordoba booster ready to be modified.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340253-2.jpg

The Passat booster has an adapting collar on it which needs to be opened up a bit to sit over the neck of the MK3 booster.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340254-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340255-2.jpg

OK classic PJ style MK1 booster mod now.

Chop off the ball end.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340257-2.jpg

Turn a M10 x 1.5 thread down the shaft.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340259-2.jpg

Of course you measure the old booster's clevis height and set up the new booster the same.

Before you know it, you've got a modern booster for your B1 Passat.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340261-2.jpg

[Peter Jones]

Installation is the opposite of removal ;)

New booster just bolted straight in.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340262-2.jpg

Now the Cordoba m/c only has 2 ports so I'm using a couple of T pieces along with a pair of the much sought after 16v Scirocco portioning valves for the rears.

Leaves me with a couple of gaps to fill in the plumbing so I made a couple of short lines up.

This is a really neat flaring tool I picked up from eBay, Awesome quality and a perfect flare every time.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340265-2.jpg

Cheapo bender to form the pipe up a bit.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340266-2.jpg

And all together again.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340267-2.jpg

The fluid reservoir is a bit tall, I can't quite get the level sensing cap on there but it clears the bonnet OK with a MK1 reservoir cap on it.

[roccodingo]

Looking good Pete, love how the brake relay rod is inside the car, just to make it even more of a headache..;)

[Preen59]

Way to go, Pete. Nice, clean and tidy job. :)

[Jarred]

Good work Pete! top notch as usual!

[DubSteve]

Once again Pete fantastic work mate, good to see its almost finished :)

[Peter Jones]

Got two new front seatbelts and fitted them today.

Fitted up a brake switch off the pedal too, there's a hole already there for the switch.

Next is the instrument cluster.

[dubai gti]

Pete,

You've excelled yourself again and are an inspiration to many others of us...if only we had the time (and a lathe...)

Glad Jody wanted to save this Passat !!!

[Peter Jones]

Crawled under the dash and stayed there for most of the day.:duh:

Pulled the cluster, cleaned and repaired all the gauges.

Upgraded to LED illumination too just to brighten things up a bit and take a bit of load out of the cluster circuitry.


http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340275-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340273-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340272-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340271-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1070540-1.jpg

We're going to get a dash re skinned once it's back on the road, ignore the cracks for he moment.

Also replaced the ignition switch, I'd patched it up as a stop gap. It was not working when we got the car, the ignition was wired to work off the parkers.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1070541-2.jpg

Found the indicator switch was coming apart. One of the cast posts that gets peened over to keep the mechanism together had snapped off due to years of yanking on the high beam.

I drilled and tapped it for a M3 Screw. Fiddly stuff but achievable.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1340276-2.jpg

Then I spent the next two hours getting the horn to work. What a right PITA!

Restored the dash fan wiring too, it had been 'modified' because of a once fitted a/c system.

Cable that operates the heater valve looks to be stuffed too, hopefully a golf one is the same length.


Nearly there....

[Peter Jones]

Here's a few more photos that were taken today.

The setting sun made for some interesting shadows.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1070548-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1070549-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1070550-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1070551-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1070557-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1070556-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1070555-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/P1070552-1.jpg

[Jace]

I'm starting to think it's not a MK1/B1 without a cracked dashboard.
It's a shame they aren't a whole lot more fixable!

[Passatts]

How's the project going since these photos

[Peter Jones]

How's the project going since these photos

Not much has progressed in the last 3 hours, the project's gone a bit of a hiatus as was was spending time on my race car.

Those photos were taken today dude!

Pete

[Jarred]

top notch as always Pete!

(I want that steering wheel!)

[Peter Jones]

(I want that steering wheel!)

It's about 3 foot across and the steering's about 4 1/2 turns lock to lock, it's like steering a boat :)

[roccodingo]

I want that steering wheel!

75 Scirocco is the same..., Is that where you got it from Pete ??

[Peter Jones]

Came with the car along with a smaller sports wheel in exactly the same style. The early Audis had 'em too.

The boss is different to MK1 though as these cars have two contacts for the horn circuit.

[Peter Jones]

A couple of bits and pieces today.

New washer bottle.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/IMG5D-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2010/06/IMG5D-2.jpg

And replaced the inner tie rod ends which was much harder than it should have been.

We stumbled across a new set on eBay, and seeing as how I'd done the outers already and the car's booked in for a wheel alignment on Thursday we thought best to get these in now.

Old vs new.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/IMG5D-3.jpg

Wheel alignment and exhaust on Thursday then roadworthy and reg.

[Peter Jones]

Got the wheels aligned today, they were well out after all my changing of stuff up front.

Then dropped it off at Unique Exhausts to get the pipes fixed up.

The chap there actually bent the rear pipe from memory of Passats he'd worked on years ago!

Now it's all 2" from the downpipes back, through a resonator and into a triple flow muffler.

It's on a 28 day permit as of today, next step is roadworthy, then Reg.

We gave it a bit of a run down Eastlink after the exhaust was fitted (Toll ways are free to permit holders ) and it's a really nice thing to drive, plenty of get up and go out of the 1600 and a great ride.

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/2ajq1sl-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/rvveip-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/2qxb51d-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/9zohll-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/mrg5zm-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/1128yv8-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/210x106-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/10770qo-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/2wnpon7-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/nccfgo-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/1z70w07-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/06/nr0sya-1.jpg

[Jarred]

Good to hear Pete!
She's looking great too. Sorry, he. lol

p.s. Get some black rattle can onto that underside there.

[16v_kid]

Model post!

Well done Pete.

[velly_16v_cab]

stunning...purly stunning

[Peter Jones]

Here's some video we shot on Eastlink. We were checking the speedo accuracy and listening for general rattles and such on the way back from the exhaust place.

VIDEO (http://s737.photobucket.com/albums/xx17/vwdasher/videos/?action=view&current=NoSubject_24-06-2010.mp4)

[dubai gti]

looking good...yet again..love those wheels, very smooth!!

[Jace]

That looks amazing Peter.
Great job. The US plates suit it. :emo_baghead:

[Peter Jones]

That looks amazing Peter.
Great job. The US plates suit it. :emo_baghead:

Thanks everyone!

We sort of forgot the US plates were on it. :) when we were driving around.

It's on an unregistered permit so I don't suppose it matters. I wonder what the eastlink operators will make of it when they see the photos!

(We did check about driving under a temp permit on eastlink and we were told it was OK.)

[GoLfMan]

top notch Pete. Really does look great :)

*tips hat*

[greasykitchen]

Good stuff. When I first started the video I thought it was of you racing in the MK1 - going by the sound and the acceleration!

Nice car, and I like the 'Work in Progess' sticker.

Cheers

[Peter Jones]

Just got the reverse lights working! It took 4 hours!

The reverse switch in these things is in about the most inaccessible place possible.

The terminals on the switch had broken loose and I was able to re-attach them with solder but the innards were stuffed too.

The body of the switch is crimped together but I managed to pull it to bits, clean it out, polish up the contacts and crimp it back together again.

Had to re-route the wiring too as it was fouling on the steering rack.

After all of that I still had no lights and tracked that down to a simple blown fuse.

Also replaced the front door rubbers with straight off the shelf pinch weld from Clark rubber. Perfect fit!

Pete

[Peter Jones]

After working through bunch of tidy up stuff this week, Frank just passed his Roadworthy!
Registration is booked in for Thursday.

Some of the stuff that I've worked through this week.



Restored and fitted battery clamp.
Pressure washed gearbox and undercarriage.
Welded in new fuse box mounting bracket.
Fixed one door lock
Repaired two window regulators
Fixed the wiring faults that arose from unplugging the fuse box to weld in the new bracket!
Connected the check straps on all doors
Bled the brakes (again)
Replaced the indicator stalk with a brand new one (from Israel!)
Replaced one of the rear seat belts.
Installed handbrake cable retaining clips
Glued down a dash mat to cover the cracks (temporary fix)
Fixed the horn again!

[Peter Jones]

We were going to move the car about the driveway and it wouldn't start.

Turns out the starter wire had been snagged by the steering arm and pulled into the block.

Not for the first time by the state of the wire.

I cut back the damaged section and replaced the wire to the starter solenoid.

On a Passat this wire is very hard to see as it runs under the exhaust manifold.

It is also exposed to extreme temperatures as it runs so close to the down pipes.

I made the replacement connection from silicon insulated cable to take the heat, the only piece I had lying about is usually used in RC cars.

Also had to replace the vacuum hoses to the brake booster as they had worn through against a sharp edge on the battery tray.

http://www.vwwatercooled.com.au/forums/images/imported/2010/07/IMAG0020-1.jpg

Frank went to the park today too.

http://www.vwwatercooled.com.au/forums/images/imported/2010/07/1znu1qu-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/07/5dpabq-1.jpg

[Peter Jones]

Just a reminder from page 1 of how this car started out.

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320585-1.jpg

[roccodingo]

Looking great Pete,

For heat applications I usually run the cable through some fibreglass wiring flex conduit, should be able to get some at your auto lekky supliers, used all the time on heavy equipment wiring.

[Peter Jones]

Looking great Pete,

For heat applications I usually run the cable through some fibreglass wiring flex conduit, should be able to get some at your auto lekky supliers, used all the time on heavy equipment wiring.

Cheers Grant, I know the stuff you're referring to. I didn't have any to hand today, I'll have to pick some up during the week.

Pete

[Jace]

As usual, you've done damn well.

[DubSteve]

Looking great Pete top work as usual :)

[Peter Jones]

News just in... Frank's registered!

Coming soon to a street near you!

[DubSteve]

Congratulations Peter, good to hear you another registered and tearing up the street :D

[Jace]

Congratulations! Awesome work.

[Peter Jones]

Random photo of the day..

http://www.vwwatercooled.com.au/forums/images/imported/2010/07/4v1myc-1.jpg

[Preen59]

So cool mate. I hope you're proud of that car. You should be!


.... Oh and the Passat isn't too bad either. :P

[Peter Jones]

The Passat certainly gets some strange looks on the street.

When people see the car they get this puzzled look on their face, then they spot the VW on the grill and look even more puzzled!

The Dasher badge on the back just about makes their heads explode :)

[DubSteve]

Haha good stuff Pete, brilliant looking car :)

[thestu]

great work pete!!!! fantastic job!

can't wait to get my licence back to come over for a visit :)

Stu

[Peter Jones]

Time to up the volume!

http://www.vwwatercooled.com.au/forums/images/imported/2010/07/P1070813-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/07/P1070811-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/07/P1070810-1.jpg

[Golf Loon]

Love your work Pete. Go the Air Horns.

[Peter Jones]

Spent most of the day stuffing about with speaker mountings.

The parcel shelf had been butchered by a previous owner so I re-used the holes as best I could.

That area of the deck isn't flat so I had to do some not so high-tech carving of MDF to make up some spacers.

The car is to be re trimmed own the track, I'll probably rethink this approach.

I sealed the spacers down with silastic but stuck duct tape down prior so it'll be easy to remove.

Speakers are fastened to the deck with M4 nutserts.

http://www.vwwatercooled.com.au/forums/images/imported/2010/08/P1070820-1.jpg

Temporary carpet back in place. Grills will go on the speakers when the final trim has been done.

http://www.vwwatercooled.com.au/forums/images/imported/2010/08/P1070821-1.jpg

Air supply for the horn mounted up neatly out of the way behind the left hand tail light.

http://www.vwwatercooled.com.au/forums/images/imported/2010/08/P1070819-1.jpg

Just visible behind the grill :)

http://www.vwwatercooled.com.au/forums/images/imported/2010/08/P1070814-1.jpg