MK1 project No. 2

[ross_m]

As some of you know I got myself a winter car. A completely original '81 CL. 77K with service history up to 67K. A bit rusty but it had never been welded. Its all cosmetic.

Some pics of it on stilts when i got it home. G60's off my red one were on for the MOT
http://www.vwwatercooled.com.au/forums/images/imported/2009/11/PC190021-1.jpg

The bumpers were really faded but straight so i sprayed them black

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1090014-1.jpg

Masked up and sprayed
http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1090022-1.jpg

Turned out really well I think

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1150028-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1150030-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1150031-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1150029-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1150027-1.jpg

Love the red interior against the white. :)
http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1090020-1.jpg

This lot will be going on today if the rain ever stops :banghead:
http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1150015-1.jpg

[Jarred]

I like it already Ross. I've been waiting for you to pop your head up and post up some work on the winter car. It's looking good already.

Still love your 2 door though! :cool:

[funkamedic]

Still love your 2 door though! :cool:

x2!!

they're both lookin good mate. 4 door interior is tidy as. what sort of coils are they? i'm risking a flaming here, but what are the wheels? love em!

[ross_m]

Thanks for the comments :)

The coilovers are TA Techniks. £169 delivered through the mk1 owners club! Cheap but they do the job

The wheels are 7x13 ats classics. You dont usually see them all silver. They usually have black in the spokes.

I think next week end I am going to colour code the centres to the red interior to be different. I did a photoshop. What do you think?
http://www.vwwatercooled.com.au/forums/images/imported/2009/11/Untitled2red4copy-1.jpg

Im going out in 2 minutes to fit the wheels etc:banana:

[Water Boy]

Nice work mate! Love both your Mk1's :banana:

[funkamedic]

The wheels are 7x13 ats classics. You dont usually see them all silver. They usually have black in the spokes.

i totally didn't recognise the ATS classics in all silver :emo_baghead:. looking forward to more pics with goodies fitted.

[GoLfMan]

wohoo!

love it, if your 2 door is anything to go by, its going to look awesome :D

[ross_m]

Thanks, what do you think of the red wheels? Im 99% sure i'll do it but just wondering what people think.

I got the coilovers and wheels fitted but it was dark before I could get pics:frown: Will maybe take some tomorrow morning. Looks better than i imagined. Its really low aswell!

[GoLfMan]

I'll reserve judgement of wheels until I see them :) but initial impression is good!

WOOT for low. :D

[mikinoz]

Yes, please do the wheels. :banana:

[Jarred]

i'm a bit :s on the centres. have to see em how they are first :)

[funkamedic]

Thanks, what do you think of the red wheels? Im 99% sure i'll do it but just wondering what people think.

I got the coilovers and wheels fitted but it was dark before I could get pics:frown: Will maybe take some tomorrow morning. Looks better than i imagined. Its really low aswell!

red on the classics should look pretty cool, esp with the white car and red int!!

would you still leave the silver edges like on the standard classics ?

like so :cool:

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

or maybe leave caps black...

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

this could make for some tricky painting tho ...

[Preen59]

Red with black centres makes for a nice contrast. Very nice.

Great work there dude. I wish i had your motivation.. :(

[ross_m]

I wont be leaving the silver edges. I think they will look better all red.

I had to grind the calipers down to fit the wheels without spacers.

teaser pic:P

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1160019-2.jpg

Will get more at the weekend

[16v_kid]

nice teaser!!

[GoLfMan]

Loooowwww :D

[Jarred]

MOAR! I like it already

[captainvw]

I like how thats sitting:cool:

[Preen59]

Ditch the tail lights, but that stance is phaaaaaaat. :cool:

[ross_m]

whats wrong with the tails? They are standard s2 ones

cheers for the comments

[Preen59]

whats wrong with the tails? They are standard s2 ones



I just don't like the big tail lights but it's only MY opinion dude. Your car. :)

The red centres are different. I kind of like them. I say do it, and if you don't like it, change them back at some stage. :)

[GRN_VAGN]

red centers are hawt, also maybe change the chrome strip along the car to red. just to break it up a bit, will looks nuts i reckon.

[ross_m]

I just don't like the big tail lights but it's only MY opinion dude. Your car. :)

The red centres are different. I kind of like them. I say do it, and if you don't like it, change them back at some stage. :)

I prefer s1 rear lights too. Were there any series 2 mk1's in Australia? Not seen many on her if any at all..

[GoLfMan]

I prefer s1 rear lights too. Were there any series 2 mk1's in Australia? Not seen many on her if any at all..

not that i know of!

[Jarred]

not that i know of!

only Imports I reckon. The latest I believe that we got were a few 81 build GLD's...

[ross_m]

Got the car running sweet today :) Fitted new points, condensor, rotor arm, plugs etc. Also finally got to take some pics with the coilovers adn classics on. :D

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1220031-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1220034-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1220050-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1220049-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1220054-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1220055-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/11/P1220057-1.jpg

Just need to fit the new door and tackle the surface rust over time. :)

[GoLfMan]

dude that looks tops!!!! :D

[Water Boy]

I would so leave it as is...

[GRN_VAGN]

Whats the offset on them rims?

They sit so awesome. perfect!!!

[ross_m]

I think I am going to leave it. I could see me spraying them and then wanting them silver again. I love the way it looks now so yeah, i'll keep it like that. Its the cheaper option too :P

[ross_m]

Oh and the wheels are ET20 all round. Perfect for a mk1. Although the rears could do with some spacers as they tuck slightly more from some angles.

[GRN_VAGN]

ahh nice, now i know what offset to get ;)

Looks good, keep it up mate

[ross_m]

Iv decided to keep the wheels silver and respray the car next year. Red wheels will look better on a mint car

[Preen59]

Looks tops mate. Don't change a damn thing. :cool:

[MiKe1_golf]

yep looks awesome!

what tyres are you running?

[ross_m]

thanks

175/50/13 yoko a539's

[DubSteve]

Any more updates on this puppy :)

[ross_m]

mmmm not really. I have swapped the wheels over from my red mk1 for winter as it was just too low for all the snow on the classics. So its on g60's now

heres a pic of it beside my mates polo

http://www.vwwatercooled.com.au/forums/images/imported/2010/01/4251978905_be510b6245-1.jpg

4 doors really suit g60's for some reason!

Cant wait to get the 13's on again though.

[GoLfMan]

so jealous... I LOVE G60 steelies, we never got them here :(

[ross_m]

so jealous... I LOVE G60 steelies, we never got them here :(

Best steel wheels ever Id say! Atleast you get the 14" mk3 steelies which look almost exactly the same. They look great banded

[ross_m]

One wheel done :)

http://www.vwwatercooled.com.au/forums/images/imported/2010/01/P1010079-1.jpg

Im going to be really picky and get a slightly darker shade so it matches the interior better. Maybe. But I love it! What do you think?

[GoLfMan]

looks good with the red mate :)

[ross_m]

Update!

Wheels are finally done and it now has a roofrack. :)

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1010055-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1010044-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1010047-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1010060-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1010058-1.jpg

[GoLfMan]

looks great mate :D

send those carrado 15" steelies over here will ya

[Whubbsie]

man send me your bumpers mine a rooted and yours are super clean, loving the wheels, I'd chop that roof rack and lowered it though.

[ross_m]

Cheers :biggrin:

I was thinking about chopping the legs down a bit but I quite like it the way it is... I'llmaybe take an inch off it

[Jarred]

needs to be lower! (the roof rack that is! :D)

Seems to have a bit more rust than the last time we saw her :(

[ross_m]

needs to be lower! (the roof rack that is! :D)

Seems to have a bit more rust than the last time we saw her :(

Yeah i only just realised that when I came back on here to update it and saw the old pics.

I think the red wheels distract from the rust a bit now though. I kinda like it looking ratty. So atleast theres a good point while its waiting to be resprayed. Needs a new tailgate and maybe wings. Oh and i replaced the falling apart door which turned out to be the wrong colour but atleast Im not getting a draft through the hole! Nah it wasnt that bad. The door card kept the draft away:P

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1010021-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1010051-1.jpg



Need some trims clips too

[WABIT]

that red int is amazing!!!

dom

[MiKe1_golf]

wow man. looks great. i think your picyness with the shade of red paid off. the dark red looks great!

[ross_m]

cheers for the nice comments

Yeah Im glad I changed the colour. Matches so much better now. I think I'll chop a bit off the roof rack tomorrow. I was going to refurb and paint it but it kinda matches the ratty look of the car :biggrin:

[ross_m]

Got some better pics today with the rack chopped down.

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1010078-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1010081-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1010076-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P10100381-1.jpg

[JoshFair]

your car is such a babe...

[GoLfMan]

nice one fella :D chopped rack looks dope

[ross_m]

thanks :)

I think its needing a new fuel pump now though :( And it definitely need a carb mount as its drawing in air. never mind!

[ross_m]

Rebuild time! Thoughtn id share pics of the work I have done recently to the 4 door.

In the garage and partially stripped. I need it for the winter again and it needs lots of welding to pass its MOT. Most of it was just cosmetic though. Then I'll spray it and stick some new wheels on :cool: Some of this is copied from another forum so it might not make sense... But anyway...

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1651-1.jpg

I got the o/s/f inner wing top finished. Took some pics along the way.

It all crumbled at the top so a lot had to be cut out.

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1435-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1436-1.jpg

Cut out the rot
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1438-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1441-1.jpg

New piece shaped and welded in

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1443-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1444-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1445-1.jpg

Welded this piece in which connects the scuttle to the inner wing
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1446-1.jpg

Then went over it with the flap wheel.
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1448-1.jpg

Just need to make holes and weld in captives for the wing bolts

O/s inner wing is now finished :)

[ross_m]

Cleaned up
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1459-1.jpg

Rot cut out
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1464-1.jpg

New piece welded into the crossmember as it had rusted away completely
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1465-1.jpg

L-piece between front panel and inner wing welded in
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1466-1.jpg

Cut and welded thin strips to mark out the curve
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1469-1.jpg

Corner piece shaped and welded in. I tried to get it as near to the original shape as possible.

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1471-1.jpg

Wing mounting tab piece shaped and welded and front panel repaired
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1473-1.jpg

Just needs skim of filler now.
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1474-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1476-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1478-1.jpg

Gaps looking good.
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1480-1.jpg

Then got the car on skates. Its so much easier to move it about.
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1493-1.jpg

[ross_m]

Finished work on the n/s inner wing and the front panel is now finished. Turns out it was just as bad at the front as the other side. Few pics..

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1500-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1508-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1510-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1512-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1513-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1514-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1518-1.jpg

I decided to tackle the front of the o/s sill

As you can see it was all holed and thin.
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1540-1.jpg

So I cut it all out. And there was a bit of surface rust on the inner sill so i rubbed it down and treated it.
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1541-1.jpg

I wanted to keep the original shape so after making it up in 3 pieces I tacked it all on
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1543-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1544-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1547-1.jpg

[ross_m]

Welded up and ground down with the flap wheel
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1548-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1549-1.jpg

Primed for now to stop it rusting
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1555-1.jpg

The other side is worse. I think I'll need to replace part of the floor....

Also a pic of the finished front panel primed for now.
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1564-1.jpg

And before and after pics of the engine bay. Alloy wheel cleaner works a treat in there :)

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF14231-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF14951-1.jpg

[ross_m]

Update :)

Got more done today. Tackled the o/s rear inner and outer arches. First time I have replaced arches so I didnt know how it was going to go

Rot behind the rear wheel
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1569-1.jpg

Cut out
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1586-1.jpg

New pieces welded in
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1587-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1588-1.jpg

Rot infront of rear wheel
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1568-1.jpg

Cut out. I havent fixed this yet as I had to get the arches on first
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1585-1.jpg

Arch cut out 8O
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1579-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1580-1.jpg

New inner offered up.
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1591-1.jpg

Cut and tacked on.
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1592-1.jpg

Seam welded and ground down
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1594-1.jpg

[ross_m]

New outer cut and offered up. This took ages to trim to the right size but got there in the end!
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1597-1.jpg

And how I left it tonight.. Tacked in position :)

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1601-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1602-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1599-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1604-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1603-1.jpg

Tomorrow I will have to sort the axle mount and finish the sill/inner wing infront of the rear wheel. I hoped to have one side done today and the other done tomorrow but as usual it didnt go to plan!

Oh and I also got the paint etc through the post the other day. Im not sure if its going to be done in time :| My mk1 polos coming off the road on the 1st of september although I could just get it MOT'd and use it for another month or so

[ross_m]

More progress

Pics of the axle mount repairs etc

Crushed and gone into holes
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1567-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1610-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1630-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1626-1.jpg

The arch is now almost finished. Some more up to date pics

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1632-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1631-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1635-1.jpg

Ready for a skim of filler

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1641-1.jpg

Filled
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1646-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1645-1.jpg

Started the o/s arch today but ran out of gas!

And thats that for now :)

[Dub Toffee]

MAAATE thats tremendous, can't believe how much effort your gone to cut all that out.
Looks so much better now hope you don't get any warps from the welds i found it hard to keep patient
and go slow but its worth it hey. Anyway awesome to see the amount of effort here!
keep up the good work!

[Jarred]

Thanks for sharing Ross!

glad to see you havn't forgotten about us! :D

[ross_m]

Ofcourse not :) I come on here quite a lot to see whats happening.

Another update from yesterday. Made a start on the drivers door

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1618-1.jpg

Take one spare GTI door and cut out the bits needed

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1622-1.jpg

Cut to size
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1623-1.jpg

Welded in
http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1672-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1671-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1670-1.jpg

Skim of filler today since I ran out of gas half way through welding the n/s arch so I cant get that finished until next weekend :redfaced:

[Preen59]

Nice work, Ross.

Loving the DIY panel work, mate. :)

[madglf3]

Good work mate, looks like you've got some skills there and the interior is pretty cool too.

Can I ask, are you using a MIG welder, and if so what type is it? Also, what gauge metal are you using for the repair panels? I've got to do some slighly similar repairs to mine and it'd be good to see what you're using.

[ross_m]

Thanks again for the comments

Yep mig welding. Its a clarke 160TM. Highly reccomended by everyone it seems for hobby/restoration and isnt expensive. This is the second restoration its been used for and its still going strong. The metal is 1.6mm thick sheet. Any more questions just ask

[madglf3]

Thanks for that Ross, keep up the good work mate.

[ross_m]

Some more updates

Treated the surface rust on the back panel. Just needs filled and painted. Theres a small dent I'll need to beat out too actually under the o/s light.

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1673-1.jpg

Finished prepping the door.

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1711-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1710-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1705-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1708-1.jpg

And jarred - you may or may not like the next update....

New shoes. Stance achieved with quality street lid and other random stuff :p

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1680-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1682-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/08/DSCF1685-1.jpg

I'll be refurbing them and they'll do for the winter. Colour coded possibly

Sorry to copy but it just happened haha :) Good wheels, good price.

[Jarred]

not like it, I love it!!

Super cool wheels, and pretty rare! tough looking wheels!

Keep up to good work! Makes me miss working on my mk 1!

[ross_m]

Yep, not sure how Im refurbing them yet. Where is your mk1 now?

[ross_m]

Loads more done last weekend.

The n/s arch/axle mount area was worse than the o/s. I'll skip the 'during' pics since its basically the same as the other side.

Axle mount repaired
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1734-1.jpg

Inner and outer arches done
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1731-1.jpg

Sill repaired
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1712-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1727-1.jpg

Front of sill/a-pillar rot.
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1764-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1765-1.jpg

The rust had spread to the floor
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1766-1.jpg

Rot cut out
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1771-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1774-1.jpg

Floor repaired
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1778-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1779-1.jpg

I made this inner sill repair panel
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1781-1.jpg

[ross_m]

Welded in
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1782-1.jpg

Painted in anti rust paint and then waxoyl
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1783-1.jpg

Repair from inside
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1786-1.jpg

Unlike on the other side i have used a section of a sill repair panel. It would take too long to shape it all right and Im running out of time! Its amazing how much quicker it is.
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1785-1.jpg

Ground down
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1794-1.jpg

Found some rot along the sill where water has got in the sill trim clip holes so I cut it all out and again used parts of the sill repair panel

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1787-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1788-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1789-1.jpg

Didnt get a pic of it ground down

And thats pretty much how I left it on sunday

[ross_m]

Tried a wing on and stuck one of the zenders on. I cant decide what to do with them
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1745-1.jpg

[GoLfMan]

nice update dude! doing a sterling job!

What colour are you painting your car? Polish the Zenders!

[Preen59]

Well done, Ross. Keep it up! :)

[Jarred]

white on white would be 80's as! Could be very cool, or very ugly, I think it's a fine line there! lol

However, I have to say the orig finish was pretty fresh in my eyes! (just like in my sig pic!)

[ross_m]

The car is going olde english white. So like the original alpine white but creamier

[ross_m]

I found a caddy in the colour Im painting mine. This is olde english white.

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/314dklj-1.jpg

And heres what im after. Photoshop FTW
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/plancopy-1.jpg

I think it keeps it looking retro. Fully polished is nice but doesnt look as retro I dont think. Plus they are winter wheels so they will be ruined in no time!

[GoLfMan]

that looks great! :D Nice colour choice too

[sports racer]

I found a caddy in the colour Im painting mine. This is olde english white.


http://www.vwwatercooled.com.au/forums/images/imported/2011/09/plancopy-1.jpg


Chrome big bumper? Where do I get one?

Love the way this is turning out and I'm in awe over your welding skills.

[Preen59]

Chrome big bumper? Where do I get one?

It's just a plastic bumper with the chrome inserts.

[Dub Toffee]

IM AMazed at your patience with al those rust spots to work on!!
your putting many of us to shame LOL All the best! i like that color as well! its a little creamier than what ive been planing paint the Caddy
Cool tread on those tyres hey

[Stan]

great work on this.

Typical UK car - , whole bottom 10cms rusted. I admire your persistence and skill, well done.

the old English white looks good

[ross_m]

Thanks again for the comments :) Photobucket has started working again so i have more pics

Lower half of the front panel down to bare metal, filled and then etch primed

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1816-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1820-2.jpg

o/s sill was a bit rotten in the centre and pitted so i welded a new section in.

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1812-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1826-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1838-2.jpg

I then got the windscreen out and started fixing the hole under where the seal sits.

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1796-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1797-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1798-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1800-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1803-2.jpg

[ross_m]

Filled and etch primed
http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1842-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1843-2.jpg

Then I moved onto the exhaust. All the hangers had rusted and fallen off, 3 manifold studs had snapped and the recirculating pipe had rusted off completely from the downpipe so I basically needed a whole new system but thought Id see what I could do.. So for the downpipe I cut up a steel pole from our old gazeebo and welded it on :lol: Perfect diameter

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1835-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/09/DSCF1836-2.jpg

I welded the hangers back on and drilled out the manifold studs and re tapped them. New gaskets came in the post yesterday so its all ready to fit :)

Its come on a lot since those pics but the cameras in the garage and I cant be arsed getting it

[GoLfMan]

awesome work as usual mate :D

[GOLFBALLS]

Yea nice work there Ross. Its great to see some serious body reps being done and put up on here. Its something i'm gonna have to do soon so I'll be going back over this info later;)

Cheers,
Wade

[Domel]

110% respect!

(You should invest in some shoelaces :))

[ross_m]

110% respect!

(You should invest in some shoelaces :))

Haha yeah, thats what happened when the grinder decided to attack my foot

[GOLFBALLS]

So you're cutting out those sections with a regular grinder?

[ross_m]

Only the big cuts or big sections. For the small hard to reach bits I use a dremel or air powered cut off tool.

[GOLFBALLS]

Hmmm, gotta get me a dremel!!

[ross_m]

Theres been a lot of progress lately :) I just didnt upload any pics because im that busy working on it!

Few pics from the last few weeks..

Borrowed an arch roller from stbaz (thanks again!) and I now want one :p Great tool.

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1851-1.jpg

Managed to get a solid door to replace one of mine which was too far gone to bother with and a solid tailgate.

Doors all prepped

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1896-1.jpg

Prep work on the shell pretty much finished at this point

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1885-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1890-1.jpg

And heres some pics from the weekend just passed

All masked up, degreased etc ready for spraying

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1899-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1902-1.jpg

And here it is in barcoat. good to see it all in one colour! Its coming on :)

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1914-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1910-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1922-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1913-1.jpg

Next weekend I'll get it in high build primer.

[antihero3000]

I can't wait to see this finished, it looks like there's a lot of attention to detail going into the build.

[Jarred]

keep it up Ross!

Looking good. light at the end of the tunnel is getting brighter!

[GoLfMan]

inspirational for me! My shell is nearly at that stage too. Keep up the awesome work mate!

What are you spraying it in. 2 pac or acrylic?

[ross_m]

Thanks guys.

Im using cellulose paint

[GoLfMan]

Thanks guys.

Im using cellulose paint

'scuse the ignorance. Whats that?

[ross_m]

Its just another type of paint. A lot safer to use without an air fed mask than 2 pack. Its actually illegal to spray cars with this in the trade now I think. But it is still sold if you know where to look. They just advertised it to be used for other purposes.

[GoLfMan]

Its just another type of paint. A lot safer to use without an air fed mask than 2 pack. Its actually illegal to spray cars with this in the trade now I think. But it is still sold if you know where to look. They just advertised it to be used for other purposes.
yeh 2pack is very dangerous. I might have to do some research on cellulose paint. I need to go paint shopping soon..........

[ross_m]

Now in white high build primer :)

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1926-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1929-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1928-1.jpg

And yes it is very cramped and a nightmare to spray like this :( But theres nothing I can do about that. It looks more cramped in the pics than it is though I think.

With some luck it will be in olde english white by sunday night!

[GoLfMan]

well done mate! Getting me all motivated to paint mine, I'm awfully close too!

[ross_m]

The car is now officially olde english white :D




















http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1966-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1976-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1953-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1952-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/10/DSCF1962-1.jpg

Now its time to put it all back together. The best bit!

[GoLfMan]

awesome stuff cobba! :D

[ByronRichesMk1]

Hells yeah!
So dope! :D

[Jarred]

Good on ya ross! now the fun really begins!

[ross_m]

Well overdue an update I think. The car is almost completely back together now. Screens in, interior back in. Just the bumpers, trim and handles to go on and then MOT.

Pics....

http://www.vwwatercooled.com.au/forums/images/imported/2011/11/DSCF1977-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/11/DSCF1979-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/11/DSCF1978-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/11/DSCF2007-1.jpg


Ive started the polishing. Its looking ok so far. Good reflection but Im never totally happy so i want to do some bits again but thats a job for next year when its warmer

http://www.vwwatercooled.com.au/forums/images/imported/2011/11/DSCF2010-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/11/DSCF2017-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/11/DSCF2020-1.jpg

[Jarred]

Looks pretty good in the pics ross!!

Good luck for MOT!

[GoLfMan]

Looking very nice mate!

[Stan]

great looking car and a very nice job - well done!

Waiting to see the finished product

[hiho]

Amazing work, especially the metalwork

[VdubEd]

Looks great, nice job

[ross_m]

Finally finished, MOT'd, taxed, insured and on the road. :)

http://www.vwwatercooled.com.au/forums/images/imported/2012/01/DSCF2076-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2012/01/DSCF2070-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2012/01/DSCF2067-1.jpg

Hmm I lied, the arch spats and sill trims arent on yet. But it will be finished after that!

[Jarred]

Good work Ross, congrats on getting it on the road again!

[killingwithasmile]

looks great.. fantastic work!!

[ross_m]

Thanks guys. Its good to be driving it again!

[GoLfMan]

looks really good mate, top work! all the motivation I need for my mk1 is right here