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RUSTY'S BECOMES "ROXY" - FINISHED AND FINAL PICS 9/12/13 - SOLD

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Hi all,

From my other build thread, you would have noticed I have brought another mk1 golf gti, that bounced around the forums for months, so i thought being the caring person, I'd take her in and restore her back to factory standards….(or there about’s ). Off i went to Nottingham with the recovery truck and in the space of 30mins of poking and testing, I realized her potential I had brought her for a bargain price. J ……problem was, the misses did not know about it. (Trouble ahead) lol
Here a few pics from the forum advertisement and the day I picked her up.









Strip, assess and Bodywork










Front panel was to messed with and full of filler…..GENWINE replacement top half sourced - thanks  "peter davies"



circular headlight section of the lower half front panel was filled with filler!!!!! no good….




new section, welded in position, headlights & grill test fit…..looks so much better.








Wings removed, inner arches pressure washed & wire brushed clean, and repaired:












lower A post and sill needed attention too…






small surface rust scabs, grinned back, treated, etch primered:



Window A post repair: inner section was soild



Corner A posted - inspected, cleaned, treated and primered:



rear arches - as always, they needed repairing too:



made this replacement section made - hand shaped and a prefect fit for the sill…








all the other rear arches had small repairs also… ;)




Rear Panel was solid apart from the bottom lip to boot floor and top inner edge. Decide to repair them instead of replace the panel. also the spare wheel well need a repair too.




another handmade panel :















Had no other choice but to replace the doors and tailgate….as they were that bad, the structures were rotten! (pictures to follow…..will update again in a few hours)

Last edit: by Swallowtail_uk

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Good grief Man, I'm not sure which one is going to be harder to repair?

A. That car?
Or
B. Your Marriage?

But good luck on both fronts!  :lol:

Sent by a smartphone and not a smartperson!

Play Guess the Asking Price 'SEASON 4' as of Sunday the 29th of October 2017.
https://vwgolfmk1.org.uk/forum/index.php?page=topicview&id=chat%2Fmk1-golf-chat_2%2Fguess-the-asking-price_2

OLD.
https://vwgolfmk1.org.uk/forum/index.php?page=topicview&id=chat%2Fmk1-golf-chat_2%2Fold-guess-the-asking

Ever wondered who's behind the scenes of this forum?
https://vwgolfmk1.org.uk/index.php?page=committee


Mike

There's me building mine 28 years ago, almost finished!        
  
001.JPG       
                                 
Be proud of your VW Golf Mk1, it's very special!

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golfcabrio said

Good grief Man, I'm not sure which one is going to be harder to repair?

A. That car?
Or
B. Your Marriage?

But good luck on both fronts!  :lol:

 :lol:  :lol:  :lol:  :lol:  :lol:  I know that feeling.

Excellent project thread dude, some nice work going on  :thumbs:  :thumbs:

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golfcabrio said

Good grief Man, I'm not sure which one is going to be harder to repair?

A. That car?
Or
B. Your Marriage?

But good luck on both fronts!  :lol:

hmm, we'll when she found out i had another project, she wasn't happy……but shes over it now lol… phew only 2 days of peace…i mean silent treatment.

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smudger1980 said

golfcabrio said

Good grief Man, I'm not sure which one is going to be harder to repair?

A. That car?
Or
B. Your Marriage?

But good luck on both fronts!  :lol:

 :lol:  :lol:  :lol:  :lol:  :lol:  I know that feeling.

Excellent project thread dude, some nice work going on  :thumbs:  :thumbs:

thanks mate.

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Looking good

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Look forward to seeing this progress.

Fair play for taking it on!

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Excellent work lad! Saw this alot advertised glad that awful front is off it…. 

Pardon my ignorance but is the swallow done? 

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looks good i saw this for sale on here and on ebay and i thought about getting it a a long term project :)

whats she like in reality then ?

Scott

South West Regional Host

Previous;
1991 Clipper, 1978 S1 GLS, 1983 Type25, 1989 Clipper GTI

Current;
Zero, zilch, nought, zero, nothing….

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Pipsical said

Looking good

thank you

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Spilz said

Look forward to seeing this progress.

Fair play for taking it on!

thanks mate

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Brad. said

Excellent work lad! Saw this alot advertised glad that awful front is off it…. 

Pardon my ignorance but is the swallow done? 

look, yeah i wasnt a fan of the jetta front end. swallowtail is still at the bodyshop…..it wont be finished for a while yet, however it is in the GOLF MAG this month :)

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arf333 said

looks good i saw this for sale on here and on ebay and i thought about getting it a a long term project :)

whats she like in reality then ?

Scott

not bad mate, all the repair are done, floors mint, sills are strong, factory sunroof only had surface rust…..its in pretty good nick……building with my spare parts…

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replacement tailgate brought of my mate nick.


Replacement doors…..the ones on the car were really rotten with Audi 80 handles, however the car can with another set of door, again with Audi 80 door handles……(i'm not a fan of the hand mod no more) lower lip edges cleaned, treated and primered:



lower edge of the front panel was bent up, looks like it hit a kerb/speed hump or even jack up on…this was heated and straightened - no issues…cleaned, treated and primered:




Sunroof - this was the first thing i checked when i went to see this car……give it a good jabbing with a screwdriver……solid, just surface scabs….. the sunroof panel itself was rotten, the outer seal was shredded and the track - half missing. Thanks to "BERT" - a replacement mk2 golf complete sunroof was purchased.
Still required work ,so ground back to metal, cleaned, treated, cleaned again, tube seam sealed around the joining of metal and primered:






New Stainless steel screws, washers and bolts for the sunroof track:









also had to buy myself a nut riveter, as some of the original fixing on the sunroof had come away- so i replaced all of them…dont seem to have a pic, but will get one 2mo for you.

Now the bit, i was not looking forward too……..removal of the old boot floor,rear panel & sides sound proofing……..what a mess it made….took me hours to clean off….





Clean off….thank god!!! no surprises found under the sound proofing:





my fave pic so far……the muti colour stage of every project :)



This was pretty much the external bodywork done, well my bit anyway…..like previously stated…..i'm not a man of filler and paint work.

Did some homework, while the misses went to stay at her parents for the night: (shh our secret and yes that's the dinner table)
Re-tumbled boot and door locks to match the ignition key:


ENGINE:
The car was a non runner, I'm not sure how long it has been standing or what the problem was with it when purchased. However it turned over freely, so i was happy with that and knew my brother "Del Mahi" would be able to get this car running for me. Once back home, my brother came around with this mk1 spares & tool box and got straight to work.  About 1 hour in and the car started….so what was wrong? ……common metering head pin stuck, fuse board messed with and dead fuel pump.
There were other problems with the electrics, like the fuel pump had a direct live permanent feed, why?…..rear tail lights not working and an old alarm system still wired in, but didn't work.
Manage to buy the fuel pump off my brother for cheap and work out why there was a direct feed to the fuel pump. Basically the relay had fried internally, so some fool, wired it direct. The rear tailgate lights didn't work to faulty bulb holders, i had two spare, so this was fixed too. All that was left was to remove the direct fuel pump feed, cut out the old alarm system and reconnect all the wiring safely……..(solder joins, heat shrink and then electric taped over)
Front head light connections were poor too, this was down to poor connects….so i redone these too, and ripped out the aftermarket electric windows:



Dead fuel pump

these were dead too, new holders ordered:


Car ran fine, as there was no water in the system, still drove it around the yard to check gear……gears were prefect.

So i filled the water up, only to find my feet & floor wet……hmm, so got the car high enough and investigated…..notice one of the core plugs had popped off. So ordered a new old, only problem was in was kind of a tough place to get too:



filled it up again and notice another small leek from the heater valve……so replace this aswell:


after this, the car bleed up fine….once again i drove it around the yard….to check the gearbox and brakes properly :) ..passed the test….. Decided to flush the system clean with water and check the thermostat too. Then i found this:


barely working thermostat……….replaced as well.

Some fool aslo cut the earth strap and starter motor lead down… don't know why? these were replaced too….



Once all above were sorted, car ran fine, no problems……..then one morning…..wouldnt start…….tried everything…..then had to call my brother out again……..i had carried out a small service, oil, oil filter, plugs, air filter etc, but the car would not start…..came down to a faulty warm up regulator and problem with metering head….my brother kindly lent me his of this car, until i got mine sorted. While my brother was working on the car, he noticed the timing was out, so ideal time change the timing belt…..timing was out by 180 degree, hence the rough running of the car. once timed up, the car was flying around the yard!
Changed the crankshaft pulley bolts to stainless steel and alternator bolt was rounded off, so hammered a spine bit into it and replaced it.

 



Mean time, i had brought a set of 5, tarantula alloys with good Tyre's…..


So are the engine was fine, i went back the inner arches and suspension for a refurb:
suspension taken off, arch, cleaned again, re-seam sealed where needed, and painted.





Suspension replaced and refurbed as well as the wishbones,anti roll bars and brakes:





Whilst  taking the anti roll bar off, i manage to twist the brackets……so i made my own out of stainless steel: :)



Skip a few steps and this is the end result: - notice the braided stainless stain brake hoses (goodridge)





Rear arches were done the same too, painted the rear axle, fuel neck (all inspected and where fine)






As the rear anti roll bar was an upgraded one, i source an original ARB, but could get mounts…..so I made these up to out of stainless steel.






Accumulator & fuel pump brackets refurbed: new rubber bobbins, nuts/washers and bolts.







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Amazing work dude, you're a talented fella. She's going to be a minter when complete. :)

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smudger1980 said

Amazing work dude, you're a talented fella. She's going to be a minter when complete. :)

shes going to be for sale as soon as she complete lol, currently in the bodyshop being striped down to bare metal and painted :)

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Ah shame mate. How come you're selling straight away??

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smudger1980 said

Ah shame mate. How come you're selling straight away??

Help pay for my house deposit with massive workshop lol

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Ah ok I know that feeling mate. :(

Shame to see her go so soon after finishing her but needs must eh. Good luck getting it finished and sold.  :thumbs:

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Underneath, treated were needed, resealed and waxolyed










Quick Scotch, mask and then stone chip applied





Next time, bodyshop photos
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