The 'simple engine swap' out of control project (pic heavy)

Hi all,

Would like to share my current project with you.

It started about 5-6 weeks ago, taking up every available weekend, evening and days off.

I got the car, a 1980 1.6 GTI 3dr tin top in black, just shy of 3 months ago. I had no real intentions of doing any work to it for quite some time, certainly not this year at least - but you all know how that goes!


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I got the car from Devon -198 miles away from me, off a guy on the E38 forum, after a lot of drama with it not starting when I got there, she finally fired up and off we went on our way back home, after about 20 miles things were not so sweet and she coughed and farted her way back the remaining 170-180 miles with several stops.

Straight away a new fuel pump was ordered and fitted along with several adjustments and replacement of other bits and pieces and she was running a lot better, still not great but drive-able. I put the issues down to over worn piston rings not creating enough vacuum to lift the flap in the metering head.

That's when I decided to go 16v.

After searching for the right engine, one came up, again on E38. A 2.0l 16v 9A from a Corrado. The mk1 then came off the road and the tear down began…


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When I realised this..


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I thought it would be best if I replaced the front panel, I knew the wings needed changing anyway.
Thought I would check out everywhere else on the car so I knew what was needed..


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So, surface rust under the paint in a lot of areas, mainly on gutters and around trim clip holes and a couple of big holes at the bottom of the rear panel.
This is when things started getting out of hand, all these big ideas come to mind.

I continued with the engine removal, didn't have a jack to hand so the whole process was undertaken with the car sat on the ground..turned out to be far less difficult than I expected!


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At this point I decided to go with a smoothed engine bay, so everything came out eventually.


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The boot became the temporary shed.


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I cut the seams off the chassis legs and then welded them up


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And got on with cleaning off the seam sealer ion the turrets


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New front panel had a trial fit


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This is when I thought a colour change would be a good idea and a sample was sprayed..


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Photo obviously doesn't show it very well but i'm going with Atlas white

Got on with templates and then cut the sheet steel to box the chassis legs


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Oh and welded the front panel on by now too


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Got the scuttle panel cut out


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Drew me and the mrs on the windscreen as you do


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Made a start on the filler work on the chassis legs


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Going to have to leave it there for today as i'm over due to go and get drunk…

Will have more updates on the progress up til now tomorrow

Enjoy..

Excellent work so far mate, will be interesting to see what other big ideas take shape!?

good work mate but pls take all thaty crap off your parcel shelf i nearly cryed lol

foxy

foxymk1 said

good work mate but pls take all thaty crap off your parcel shelf i nearly cryed lol

foxy

Ha ha, parcel shelf has had it's day anyway mate, so don't worry yourself too much over it  

Thanks for the comments guys, the engine bay is soul destroying, hats off to anyone that does bodywork for a living!!

I won't be doing anything ground-breaking or 'never been done before' just making it exactly (or as close to) how I want it, with a very limited budget.

I am also attempting to do everything myself, I am pained to pay anyone to do anything that I feel I can have a half decent stab at, even if it nigh on breaks me in the process!

Rich

Just got a few minutes spare to add some more pictures..


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Stripped to a rolling shell


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Found this on the top left corner of the driver side inner wing..


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Painted a wing, in my clean and well equipped spray booth  :wink:


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Not sure cable ties make for a good earth..


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Wing sat on the car, pattern panel and a horrific fit!  8O


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Finally got a ball joint splitter and removed the steering rack


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180 mile round trip to collect this courtesy of Mr Lazey_boy..


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More prep work and also painted the other wing, also pattern part but a perfect fit  :dontknow:


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My £17 B&Q shelter


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The horrible job of stripping the sound deadening from the bulkhead


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Repair on the inner wing


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'Technically' back on the road..


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Zinc primer


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My extra £17 B&Q parts and panels spray booth at the side of the house


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New compressor


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Went mental and blew £523 on new parts at B+B components in Maidstone, Kent, doesn't seem like much considering it was half my available budget for the whole car!


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First full High build


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Filler and flatting


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Just spent the day sanding again and got another coat of the high build on, will get pics up tonight/tomorrow.

Really pleased to see it getting somewhere now, filler and sanding work seems to have gone on forever and I was losing faith!

Rich

That is lookig superb mate, hope your enthusiasm doesnt fade keep up the great work.

i feel your pain in the engine bay mate iv done few now not enjoyable

Looking good! Where abouts in Kent are you? I am in Maidstone, not far from B+B.

wannabemk1owner said

Looking good! Where abouts in Kent are you? I am in Maidstone, not far from B+B.

Cheers! Im in Tenterden, don't seem to be many of us around here! Should meet up if I ever get back on the road!

Thanks also waterwox and foxy  8)

Rich

keep it coming pal
Doing really well

LOVE the cable tie earth, that is first class.

i would love the time to do another project like this. great stuff.

Great work! Love the parts haul. Got a pair of wings sorted for my cabby so be on to this next year I reckon..just finishing prepping my VW Derby..literally about a 100 hours went into the bay and front inner wings of this, just did the scuttle last week- soul destoying isn't it!

Thanks again for comments guys!

Spent another 5 hours this afternoon giving a guide coat and flatting off the primer, turns out it wasnt that flat! I've had to go back to metal in alot of places so another primer is next on the cards.
I was hoping to get to topcoat stage today but work and then the never ending rain didnt allow that! Weather isnt looking good for the rest of the week either so likely more delays to the project

Oh i did also get some stone chip on the front panel too.

Rich

good work, not that far from me!

Great work so far mate. Nice to see another local mk1 build coming along.

Great progress Rich and should look great once complete. Factor in loads of time for getting it all back together as it will take longer than you think.

Also worth welding up the wishbones along the lengths of the seams as it'll help with the driving

I am in Herne bay not to far from you ,great project as well

collo16v I came to a vaging it meet 2-3 years ago with bens_cab when I was doing my last mk1, we followed you en route to the pub and the Gulf had me in total awe  8)

So there's a few Kentish lot then it seems, is there a regular meet at all?

I appreciate all the kind words guys, they help!

I can see light at the end of the engine bay tunnel now, got the first topcoat on today, more pics to feast on..


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The repair on the inner wing is good enough for me..


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More..


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Do I look like i'm having a good time?!  :mrgreen:


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Topcoat


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My technique leaves a little to be desired  :redfaced:


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All in all i'm really pleased that I chose Atlas white, it's exactly the classic creamy-white tone I wanted.

Will be leaving the runs to get nice and hard over a few days now before rectifying them for the next coat.

Thanks all

Rich

I tried a few years back to try to get a monthly meet together on the back of Vagingit and Prept meets but there was no real interest so I gave up I still go to Vagingit meets and the next one is this sunday at the Grove Ferry Pub in Upstreet my Mk1 is making a rare appearence as its just out of Jim's Garage after all its make over.

Well, I'm shocked and totally impressed to say the least!
You've been to Hell and back without having to leave home )

At one point I was going to offer you a fiver for the car and your money back on the tent. Just kidding Mate!

Fantastic job, the MK01OC version of the 2012 Olympic Marathon combined with every other endurance race, just stunning.

I take my hat off to you and your lovely finger painted Wife.
Hang on in there, it will be worth it and you can be seriously proud of yourself and your skills.

All the best and keep us updated please!

Mike.