Golf mk1 1.1 '80 full restoration project (Loads of pictures!)
Posted
#1502209
(In Topic #199723)
Old Timer
My brother and I bought this car from a guy, he already started dismantling the car, but quitted when he had the opportunity to do a T1 bus.
The car is from 1980, short lights, 1.1 GG engine.
Picked up the car with our uncle since he can pull a trailer.
Car at home.
Rear arches need to be replaced, front panel, inner front side panels…
At first we thought of letting a bodyshop do the work, but then decided to do the welding ourselves since I've learned to weld a bit in school.
Before we could weld, we had to remove the engine.
(Don't mind our wooden contraption we use to remove it :p )
Now that the engine is out, we can start welding and patching up the car!
Meanwhile, my brother cleaned the dash, polished the rear lights, cleaned the grill and steering wheel, radiator and fan and some other stuff…
When the engine was out, we removed the whole front and rear suspension. Then we welded a little frame so the car could rest on it.
After we managed to get the car onto the frame, we removed the front panel.
We also started removing the rutex in the wheel arches. at first we removed it with a spatula. Since this took too much time we used a wire wheel for the other 3 arches.
Now we could finally begin welding!
We also replaced the other side
We then cleaned the inner beam, brunoxed it, added zincspray and sprayed bitumen inside.
After that, we welded on the panel
Now we could start patching up the floor,
Same thing at the other side..
Since now, we also refurbished quite a few pieces, some examples:
Radiator motor
Finished radiator
Brake servo
Ignition coil:
Front & rear axles
Drum brakes
Front knuckles:
Horn:
Engine pulley
Front Girling brakes, painted and installed new seals
Last edit: by D_Martijn
Posted
Old Timer
All cleaned up, ready for some filler
After that, we made a new patch (also passenger side wheel arch) and welded it into place
Welded the other piece also inplace + welded the plate from the inside too
Then, we cleaned the engine compartment and sandblasted the little clips and holders + sprayed some primer.
Finally, we rolled the car on its side with the help of some friends
Now we could start welding the rear spare tire room
We also welded a new plate for the rear panel, but I don't have and pictures of that..
When removing the rear axle, we snapped off one of the bolts, so this had to be fixed,
We cut a little door in the rear beam, drilled out the old bolt, or at least, the remainings :p and welded a new one in.
Now we cleaned up the rest of the underside of the car and sprayed 'bitumen' over it.
Most of the welding is done now, all that remains is the rear arches and inner wings.
Last edit: by D_Martijn
Posted
Old Timer
Also cleaned the fuel tank and added some primer + bitumen
Around this time, we had send most suspension parts the the sandblaster, some parts we painted right away, others went to the powdercoat factory
Also bought some new shocks for our golf
The only welding that now had to be done were the rear outer arches, this was something we were a little 'scared' of, didn't really know how to start with this job.
Some research on the internet, a little topic on this forum and some advise from our painter and it all turned out OK tack welded into place
Other side:
close up of the weld (please note, I never welded before this car other than 4 hours of MIG welding in school)
Also removed some rust at the front window
Since all of the welding it done, we can begin sanding the car.
Also added some metal filler on the welds inside
After sanding, added some fine filler
All smooth
While my brother was sanding the other panels, I added metal filler on the arches.
Sanded it and then some fine filler
more sanding and filler..
Spraying some spray putty + sanding and filling the low spots.
Added filler on the rear panel where we welded.
Can't wait to mount all these parts back on the car!!!
We also got our parts and wheels back from the powdercoat and yellow passivation so we can start assembling some parts
Valve cover
Rear shocks
Front brakes
Rear brakes
Press fitted new bearings + added the dust shield
Pressed new rubber bushings on the A-arms
Also pressed the front axle in
And added the front disks
And finally… our 'new' wheels
Oh and also the front hood mechanism which we passivated yellow
After assembling all the new parts, we took the CVDs apart.
Here you have to make sure if you got the old of new style CVDs. (we had the older ones, with the circlip)
Sprayed some primer and black paint on the shafts and installed new boots (and grease).
Now all that's left is some little things before we can get the car to the paintshop
Sprayed some bitumen on the front panels and in the rear arches.
Also drilled the holes for the stoneguards
Other side
They fit great!
That's it for now, feel free to comment and ask questions!
Last edit: by D_Martijn
Posted
Old Timer
Posted
Old Timer
watson said
Nice work on your mk1. Good to see another 1.1L being restored. Looking forward to more updates.
Thanks, I just started watching your build, WOW just great!
This week it'll be going to the painter so then we'll start working on the engine
Posted
Moderator
What a fantastic job you guys have done, simply outstanding!
The level of detail you've gone into is excellent and for having 4 Hours welding experience at School quite remarkable.
I take my hat off to you both!
So tell me, how much time in man hours do you think you two have so far on this project?
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!
Be proud of your VW Golf Mk1, it's very special!
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!
Be proud of your VW Golf Mk1, it's very special!
Posted
Old Timer
Golf Cabrio 1990 said
Just read the whole post with my Sunday morning coffee.
What a fantastic job you guys have done, simply outstanding!
The level of detail you've gone into is excellent and for having 4 Hours welding experience at School quite remarkable.
I take my hat off to you both!
So tell me, how much time in man hours do you think you two have so far on this project?
Thank you for the nice compliments!
Honestly, I really have no idea.
We bought the car somewhere in late May, since we both had exams we couldn't start immediatly, only cleaned some small parts etc.
I think 17th of June we really started working of the car. Some days we start at 9-10am till 11pm other days we don't work much at all.. I have no clue :p
Posted
Old Timer
Posted
Old Timer
Going to the painter on Thursday
Posted
Old Timer
Rubbadubdub said
This is going to be lovely! keep the good work up, and good luck deciding who gets to keep it at the end of it all
Thanks! We still got enough time to decide that
Posted
Old Timer
Posted
Old Timer
watson said
What colour are you having it done ?
The same green, only problem is, we can't figure out what the color code is..
Can't seem to find a good VIN decoder so we can look up the paint code via the chassis number
I think it's Lhasa green or Onyx green
Posted
Old Timer
Also did a little fitment, I like it
Last edit: by D_Martijn
Posted
Old Timer
Posted
Local Hero
Keep us updated
1988 Mk1 Golf GTi Cabriolet 1.8cc DX, K-jet. Daily drive. 317,000 miles and counting
1978 Mk1 Scirocco GLS 1.6cc FR, Webber carb. Weekend toy.
1978 Mk1 Scirocco GLS 1.6cc FR, Webber carb. Weekend toy.
Posted
Old Timer
mark1gls said
Cracking work going on here, you have been busy and got so much done in a short time? Great attention to detail and so glad the car is being kept original.
Keep us updated
Thank you for the kind words!
Posted
Local Hero
Our first Golf mk1 1.1 project (Loads of pictures!)
My Build Thread
All My Build Photos - https://www.flickr.com/photos/pix-al/albums/72157622794406840
My other hobby - www.pix-al.co.uk
All My Build Photos - https://www.flickr.com/photos/pix-al/albums/72157622794406840
My other hobby - www.pix-al.co.uk
Posted
Old Timer
AL_Mk1 said
Looking very good!
Thanks mate!
Posted
Old Timer
Springs, upper spring cap and the front shock struts were sandblasted and powder coated, all other parts are new.
Only thing I noticed is that there is quite some play on the rubber silent block. Suggestions on what could be wrong?
Car fully prepped to get some much deserved paint!
Last edit: by D_Martijn
Posted
Old Timer
We first degreased the engine and transmission. Then we took the transmission off and cleaned it inside.
We will replace the pressure bearing and guide sleeve.
Also cleaned the air intake manifold and startmotor.
In the evening we polished the rear Hella lights we recently bought second hand.
(left one is polished, right light not)
And finally we mounted the new steering rods, boots and tie rod ends.
Last edit: by D_Martijn
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