Mk1 Golf Full Rebuild

Hi guys I'm Conor, 21 from Surrey, currently working as an engineer for a company that build  truck mounted road sweepers (random I know)! Previously owned a mk2 which looked like this…

I've been after a mk1 since I was 16! Just before christmas I got hold of an alpine white Mk1 shell off a mate, virtually the bare bones so will be restored and rebuilt from the ground. The car was originally a 1.1 Golf C, but will be built up with a 2.0 16v 9A from a Corrado and run on carbs. Bodywork is getting a full makeover. I'll let the photos do the talking..

How I got the car…








Began just starting to strip it, didn't really require too much. Decided to throw the carpet away as it was haggard, filled a rubble sack with random rubbish that was inside the car alongside little bits of broken trim etc. that I don't want.


It all started out good, didn't really come across any rust at first, until I took of the arch spats, and realised that the inner and outer rear arches were made mainly from filler and fibreglass. That's a problem for another day, gonna be quite a lot of work replacing them so I'll sort out some of the easier and cheaper jobs and come back to the arches.








I then decided to remove all the sound deadening from the footwells inside the car. used a heat gun and a chisel as I didn't have a scraper.


Can't believe how much that stuff weighed, that bag must have weighed the same as a small child!


I then let it dry again and went over it with a wire wheel. I like to call this tool…the rapist. It took half my fingers off, didn't really think about the size of it when I ordered it, 150mm in diameter however it expanded when it span round on the angle grinder. Worked really well though.


Part way through…


I then came as a runner up in the VW Heritage winter wish list competition and got myself £250 worth of free parts. Took this opportunity to get hold of a front panel that needed replacing as it had previously hit a bollard and caved in. No damage to the chassis itself though.


Also got some other parts too…






Some random photos…




So i cut the front panel out and figured that whilst I have easy access to the bay, then now would be a good time to start removing all the bits I don't need so I can begin smoothing it. So out with the battery tray, scuttle tray, all the little brackets from here and there. I won't be running a heater so have gotta get a plate cut and will then weald over the heater hole. Never used a spot weld drill before and made a bit of a meal out of some parts i.e. drilling all the way through the metal haha, but all the holes will be welded up alongside the ones that were there from the factory. I won't be boxing the chassis leg, personally not too keen on it.






My friend moved to America last summer, and came back for chirstmas with these little gems for me. Although I'll be running carbs they're worth keeping hold of, whether I use them or not.


That's all been happening over the last couple of weeks, the most recent news is that I picked up a Corrado donor car for the engine swap. Got given for free so can't complain, although no key and hadn't been run in over 2 years so it's safe to say I'll be rebuilding the engine. Engine in question is a 9A and will be the last pier of the puzzle, aiming to get the engine mounted so I can move the drivers side engine mount, then it'll come out so I can do the bodywork/paint, fit the running gear and then deal with the engine.

Awful picture of the engine, have got some better ones from my SLR just haven't got round to uploading them yet…


The plan is to run this on the carbs with a JMR motorsport shifter and 020 box!.

This evening I spent a little time down at the workshop, cut the window seals to get al the windows out, I'm replacing virtually everything on the car so a few seals won't hurt…


And what's this?! Someone seems to have drawn a rectangle around my roof, almost as if they intend to cut it out :O
The inside of the roof is rusty where its a crappy sunroof model, I'm cutting it out and will be replacing it with a Carbon roof from LWS Design, I also inter on switching to a Carbon bonnet too.


So buying the roof is next on the list, after that's fitted I've gotta get some new genuine wings from VW Heritage (I'm praying they will still have some in stock by then) and it can can be painted (the rear arches will be sorted by this point as well as the bay being smoothed). I'm still unsure of colour, I did want to do it a pastel colour, however the more I look at GTI spec Mk1s the more I change my mind, so the car will either be staying Alpine White, or will be done in the original GTI black. A Cage is also on the cards, however I'm not 100% sure on this yet.

Although I've done the majority of my qualifications I'm still an apprentice until August 2014 so money is tight and updates won't be as regular or exciting as I would like them to be. Motorsport or cars in general aren't really anything that's run through my family before so have nobody to hold my hand through is as such haha, it's gonna be a big learning experience and I intend on doing as much of it as I possibly can on my own. I'm sure I'm more than competent, I've been looking at build threads and gathering knowledge and ideas on mk1s for the last 5 years!

Thanks if you bothered to look at any of this so far I appreciate it, feel free to leave comments! Good or bad, but preferably good!

Hi Conor and welcome

Very nice build thread and good to see you getting stuck in    Great news on the runner up with VWH, bet you were pleased

I haven't stripped the sound deadening off the floor of mine yet - I know I should really but not looking forward to that job. I'll watch my fingers though!  

Carbon roof sounds interesting. I was thinking the white option would be good to contrast with that, but then again you mention black too which would be nice and subtle.

Looking forward to updates

Oh there were no pics of your mk2  

Nice project connor. Looks like you've got plenty to keep you busy there.

Have a look for Jimievo thread, he is doing the same to the roof as you plan to do, I'm sure he will point you in the right direction  

Andy.

Hairyarse said

Hi Conor and welcome

Very nice build thread and good to see you getting stuck in   Great news on the runner up with VWH, bet you were pleased I haven't stripped the sound deadening off the floor of mine yet - I know I should really but not looking forward to that job. I'll watch my fingers though!  Carbon roof sounds interesting. I was thinking the white option would be good to contrast with that, but then again you mention black too which would be nice and subtle.

Looking forward to updates Oh there were no pics of your mk2  

Thanks mate I appreciate it Yeah it was definitely an awesome phone call to wake up to on christmas eve!

to be fair mate it's not actually that bad. It was time consuming but a heat gun and scraper does the hard work easily. Then just get a monster of a wire wheels haha. Wear a set of welding gloves though -_-

Yeah not only does the sunroof leak, and weigh a tonne, it is rusty, otherwise I would probably opt to keep it just because it's less hassle. I want this car to drive well, not just be some sort of show pony. I am going to the effort of fully painted inside and smoothed bay etc. though so I do want it to get some credit for looking good. Still unsure whether or not I should paint the carbon roof the same colour as the rest of the car.

Yeah I do like white but every time I see a GTI i see it in white or Red, which makes me want to do it in black haha.

Thanks for your comments mate Pictures of my mk2 are here…

Melteddrummer said

Nice project connor. Looks like you've got plenty to keep you busy there.

Have a look for Jimievo thread, he is doing the same to the roof as you plan to do, I'm sure he will point you in the right direction  

Andy.

Oh yes I sure do! Except I've broken the angle grinder for now so am temporarily stuck, just gonna have to use it as an excuse to get rid of the corrado shell and have a good ol' tidy up in the workshop!

Brilliant I will do, thanks mate. I already know what has to be done, I've left 50mm of the actual roof around the edges to bond to (not actually cut it yet just on the marking out) and will then neaten it up and grind it all back to about 40mm.

 

Cheers for the MK2 pics, love that last one - nice uncluttered look  

Hairyarse said

Cheers for the MK2 pics, love that last one - nice uncluttered look  

Yeah I sure did love her! beasty little 1.3 carb haha. Did have a splitter on it but it ripped off haha.

Sadly I hit a hole in the and bent the dub frame, snapped the gear linkage, broke the rear engine mount clean in half, and lost all my brakes. Ended up breaking it for parts and selling the shell to a friend.

Looks like a very interesting project, and coming along nicely.

That Christmas phone call must have been sweet, I entered, like most people on here did, but didn't win

Good luck with the project, I'm going down a similar engine route, so looking forward to updates.  

Matt

pazwaa said

Looks like a very interesting project, and coming along nicely.

That Christmas phone call must have been sweet, I entered, like most people on here did, but didn't win

Good luck with the project, I'm going down a similar engine route, so looking forward to updates.  

Matt

Thanks mate I apreciate it!

Yeah it was awesome, it woke me up but I can forgive that! I wasn't sure that lots of people would have seen it or entered which is the only reason I did. I can honestly say until that I've never won anything in my life haha.

Awesome! Have you got a build thread on the go?

In other news I've acquired myself a mk1 gti rear beam with ARB so can get to work on refurbing that! So far I've spent £300 and got a shell, engine and beam, made a fairamount on breaking the corrado. If it wasn't for the plans of carbon fibre this could have probably continued to be a bit of a budget build

In all fairness I haven't set myself a budget or a time scale so I'm gonna try and enjoy building the car as much as I can and not care about the rest!

Glad someone on here won it  

I've got a build thread on here, search for "shellby", haven't updated for a while due to Christmas and slow progress with paint the shell are holding me up.  

Sounds like your doing well money wise. I wouldn't worry about a budget, within reason, think all budgets tend to get blown. Parts are become hard to get, plus "scene tax" on eBay, probably gonna cost more than you thought. As you say, just enjoy it.  

I've started looking into carbon fibre, very nice looking, and expensive    Search for a chap called Mugly on ED38, there's a carbon fibre appreciation thread, he's made some stunning parts.

Matt

Haha, I've lurked on here for years but as I've only just acquired the mk1 I've never had much to contribute, but thanks  

Ok sweet I'll check it out now  

And yeah I've seen so many people obliterate their budgest and timescales it's not worth it.

Yeah I'm a regular on ED38 (hang head in shame) haha, amongst all the rich kids with their polo's and air ride there's so awesome cars and some good inspiration. I've seen alot of mugly's stuff, only problem is he does carbon skinning as opposed to actually making carbon parts, certainly pointless as far as I'm concerned, it defeats the object of carbon fiber being light as you're just adding weight to the original item. My carbon roof and bonnet will be pure carbon fiber to make the most of the weight saving  

nice build so far, and jammy git with the vwheritage wish list! where abouts in surrey are you from mate?

Ah, thought you meant carbon wrapped to make parts look nice    but you're going for the fully carbon parts, good job you haven't bothered with a budget    

Will you paint over the carbon or leave it on show?

Matt

Rubbadubdub said

nice build so far, and jammy git with the vwheritage wish list! where abouts in surrey are you from mate?

Haha why thank you

And I'm from Reigate/Redhill. I spend a ridiculous amount of time around Crawley and West Sussex though, and my workshop is in Pulborough in the middle of nowhere so I get around alot. Lso, I work in Dorking haha.

You local?

pazwaa said

Ah, thought you meant carbon wrapped to make parts look nice    but you're going for the fully carbon parts, good job you haven't bothered with a budget    

Will you paint over the carbon or leave it on show?

Matt

Haha no not carbon wrapping, it looks cool, but doesn't really have a purpose. The carbon roof is £650 iirc and the bonnet is also expensive haha. That's as far as it's going to go though.

I'm not too sure, the bonnet is definitely going to be painted body colour, and I haven't decided about the roof. For subtlety I want to paint it but there's always that part of me that will want to show it off a bit  

What colour you going for?

I think with the right paint colour leaving the carbon roof unpainted will look great 

Only other worry is some jealous scrote decides to scratch it 

I'm either gonna go with black or white, curently swaying more towards white, but as opposed to the original Alpine White I'm thinking Audi Ibis White. I hope that with the right wheel colour (most likely metallic grey centres with polished dishes) the carbon roof will work well.

Yeah I never thought about that really, the car won't be a daily and when not in use will be kept locked in the workshop. There's always that risk but then if they're jealous what's to stop them scratching the whole car? It's a risk you take when owning anything these days unfortunately  

great buld so far mate, i got excited when i seen that first pic haha  

the car is going to look lovely by the sounds of your plans.

i think it is hard to do one of these on a budget, original parts arent getting any cheaper and are becoming more scarce. i started mine on a "budget" and its cost me a small fortune haha… worth it though

have you not thought about any other colours? maybe a US mk1 colour?

mike  

I'm sure I've seen a build thread before done before in ibis white, looked beautiful. And id definately leave the roof unpainted if you're going white, will look amazing. 

browner01 said

great buld so far mate, i got excited when i seen that first pic haha  

the car is going to look lovely by the sounds of your plans.

i think it is hard to do one of these on a budget, original parts arent getting any cheaper and are becoming more scarce. i started mine on a "budget" and its cost me a small fortune haha… worth it though

have you not thought about any other colours? maybe a US mk1 colour?

mike  

Haha this car was pretty low when my mate owned it, I'll post up a pic in a sec, not really my cup of tea, wat this to be more practical haha.

Yeah I know exactly what you mean, I got this with nothing in or on it aha, it's my first project and am lacking confidence in terms of the wiring, tere's bits missing here and there so the chances are I'm gonna be buying another mk1 as a donor for all wiring, and silly things like wishbones, stub axles etc. when the bodywork on this is finished. I also donated a front wing to a mate for his project and threw the other away as it was bent on the bottom corner. New genuine ones are a small fortune from VW heritage but I'm gonna be buying them anyway haha.

I have, I put up a thread on edition asking for people to list any retro original VAG or porsche colours that they liked, didn't get a whole of relpies to be honest. If you can list any then pelase feel free haha, would be a great help.

pazwaa said

I'm sure I've seen a build thread before done before in ibis white, looked beautiful. And id definately leave the roof unpainted if you're going white, will look amazing. 

Yeah there's one on air with image splits with red centres running a 1.4 16v AFH from a polo on ediiton38. And another on there with a 2.0 16v on bike carbs, but he's on;ly done bay so far

This is what it looked like previously, clearly not as clean as it looks here…