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Golf mk1 1.1 '80 full restoration project (Loads of pictures!)

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This will be our first ever project.
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

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Next we patched a  few holes in the inside wheel arch (passenger side)



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

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The inner wings were a pretty direct fit





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 :D

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

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Nice work on your mk1. Good to see another 1.1L being restored. Looking forward to more updates.

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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

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Just read the whole post with my Sunday morning coffee.
What a fantastic job you guys have done, simply outstanding!  :thumbs:

The level of detail you've gone into is excellent and for having 4 Hours welding experience at School quite remarkable.  O_o

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?  O_o

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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Golf Cabrio 1990 said

Just read the whole post with my Sunday morning coffee.
What a fantastic job you guys have done, simply outstanding!  :thumbs:

The level of detail you've gone into is excellent and for having 4 Hours welding experience at School quite remarkable.  O_o

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?  O_o

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

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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  :lol:

Flick r - Flickr: ErosUK's Photostream Insta g r a m - @MK1_TOBY

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Done some more sanding today, filled up some little pits.
Going to the painter on Thursday :)

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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  :lol:

Thanks! We still got enough time to decide that ;)

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What colour are you having it done ?

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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

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Went to the tire shop today and they mounted the new tires on the wheels that we've sandblasted and powdercoated.



Also did a little fitment, I like it :)
 

Last edit: by D_Martijn

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awesome work :)

Banner

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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  :thumbs:

1988 Mk1 Golf GTi Cabriolet 1.8cc DX, K-jet. Daily drive. 300,000 miles and counting
1978 Mk1 Scirocco GLS 1.6cc FR, Webber carb. Weekend toy.

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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  :thumbs:


Thank you for the kind words!  :thumbs:

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Our first Golf mk1 1.1 project (Loads of pictures!)

Looking very good!

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AL_Mk1 said

Looking very good!


Thanks mate!

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Since all of the sanding is done for now, I got started on assembling the front shocks.
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

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Today we started working on the engine.
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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