My mk1 shell rebuild

Ok so bought this pretty much mint mk1 shell and decided to build the whole car up from the shell.
I inteneded on doing all the work myself bar the bodywork and paint but because of time i didn't have towards
the end and because i wanted it to be mint i got psi to finish it off. So here's how it went.

The shell in the condition i got it, bodywork was really good and only had a couple of light rust patches, the guy who
did the bodywork and paint used lead filling on these areas instead of cag.




Some more of it almost ready for paint.








Because i had the scuttle cut out the guy strengthened this for me



And here it is getting its paint, the colour is mk5 golf Candy white. Had a new windscreen and rubber too.
Also had the sunroof suround done so it was nice and fresh.
Put all the windows back in after she was painted and the rubbers, had two new full door rubbers just to be nice












Few pics of it retuning home for the first time. And the trial fit of the ats classics.









When i got it home i lifted it up and fully schultz'd the underside with the gun, did under the arches
in bottom of the engine bay and inside the wings, so everywhere lol. Also waxoiled inside the doors and
the rear arches and all the other parts in the sides at the back. Few pics of that,

Masking up the bay.



Then the schultz







I stripped down the engine just to the block and head and removed the power steering, i put a new cambelt
and tensioner kit on, waterpump, spark plugs, leads, coilpack, solenex racing oil, oil filter, fuel filter,
rocker gasket, took the inlet manifold and rocker cover back to bare metal and resprayed them black, cleaned
up the gearbox which came out really well. Its had a new clutch kit whil it was out, crank sensor, clutch cable,
throttle cable, speedo cable and drive. The radiators out from a mk2 gti and is new, i repainted the cowling.
New header tank, new master clyinder and servo again from a 16v mk2. Goodridge braided hoses all round. Repainted
the brake bar, repainted the gti steering rack and cleaned up the tiny rust spots on the gti tank,por 15'd them,
re painted that and went over the whole of it with shultz. i also took the filler neck to bare metal and painted
up too. Alot of pics are not on this computer but here's the few i have off the camera of some bits,

Rack painted



Gearbox cleaned up


Brake calipers and carriers painted, green stuff pads aswell


Fan cowl


Other random bits


Box of new bits, handbrake cables, complete rear brake setup so drums, shoes, fitting kit, clyinders,
wheel bearings front and rear, front strut tops, wishbones and balljoints, gearbox mount. the wishbones
steering rack and rear axle are all polybushed too.


Rear axle was galvonised


Clutch


Coilovers


Petrol tank


Some of the engine



It built back up


How it sat for abit



Then i built up the front







So this is where i got up too before it became winter and i had hardly any time to work on it when i was back from base
at weekends, so i took it to psi to be finished, they sorted the wiring out, taking out all the unesescary bits of the two
looms out so it looked as tidy as possible in the bay, wired the dash up, made up and fitted new fuel lines and brake lines,
tucked the ecu nicely under the dash so its accessible to plug in in the passenger footwell, fitted the rest of the new ashley
exhaust system, sorted the gear linkages out, located the battery into the spare wheel well, mot'd it and basically sorted it out
so i could start using it on the road. Cost me a fair whack but i didn't have the time or the skill to get it how they did so it was
worth it.

So thats it up to now, ive been driving it about for the last month, fitted a brand new fuel pump 2 weeks ago and thats been the only hiccup
its given me, just put a new heater control switch in today as its not had one yet so thats nice, and put a cd player and 4 good jbl
speakers in last week so ive got some music aswell. Need a new ashtray bit as mines broke, seized in. I do have a few more pics but
im doing this thread on a mates computer so only have the ones off my camera, i'll try and get some of how its standing now and put them
up soon. Just enjoying how it goes right now to be honest, which is rather well!

Some pics of it today, finished basically bar the sill trim im working on and just little
cosmetic odds and sods like when i broke the ashtray yesterday when it got stuck all good
stuff. O yea, does anyone else's doors sag a little, really annoys me one sides worse than the
other. Is it just the interferance fit pins that wear out a little that cause it?












And finally an emu, it'll get ya!


Don't no whether im keeping it yet or not, quite feeling the idea of a 330ci so if anyone
wants to pm me an offer i'll get thinking. Dunc

dunc said

Don't no whether im keeping it yet or not, quite feeling the idea of a 330ci so if anyone wants to pm me an offer i'll get thinking. Dunc

emu or car

Oh i'd never get rid of the emu, who knows what it'd do in revenge……

Bay pics, not spanking clean but its driven daily and frezzing so!

quick bump up

nice, i love the red trim around the grille, i want that for mine!!

is that tinfoil around the steering gaiter??

Is your exhaust loud, i have no seats in the back of mine either and find it far too loud, when i can afford it i'm getting a quieter exhaust for sue, either that or new back seats lol…

Yea mate its tin foil wrapped around the rubber steering gaitor, it works the best against the heat off the exhaust.
It is loud yeah but bearable can still talk over it easily like, makes an awesome noise when its going though.

wish i'd seen your tin foil idea a week or so ago, took mine for its mot and then it was fine, failed mot on other things but in the 20 mile round trip back i managed to melt two wee holes in it, still in the garage getting the carbs tuned without mot at the moment, hopefully when they go to do it again they don't notice it… But i'll be doing this when i get the new gaiter fitted, cheers

how you doing?nice motor, are you using those red prothane bushes from gsf? i have a set on my car there a bit harsh i think but bearable when you offset it against the handling which is really tight on the car you can really throw the car into the corners +bends and on roundabouts the car  is like a go kart .love the colour of your car by the way you dont see to many that colour