My 'project' - Updated 08/08 - Engine swap & headgasket

Thought I would post a little thread about my Mk1 Project called PAFY, as im sure Ill be posting questions every other minute.

I had been on the look out for a mk1 project for several months. I went to see one 3 weeks ago, which has been sat at my friends workplace for about a year.

It ticked all my boxes, and came about at the right time financially, and the shell was one of the best ones ive seen.

Its a 1.6 GTI, 5 speed, 3 door, silver, with a few extras, and in my eyes was bit of a bargain at ?400.

I picked it up a couple of weeks ago, with the help of a good mate and his trailor, we got it back the 10 miles to my garage, where it has now evicted my mothers volvo, and is sitting pride of place.

Here are some pics from the morning i got it back to mine.

Tax from last time it was on the road….  












Tow-Bar…?



Interior half stripped







And one of the best bits…Fully working (albeit a little stiff!) Webasto roof, in brilliant condition…

First day i had to spend some time on it, i couldnt wait.

Started by stripping the interior for some cleaning, and to also find out what parts i had, and what was missing.



Now bearing in mind i bought this car without knowing what the floor or boot floor looked like (or even what was in the boot for that matter!) I was pleasently surprised.

Spare wheel well pretty clean: As was the entire floor! *phew!*



I gave it a good clean, and then went to work on any rust patches, sanding them down, and also using a wire brush. This still needs a bit of work, despite sitting on primer currently.



Then de-bumpered it and de-towbarred it.

Got a few hours over the weekend, but not as long as i would have liked.

After cleaning the floor, i used some paint to just neaten it up. Its certainly not to show and shine standard, but i dont intend it to be for that. Its just for my piece of my mind. Maybe one day soon ill be able to afford a full respray…



Also 'finished' painting the sills. Silvers a bi@ch of a colour to try and match, but i feel it came out really well, and i was really surprised with how good the finish was. But at the end of the day, most of this is going to be covered by carpets, and sill covers, so im not too worried.





I spent 3 hours on friday evening steam cleaning my seats, and carpet. Got through 9 litres of water, and the colour of the water because of the dirt was pretty…well it was just wrong. But thats 23/24 years of dirt removed, so hardly surprising!!

i then managed to lay some fatmat sound deadening down. I got this far before my camera batteries died.



Then i got the carpet back in, and for the first time mounted the seats. The interiors beginning to look a little more like, well, an interior really.





Big sense of achievment after this, so with a big smile on my face i sat in the drivers seat, and made engine noises…!!

I then turned this:



into this:

This has pretty much been what ive been spending my "free time" doing in an evening after work, and has been my life for the last 2 weeks.

My basic plan is to get her back on the road as soon as possible. Then some wide wheels (maybe banded steelies - im aware of the legalities… :wink: ), and coilovers.

Ive picked up a rad and fan this morning, and have bought a few items from people on here, but theres a long way to go.

I posted this on another forum, and have been in contact with a guy who used to own it, who informed me that the roof material was replaced by a guy around 14 years ago, when he sold it.

After that, it was bought by a local guy who had it sat in his garage for 3-4 years before selling to a mechanic, who left it in his workshop for another year, before i came along.

I turned the engine over by hand last night, and fortunately nothing was seized. So a good going over, and service will hopefully see her fire up into life in the next few weeks.

Thanks for reading.

Nick

looks a good shell! good work 8)

Great work - Hi and welcome - gimme a shout if you need any parts

Looks nice (Change the wheels!   )

I quite like the webasto roof, as long as it doesn't leak, should be a great little runabout!

Looks good, whats covering the rear inner arch/strut turrets in the boot?

Early-1800 said

Looks good, whats covering the rear inner arch/strut turrets in the boot?

A good question…

It went on in liquid form, but has hardened. I can chip it away, but was hoping for a more effective way of removing it.

I can only assume its some kind of liquid sound deadening…? :dontknow:

Make sure you give the drivers side rear seat belt mounting a good tug, they corrode from the wheel arch side.

Looking good mate. What are those wheels about though?! Hope it fires up ok. Disconnect the main coil lead and crank it a few times to get the oil pressure up and circulated a bit before trying...

Nice one mate. Looking good.

Those wheels are seriously strange.

Is it me or has anyone else thought the way the tow bad is just attached to the rear valance is odd? Surely if you were to tow anything the valance would buckle- its only a thin bit of metal sheet.  :dontknow:

D

DAG4R said

Is it me or has anyone else thought the way the tow bad is just attached to the rear valance is odd? Surely if you were to tow anything the valance would buckle- its only a thin bit of metal sheet.  :dontknow:

D

I thought that. Must be reinforced behind the valvance though…

Yes that was my old mk1  ,I owned it fifteen years ago.I wasnt a fan of the sunroof or the wheels.
  I replaced it with a later 1800 with factory steel roof,which I still own.

 Coming on well Nick,I have a alternator if you still need one

I think you will be on the road before me,I must get some pics up of mine

   Mark

Early-1800 said

Make sure you give the drivers side rear seat belt mounting a good tug, they corrode from the wheel arch side.

I can confirm this.  You only need to check my thread to see the state of the rear inner arches on my first Golf project :cry:

The car looks good, but I have to agree with the majority about the wheels 8O .
I cant believe how straight the sills are.  they look in really good condition.

Thanks for the words of encouragement.

mark83, a previous owner informed me that when he sold it, the buyer intended to put a new roof on. Can you remember what year you sold it Mark? The roof is in really good condition. Should hopefully get a chance to treat the roof and paintwork this weekend.

I might take you up on the offer of that alternator later Mark, gotta get a battery today, so will see if it goes then.

The condition of the sills were a good reason as to why i bought it.

The wheels i have been informed came attached to imported cabbys? Not seen many around, but not really to my tastes, and will be changed at some point soon!

Nick

    I sold it in 1993, I can remember because I sold it for a deposit for a house.The person I sold it to had the new roof fitted at south west sunroofs,I think they were based  near wellington,not sure if they are still in bussiness

I think I have some old photos of when I owned it ,I see if I can dig them out

  As for the wheels I am sure they were fitted from new

    speak  soon  
           
          Mark

DAG4R said

Is it me or has anyone else thought the way the tow bad is just attached to the rear valance is odd? Surely if you were to tow anything the valance would buckle- its only a thin bit of metal sheet.  :dontknow:

D

I took a few pics of whats been left now the towbars been removed.





The holes were reinforced by a metal strip inside the rear valance. It also went under the wheel well, and i have two holes in that too… There was also a couple of bolts just inside the boot, that bolted down through the floor. As a result im now left with the holes you can see in the pictures. Should be easily welded over however.

Also after a good clean, I started putting a few more bits back on. The rear lights, and number plate. The bumpers just balanced on.



Managed to remove the boot, to get to the rust along the top shut line, which i have started sanding down, and with any luck should have looking good as new in no time.

And had a few bits and pieces arrive in the post. Should keep me busy for a few hours.  

Update time…

Ive been collecting bits that i was missing.

Ive now got a new radiator, fan, battery, fuel filter, oil filter, plugs and dizzy in place. With a fuel pump and headlights still to wire up. Ive got a brand new door handle and front bumper, which arrived on monday, but unfortunately it looked like this:



I wasnt planning on putting the rear seats back in, but changed my mind, so chucked them in.





These were past their best:



So i made some new boot door cards:



And in place.



Temporary strut brace, before i have a large chunky one welded up.



And i have seen the first signs of life…



Gave her a quick clean last night, as i didnt have much time, and snapped these:





Also need to try and work this one out…





Cant work out if im missing something, or the wirings all to pot. TBH, i hate wiring, so i will prob just leave it alone and get my mate to do it!