My resto

http://homepage.eircom…eilly/MK1_golf/index.html

quality....good job your quite handy with the old bodywork aint it !!!

Superb, good job dude  :y:

Great resto there, love the sunroof repairs. I've been working on something very similar myself (although more rust in the tray to repair) almost ready to refit.

Cheers

nice work there mate, top job  :y:  :y:  :y:

hi what underseal did you use and how was it applyed? also great resto mate

Great job, well done  :clap:

Must be better than when it was new now! very impressed.

Chris

How many people would have thrown the towel in on that one!  Just goes to show what can be salvaged, what a job, i love it.

Thanks everyone. It was this site that gave me hope and in particular carbs4ever's resoration. That kinda inspired me.

That was just stage 1 of the resto. Its up and running but I've a few more plans for her to come. The engine I fitted was a mk2 gti Digifant engine.

Blimey billy, you're not afraid of getting stuck in are you!

Glad to see this - I need to do similar with my sunroof. I had thought about taking the tray out as you had but was really worried I wouldn't be able to line up acurately again.

How easy/hard was it to line up in the end and how much margin for error is there to ensure the roof closes properly?

Cheers and well done!
Andy :wink:

Thanks hairyarse! The sunroof repair was my biggest obstacle…if I couldn't complete it I was afraid it have to abandon project or get re-placement foof skin. From lookin at this forum I notice its one of the more difficult areas to fix on a mk1. My resto was like any other resto, nothing different except for the sunroof so I hpoe it helps others.

To margin of error with the sunroof is .5mm Id say. Its really tight and has to be exact. The seal gives a slight relief in that it can squeeze a little bit more if it has to.  to be honest, you need to get it back in in the exact position it came out or your going to run into difficuly.

To remove the tray, cut the 4 lugs, theres 2 on either side. you have to cut through the welds in such a way as to not shorten the length of the lugs. Cut the front mount the same way. The difficult part is the lip that folds over the front roof support on the tray. This lip is a continuation of the roof skin. It needs to be folded back carefully. not easy to be honest. Then, To fully remove the tray i cut just below the over lap between the fold down of the roof skin on 3 sides and the sunroof tray. It came out hany after that and I could begin re constrution work to the tray.

A tray from a mk2 golf might suit but Im not sure. I might be easier than repairing the old one.

Every resto is different, every sunroof resto is gonna be different but hope this helps if any one needs to remove the tray.

Thanks for the extra info Billy, big help! I was like you - worried I'd have to scrap shell if couldn't repair so was going to do first.

However, I want to practice my welding skills on less critical areas first! Plus, having seen Chudds Webasto roof conversion, if the worst happens, I'll just go down this route.

Cheers again
Andy :wink: