part-way through renovation of underside

Yesterday I reached turning point in the renovation of my black GTI. A couple of months ago, I took it off the road and removed the rear axle & fuel tank, to do some welding. I thought, while its all apart it would be a shame to simply put it back together as-is, and also there were some ominous looking holes in the rear crossmembers. So I've slowly been welding repairs here and renovating all the removed components. So, my turning point is that now I've addressed all the additional work I found which needs doing, leaving me with the original work ahead. I've not even started the welding I originally planned to do! But there's nothing stopping me now (apart from the weather, lack of time, etc etc).







More pics will be added soon…

That looks like some fine work!

Nice one, what did you coat the underside in? gotta do mine soon

good work - will keep it right for the future

Hairyarse said

Nice one, what did you coat the underside in? gotta do mine soon

Black stonechip, apparently its alkyd based and its a rubbery flexible paint which can be overpainted and lasts longer before flaking, than traditional underseal.

Looks tidy Paul. Any particular brand?

Hairyarse said

Looks tidy Paul. Any particular brand?

No particular brand, I just went for the one that my FLAPS has on the shelf.

Okay, now I've finished the underside areas, I can reveal the real area of concern. As can be seen, I have removed the seat back support panel to gain more access, and tomorrow I'll be cutting out the rusty areas and making up new ones to let in.

Well done Paul,you will get there ............... ,

A bit more work done, the rusty areas have been cut out ready for repair panels to be welded in, a little more cleaning up is required before repairs can be welded in:

Paul,
What alerted you to the presence of the rust. The area is hidden under the seat back support and linings isn't it?

Paul

Could almost sworn I was looking at a picture of my car. Its sitting ready to be done, in a very similar state. I have bought a replacement inner wing panel to fit.  The Golfs all seem to go worst on the offside.  The nearside on mine aint half as bad as the offside.
Keep meaning to take some pictures and put on my own thread but always just seem to get carried away working on something else on the car.
Mark one did a similar job on his car an made a great job of it.
Maybe soon I will get around to taking the photos and post them. :roll:

AUSGOLF said

Paul,
What alerted you to the presence of the rust. The area is hidden under the seat back support and linings isn't it?

Paul

Only some of the area is hidden, the rest was visible inside the boot. Once I'd stripped other items and trim away, I could see the extent of the rust, which has nearly all been cut out. I will make replacement panels to go into the cut away areas. I need to somehow fabricate a seat belt reel mounting point, though.

Paul
Get a nut which is the same thread as the seat belt fixing bolt. drill a hole in the repair panel in the correct position for the seat belt holder (before welding the panel in) then weld the bolt to the rear, or inside of the repair panel. There you have it. :y:

Macca said

Paul
Get a nut which is the same thread as the seat belt fixing bolt. drill a hole in the repair panel in the correct position for the seat belt holder (before welding the panel in) then weld the bolt to the rear, or inside of the repair panel. There you have it. :y:

Any idea of the correct thread pitch? I know its an M10 (17mm) nut. I'll need a new bolt too, due to rusting of the original one. Aren't they corrosion-resistant too? Like a yellow coating?

I'm not sure at this time. As I said I have similar problems, but the fixing bolt for mine is okay. Will check tomorrow and let you know.

Macca

Macca said

I'm not sure at this time. As I said I have similar problems, but the fixing bolt for mine is okay. Will check tomorrow and let you know.

Macca

No worries, I forgot I can simply look at the other side to find out the thread! I know its a finer than usual one.

In fact is M10 not a standard thread size :dontknow:

Anyway keep us posted as how you get on. I will try and get the photos taken and start my own thread.

Off to bed now. Need my beauty sleep lol

Macca said

In fact is M10 not a standard thread size :dontknow:

M10 is the width of the bolt, but the thread could be 1.5mm (standard), 1.25mm or 1.00mm. I'll buy them off these guys:

http://www.namrick.co.uk/browse.asp?PCID=9

In between the rain, I've got stuck into the worst job - the corrosion of the middle panel, in between the outer rear wing and inner panel you see in the boot. Its tricky to work here because its so cramped, the conventional grinder and wire brush couldn't reach. Some of the cutting was done using this little fella, a drill mounted nibbler:



The rest was done using a junior hacksaw, or grabbing the metal with pliers and wiggling back & forth until it snapped. I'll do my best to straighten out the remaining good metal, which will be welded over with a cut repair panel.

The pics aren't terribly clear. Imagine you've completely taken the wheel off and are looking directly upwards.











Tomorrow (weather permitting) I'll be welding (upside down) the repair panel into place.

Looks like you're getting stuck in Paul!