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

With your steering rack make sure that the jubilee clips are on the right angle so you can get a screw driver/spanner in there to undo them when you need to replace the rubber boot.
I've not see jubilee clips used before, I use cable ties and some kits come with a metal clip to fit the outer side.

mark1gls said

With your steering rack make sure that the jubilee clips are on the right angle so you can get a screw driver/spanner in there to undo them when you need to replace the rubber boot.
I've not see jubilee clips used before, I use cable ties and some kits come with a metal clip to fit the outer side.

Yes, we checked that we can still get to them.
The boots we got were a little bit different than the originals, that's why we used these clips

Yesterday we started degreasing the transmission and blasted it afterwards.

Small part done


Almost there!


Now we can start working on the engine.


We first degreased it and then painted it black



Fully painted, looking good so far!

After the engine was painted, we took the head and clutch assembly off.




After that was done, we started working on the little interieur panels in the boot and the tray under the dash, we decided to wrap them with vinyl.



We took the cilinder head to a friend, he's an old mechanic who worked in a VW garage.
He removed the springs and valves.




Today, we blasted the head.

That difference

Like new



Yesterday we couldn't find the other panel from the boot.
Today we did, so we also wrapped it in vinyl leahter


 

Not much done today other than,
Removing the remaining gasket on the cilinderhead and the engine block

Repainting the intake manifold


Also took the flywheel off the engine


And finally, we bought an engine stand, this will make working on the engine much easier.
Only problem.. the bolts of the transmission are to short  so before we can mount the engine we'll have to get longer bolts

I found the same problem with my new engine stand….
I'm sure you know but make sure the head etc is super clean inside when rebuilding it as you don't want any grit from that blasting wearing away the internals of your engine.
I've read about rocker covers getting blasted clean and power coated then not properly cleaned then grit getting into the cylinders and it not looking good for the engine a year down the line.

When I rebuilt my head I took it to a engine re builders and they have a big sort of dish washer to clean the head and for £20 it saved me alot of time and effort.
 

mark1gls said

I found the same problem with my new engine stand….
I'm sure you know but make sure the head etc is super clean inside when rebuilding it as you don't want any grit from that blasting wearing away the internals of your engine.
I've read about rocker covers getting blasted clean and power coated then not properly cleaned then grit getting into the cylinders and it not looking good for the engine a year down the line.

When I rebuilt my head I took it to a engine re builders and they have a big sort of dish washer to clean the head and for £20 it saved me alot of time and effort.
 

We taped the room where the valves and springs sit, only blasted the outside.
Afterwards we got rid of the grit with compressed air till there wasn't any left.

Today we disassembled the engine further

Started with mounting the engine (with the longer bolts ) on the engine stand.
Then removed the oilcarter. Now we could start removing the pistons.
When disassembling them we punched some holes in them to make sure we don't mix them up.
We'll be replacing the piston rings and piston bearing shells.

All pistons out (notice the marks on the engine block)


The pistons (Same thing, notice the marks.)


Also removed the oilpump.

Nice work there Martijn on the engine and interior panels. Looking forward to seeing pics of the newly painted shell.

watson said

Nice work there Martijn on the engine and interior panels. Looking forward to seeing pics of the newly painted shell.

Thanks Dave, I do too

Wow, some great work guys, look forward to seeing how this one progresses  

Best of luck with it

richyhill said

Wow, some great work guys, look forward to seeing how this one progresses  Best of luck with it

Thanks, I hope we can finish the engine this week and get the car back from paint so we can start putting the headliner and windows in.

Cleaned the oil carter and pistons, took me almost a full day Degrease the oil carter, outside is ready for some fresh black paint


First I started with removing the piston rings. I did manage to break a few but these will be replaced so no big deal.


Started cleaning the pistons with some diesel and a very soft bristle brush so it won't cause scratches.
Cleaned the slots with a broken piston ring.


Face of the piston, cleaned with diesel and a scotch brite pad


All four pistons

Today we had our cylinder sleeves honed by a friend.

Looking fresh and ready for some new piston rings

Today I spray painted the fuel tank straps + also applied some foam tape


Painted the oil pan in heat resistant paint


Also got our new clutch and bearing


My brother cleaned the carburator with some petrol


I also cleaned the oil pump and rear plate for the crankshaft oil seal



And finally we cleaned the rubbers of the rear side windows


Also started fitting the window trim 1 window done


Both windows


Also the rear window Some painters tape holding the seal in place

Yesterday we got our piston bearing shells and piston rings The engine rebuild can begin!

Looking good...

Nice attention to detail Martijn.  Any paint pics yet ?

watson said

Nice attention to detail Martijn.  Any paint pics yet ?

Nope.. They haven't started yet
Hopefully this week..

Ice2812 said

Looking good…

Thanks!

Today we got our cylinderhead back.

Cleaned valves and gasket surface



Couldn't wait and aready mounted the valve cover and placed the head on the engine block

 

This is an awesome thread! thanks for showing the detailed bits of welding - has helped me get my head around a lot of what I need to get done!  Keep up the good work

Did you buy the replacement metal for this bit or did you make it?  … if the later … how did you get the same shape?  I've been wondering how to get this section sorted.