Mk1 GTI Blue G60 Conversion

Nice work

Spent a few more hours this week tending to the body work  





More work on the windscreen!











Roof!





Rear quarter repair.







I have a few small holes to repair on the floor pan then the bigger works can begin, rear panel, front panel and inner and outer sills!

nice work mate, repairs are good and shaped well.

Swallowtail_uk said

nice work mate, repairs are good and shaped well.

Cheers mate! Almost at the point where I need to decide which to do next, rear panel and lower corners both sides or both inner and outer sills 

Recieved some parts from vw heritage so decided to start with the fuel filler panel repair.

Also made another purchase to assist me with my welding…… An auto dimming welding helmet from fleabay!



Old………. And new!

The hand shield is ok for long runs of weld, but when doing spots of welds it is difficult to be precise. The new helmet makes it much easier!



The area was cut out large enough so I could repair the inner wing which was rotten aswell!



Then the repair panel was cut to fit and used as a template to cut the hole in the inner wing repair. 

Welded and painted.

Nice work. Auto-dim helmets are brilliant, so much easier than a hand-held jobby!

One reason I love my speedglas

Good progress matey! 

Hairyarse said

Nice work. Auto-dim helmets are brilliant, so much easier than a hand-held jobby!

Brad. said

One reason I love my speedglas

Good progress matey! 

Cheers, with the hand held shield, you line the mig gun up with where you want to weld but by the time you hold the shield up to your face the gun has moved slighty and sometimes you miss where you were aiming for.  
plus you can pick up those auto dim helmets cheap enough now  

Some good pregress mate. Good skills. Like the helmet.      

Awesome repairs mate,mopar do a banging green it's almost black under normal lighting but has stunning green highlights in the sun

smudger1980 said

Some good pregress mate. Good skills. Like the helmet.      

Cheers mate, still lots to do  

utterly-dubberly said

Awesome repairs mate,mopar do a banging green it's almost black under normal lighting but has stunning green highlights in the sun

Thanks, I will look up the colour, sounds like the old lotus calton colour, imperial green which can look almost black.

On the face of it the car looked pretty good before you set to work on it.  Scary just how much rot can exist on a 'Solid' looking car.

butleraw said

On the face of it the car looked pretty good before you set to work on it.  Scary just how much rot can exist on a 'Solid' looking car.

Thing is the car had a respray a few years ago, and if you havent had it done yourself it could be hiding all sorts, most probably filler, fiberglass and rot as in my case . The paintjob would have looked ok for a few years until the rust would start bubbling through again!  only one way to do it properly ands thats to cut the rot out and weld in new metal.

Decided my next move would be tackling the n/s outer sill.
It has had a new sill on at some point in its life and had been put on by partly overlapping the original sill.





How does the old saying go? Something like if you can see rust on the outside it is 10 times worse where you cant see?

Anyway sill removed.



Here you can see where sill was overlapped



Rot cut out of front inner sill and tacked up


Floor pan cut out and repaired










Now started on the back area of inner sill

Rot cut out



New piece cut out, folded and tacked in



And fully welded



Next outer sill and car were fettled so new sill could be butt welded in.

Clamped and tacked in place



Door fitted to check gaps!



And fully welded





One down, one to go! 

Really good effort, i hope mines not like this lol

Top skills mate. Progress made.    

Pipsical said

Really good effort, i hope mines not like this lol

Thanks….. I think. 

smudger1980 said

Top skills mate. Progress made.    

Cheers mate

Jimievo said

Pipsical said

Really good effort, i hope mines not like this lol

Thanks….. I think. 

I meant hope mine isnt rusty like this was, not your work thats looking awesome. I wouldnt dare go this far with a strip down. I'd get bored, the end result will be epic. Keep it up.