'90 Cabrio Karmann

Some before and after pictures

BerT3

The test mats went in the post last week for you BerT3, looking at those pics I think the floor pan is the same.  

GavB95 said

The test mats went in the post last week for you BerT3, looking at those pics I think the floor pan is the same.  

Received them Gav - they do need some alterations though…

I'll get back to you

BerT3

Bought me a USA rear trunk - needs repainting though - already has the holes welded up

Might find it's place in the future as the brake light is a bit more visible while braking

Also found a corect gear lever bracket - even has brass bushings - tight fit it is - I am going to have an experiminet with it to rectify the out of alignment of the shifter rod due to an aftermaket steering rack

Bought some NOS small parts to install - shame I ordered the wrong key - it will be for sale - it's a HV code

I know it's an early window washer but that's due to the incorrect engine bonnet - might rectify that if I come across a correct bonnet

Some photos

BerT3

Found me a correct NOS Pierburg 2E2

Might come in handy when the one in there seems irrepairable

Some photos of these over engineered beast

BerT3

Next job on the list

I guess there is a head gasket failure waiting to happen

No foam or mayo in the oil yet - just a slight coolant leak

Ordered all necessary parts to replace the head gasket

Will remove the manifolds as well to replace all seals as well

On the other hand:

- Does the head needs skimming ?
- Do I need to remove the camshaft and / or valves to have it skimmed ?

BerT3

Bought me a spare ABS code engine - a spare AUG 5-speed gearbox and a correct OG bonnet to replace the repro flimsy one in the future

The bonnet came wit a very nice dampening liner which I already put into place to replace the damaged around the air filter - reverse installed one

Even had enough correct clipses to attach the edges of the liner

At least I can use my bonnet prop now

BerT3

To cure my leaky head gasket I bought some spare parts

- New head with 40mm inlet valves and a G code camshaft and adjustable camshaft wheel
- New head gasket seal set from Elring
- New Elring head bolts
- New belt and roller
- New manifold bolts - washers and nuts

Bought some tools as well

- The tool for removing the big C exhaust clamps
- The tool for adjusting the belt roller

Spare parts which will be cleaned and installed before the swap

- Inlet manifold
- Exhaust manifold
- Some carb to manifold hoses
- The water inlet and outlets
- The carburetor flange

After the swap I will do maintenance as well

- New oil
- New oil filter
- New air filter

Some photos of it all below

Bert

Got the new head installed

All new parts fitted - CO adjusted etc.

Drives very nice now - bit of extra power with the bigger valves and the GTI camshaft gives it a better acceleration

Now I hope to keep it going without major work…

BerT3

Finally fixed that notchy gear shifting

Turned out the bracket on which the gear lever relay mounts to on the servo assisted steering rack was out of center a 6mm

Bought a spare gear lever relay bracket - cut the ends of - welded them 6mm out of center

Set up the linkage per manual and everything shifts ver smooth

The gear lever relay bracket even came with bronze bushings for the shaft

Shifts very tight now throughout all gears

Picture of the result later for future reference

BerT3

Nice Cabby Bert!

It interesting to note that all the Australian delivered Cabriolets had the extra brake light as part of the rear tailgate.

VW re-introduced the Mk1 cabriolet into Australia from 1990 to 1993, then moved onto the series 2 Cab based on the Mk4 golf.

Out of curiosity,how much per wheel were the Fifteen52 16" wheels?

They're "sweet as" on a cab and a change to the usual RS/RA BBS wheels.  

ConvictGTI-No.1983EW said

Nice Cabby Bert!

It interesting to note that all the Australian delivered Cabriolets had the extra brake light as part of the rear tailgate.

VW re-introduced the Mk1 cabriolet into Australia from 1990 to 1993, then moved onto the series 2 Cab based on the Mk4 golf.

Out of curiosity,how much per wheel were the Fifteen52 16" wheels?

They're "sweet as" on a cab and a change to the usual RS/RA BBS wheels.  

Thanks,

Those were close to € 2000 since we have to pay 30% import taxes

BerT3

Photos of the rewelded gear shifter bracket

6mm out of center in my case - the ball sits dead center in it's cage now

Shifts smooth as can be

BerT3

Went to the annual MOT yesterday

1 year - lots of repairs - covered over 8000 kms

Passed the MOT without remarks !

BerT3

Another year passed with about 8000 km's extra

Have to go the MOT

Just had to do an oil and filter change this year

The varnish on those wheels are starting to flake - USA varnisch I guess

On the other hand I won't be able to cover that much kms over the next years because our city implemented a low emission zone where I live

Bought a new house in another city and got a permit to build a big garage

Next month MOT again…

Here's a photo of the car after a winter

BerT3

Lovely car and great work, please keep up the posts, looking forward to working on mine.

Cracking looking car you have there.

The car passed it's MOT after I changed 1 rear disc brake caliper because of a stuck handbrake lever.

Bought an OG VW Girling one.

Drove a bit over 5000km's  this year.

Bought me a NOS OG VW white headliner still in the box which I might install in the future.

Also bought me a good used heater face plate with hopefully ALL working lights since it bothered me that the blue one didn't light up.

Next on the list is a nw pair of mats.

Bert

Just to update this thread.

Due to a new implemented low emission zone I didn't make any mileage last year.

In fact I only drove it from the MOT to the MOT 1 day of a full year apart to cover just 34 kilometers.

Needless to say I got a blanco MOT since it had one last year.

My new garage at the new house outside the low emission zone was finished just in time.

Since then I drove it everyday and intent to keep doing.

Replaced the mats - that's the only thing I did to keep it at a certain detailed level.

Will post a recent photo of it this weekend after I cleaned the car.

BerT3