1990 Alpine White Mk2 Golf GTI Rebuild

Discussion in 'Members Gallery' started by Chris92, Jun 5, 2017.

  1. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    Update since July, been lazy with this thread[:s]



    Before working on the shell I wanted to get the running gear sorted so i could get it back on the floor once the underside was done, so I overhauled the rear axle first...

    Before pulling it apart
    [​IMG]


    Proper state
    [​IMG]


    Lots of air ratcheting and breaker bar-ing later..
    [​IMG]

    Calipers seen better days
    [​IMG]

    Everything wirebrushed down and painted
    [​IMG]

    [​IMG]

    New dust shields and hardware from VW Heritage :thumbup:
    [​IMG]

    Standard disks on the rear, will likely upgrade a lot later down the line
    [​IMG]


    [​IMG]

    Rear axle done!:thumbup:
     
  2. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    Found some time to update this a little, i got in contact with the guys at Proengines in Hatfield to see if they could do anything with the 8v engine, they gave it a good look at and determined it needed a rebore because the cylinders had some wear, hence the reason it was smoking so bad. They fitted oversize pistons and skimmed the block. They also skimmed the head, 3 angle cut the valve seats and fitted new valve guides and seals and new lifters, gotta say a massive thanks to them, wouldnt be able to do any of the work they carried out for me and I cant wait to see how she runs now :thumbup:

    [​IMG]

    [​IMG]
     
    erreesse likes this.
  3. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    Next thing was to get the shell on a rollover so I could sort the bad bits underneath...

    [​IMG]

    [​IMG]
     
    erreesse and Sirguydo like this.
  4. Farmerchris

    Farmerchris Paid Member Paid Member

    Joined:
    Mar 21, 2017
    Likes Received:
    13
    Great work so far. Looking forward to the putting back together stage.
     
  5. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    Me too mate haha
     
  6. sports racer Forum Member

    Joined:
    Dec 26, 2014
    Likes Received:
    200
    Location:
    Australia
    Just bought it and you're pulling it apart.

    You're either masochistic or plan on keeping this car for a long time.

    Hope it's the latter.

    Well done so far. Much rust underneath?
     
    stevencooke likes this.
  7. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    I know it seems mental mate but I'm keeping this for life so there is some sense in the madness haha, I got some pictures to put up of the underside but its not been too bad compared to what others have had to deal with so I've been lucky. I'll put the pics up now actually.
     
  8. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    I'd love to have the space and time to do a full strip and rebuild, I envy you sir!

    Looking good, keep with the updates [:D]
     
  9. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    So yeah, the underside, I'd consider myself lucky compared to others, not been too bad tbh. Took ages to decide whether I was going to bother removing all the underseal but ultimately decided against it, mainly because it saves time and effort and the fact that most of it was still firmly stuck on and doing a good job of protecting the underside, Im confident I got all the rust removed without having to remove all the underseal.

    [​IMG][​IMG]
    Front offside subframe mounting area, not too gone that it needs new metal, just a clean up with wire brush.

    [​IMG][​IMG]
    Jacking point, pretty common from what I've seen

    [​IMG][​IMG]

    [​IMG][​IMG]
    First ever welding I've done on a car, wont show you what it looked like before grinding down lol

    [​IMG][​IMG]
    End of the chassis rails, was like this both sides

    [​IMG][​IMG]
    Something hiding, I just cut it back a section at a time till I got to the end of it

    [​IMG][​IMG]





    [​IMG][​IMG]
    Plated back over, sweet as

    [​IMG][​IMG]
    Really didn't want to do it but had to pull the seat mount off cause there was a couple of rust holes under there.

    [​IMG]

    [​IMG]

    [​IMG][​IMG]
    Was really hard to weld this back on, the metal is so thin it blows through well easy, just have to be really careful with it, hope the seat will fit back in haha

    [​IMG][​IMG]
    Wire brushed all the brake and fuel line studs.

    [​IMG][​IMG]
    A couple of other new bits of metal that needed in.

    [​IMG]
    [​IMG]

    So yeah I think I've been super lucky with the lack of rust on the underside, Ive seen people replacing whole floorpans, respect to them guys, this is nothing compared to that.

    I'll upload pics of the undersealing and painting next, cheers for looking:thumbup:
     
    erreesse likes this.
  10. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    @savagesam, Cheers mate, yeah its wicked, all my weekends are lost to this thing though, pretty much been every weekend for a year solid and no time in the week because of work, hope its worth it lol
     
  11. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
    Sounds like the perfect way to spend a weekend to me!
     
  12. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    Next up was cleaning up the chassis rails, had a lot of failed underseal and a bit of rust on the bottom of them.

    [​IMG]

    IMG_8839 by Chris Redford, on Flickr

    They cleaned up really well, gave them a good key with a DA for a good key for the paint.

    [​IMG]

    IMG_8841 by Chris Redford, on Flickr

    Gave them a couple of coats of zinc primer.
    [​IMG]

    IMG_8844 by Chris Redford, on Flickr

    And them I masked them up for putting the underseal of, used the 3M two part stuff, came out nice.

    [​IMG]

    IMG_8908 by Chris Redford, on Flickr


    [​IMG]

    IMG_8915 by Chris Redford, on Flickr

    [​IMG]

    IMG_8925 by Chris Redford, on Flickr

    [​IMG]

    IMG_8926 by Chris Redford, on Flickr

    At this point I applied the underseal to all the reworked areas and done my best to blend them into the original underseal.

    [​IMG]\

    IMG_8951 by Chris Redford, on Flickr

    [​IMG]

    IMG_8953 by Chris Redford, on Flickr

    [​IMG]

    IMG_9037 by Chris Redford, on Flickr

    [​IMG]

    IMG_9035 by Chris Redford, on Flickr

    [​IMG]

    IMG_9036 by Chris Redford, on Flickr

    [​IMG]\

    IMG_9038 by Chris Redford, on Flickr

    And that's how it all looks finished:p Gonna black the whole underside to finish it off and then I can get it off the rollover jig!
     
    erreesse and beetie like this.
  13. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    erreesse likes this.
  14. Savagesam

    Savagesam Moderator Staff Member Moderator

    Joined:
    Nov 24, 2012
    Likes Received:
    1,096
  15. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    Right, so with the underside sorted, I made a start on the absolute state that is the front running gear, lots of seized bolts and hammering required...

    [​IMG]
    IMG_7387 by Chris Redford, on Flickr

    Front callipers have seen better days, will be getting the same treatment as the rears.
    [​IMG]
    IMG_7391 by Chris Redford, on Flickr


    Suspension uprights also in a bad way, nothing unusual though just what 30 years of use looks like.

    [​IMG]
    IMG_7719 by Chris Redford, on Flickr


    Anti-roll bar can be saved, just needs cleaning up

    [​IMG]
    IMG_7739 by Chris Redford, on Flickr


    Same with the subframe, just needs a clean up although I will replace the wishbones as they are cheap enough new anyway.

    [​IMG]
    IMG_7400 by Chris Redford, on Flickr
     
    erreesse and Savagesam like this.
  16. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    Okay so the following photos are over the duration of about 3 months work between doing the body where I had time to squeeze in a bit of time after work, found it easier to dip into cleaning these bits up on a work day rather than setting up for welding and all that on a school night haha.

    Got a local garage to let me borrow their press for getting the front wheel hubs and bearings out [:D]

    [​IMG]
    IMG_7749 by Chris Redford, on Flickr

    Took me a while to work out how/where the bearing split from the hub, had some help from you lot on the facebook group, so cheers for that :thumbup:

    [​IMG]
    IMG_7742 by Chris Redford, on Flickr


    Buzzed down the grime and rust of the front subframe, got it as clean as I could, at the end of the day its going on the bottom of the car and wont be seen again, as long as all the rust is gone I'm happy with it :)

    [​IMG]
    IMG_7763 by Chris Redford, on Flickr

    Here's the result of HOURS of wire brushing and scrubbing lol never again, what a ballache, result is very satisfying though. I used this stuff from a company called Bilt Hamber, deox C, which is basically a solution you put in hot water and then soak your parts in, works really well and got the bits dead clean.

    [​IMG]
    IMG_7778 by Chris Redford, on Flickr

    [​IMG]
    IMG_7779 by Chris Redford, on Flickr

    Arty shot haha

    [​IMG]
    IMG_7781 by Chris Redford, on Flickr

    Cleaned up the brake pistons, will reuse them as they seem alright

    [​IMG]
    IMG_7784 by Chris Redford, on Flickr

    Rattled the subframe in primer for a bit of protection

    [​IMG]
    IMG_7786 by Chris Redford, on Flickr

    Gave it all a lick of good old smoothrite, can't go wrong haha

    [​IMG]
    IMG_7796 by Chris Redford, on Flickr

    Result [:D]

    [​IMG]
    IMG_8144 by Chris Redford, on Flickr

    Borrowed the garaged press again to get the new bearings in, got em from GSF car parts.

    [​IMG]
    IMG_8139 by Chris Redford, on Flickr


    This is how I split the inner bearing race from the wheel hub, had to google how to do it though lol

    [​IMG]
    IMG_7897 by Chris Redford, on Flickr

    Cleaned the hubs up

    [​IMG]
    IMG_7925 by Chris Redford, on Flickr

    All assembled ready to go back on!

    [​IMG]
    IMG_9065 by Chris Redford, on Flickr


    So the idea is to get the front and rear subframe bolted back on and get the car back on the ground so I can start working on the upper body and engine bay, well pleased with how its turning out, shows what a bit of hard work can do :)
     
  17. oldnick

    oldnick Paid Member Paid Member

    Joined:
    Apr 27, 2009
    Likes Received:
    86
    Location:
    Farnsfield, Notts
    Looking good, I'm just jealous that you have/make the time for it ;)
     
  18. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    Long overdue update time, been busy so not had a chance to upload anything. After finishing the underside I got the golf back on the ground by fitting the rear axle and front subframe back on.

    [​IMG]

    [​IMG]
    Suspension is Volgtland :)

    [​IMG]

    [​IMG]
    End result, tastefully lowered obviously lol

    Next up will be cleaning up the engine bay and all the upper body work:thumbup:
     
    erreesse, oldnick and Sirguydo like this.
  19. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    Okay, long overdue update, still been working hard on the golf[xx(]

    After getting it back on the floor I made a start on the engine bay and upper bodywork, first thing was to remove all the seam sealer in the engine bay:

    Before

    [​IMG][/url]

    After

    [​IMG]

    [​IMG]

    Wasn't too bad a job after having tackled the underside was like a walk in the park in comparison haha

    Next up was the window cutout, was a bit shocked to find it this far gone at first but now realise it's a very common problem area, not sure if mine is a particularly bad one or not?

    [​IMG]

    Basically cut as far as I needed to right down into the firewall and up the corner to get rid of all the bad bits:

    [​IMG]


    Had a bad bit on the inner wing that needed sorting:

    [​IMG]

    [​IMG]

    Got a good cut from another golf and trimmed it until it fitted nicely :thumbup:

    [​IMG]


    Next was a bit I found under the right gutter, used a cut from another golf again:

    [​IMG]

    [​IMG]

    [​IMG]

    Super happy with how it turned out even though it won't be seen under the trim but still nice to know its done right haha

    Next up will be sorting the engine bay out; removing all the rust and a little bit of smoothing, nothing too crazy just a little tidy up[8D]
     
  20. Chris92 Forum Member

    Joined:
    Jan 6, 2017
    Likes Received:
    54
    Location:
    Woking
    Still going [xx(]

    Sorted out the window scuttle:
    IMG_9942.JPG IMG_0009.JPG


    Next thing to sort out was the engine bay:

    IMG_9298.jpg
    IMG_0020.JPG

    I done a bit of smoothing as well, nothing crazy just deleted a few holes that I don't need:

    IMG_9988.JPG IMG_9987.JPG IMG_0019.JPG IMG_0018.JPG

    I've kinda picked the best pictures cause I don't want to bore you with all the ones I have but its mad to think the best part of a years work can be shown in a handful of pictures haha
     
    Steffen and erreesse like this.

Share This Page

  1. This site uses cookies to help personalise content, tailor your experience and to keep you logged in if you register.
    By continuing to use this site, you are consenting to our use of cookies.
    Dismiss Notice