1991 Pearl Grey Golf MK2 GTi Project

Discussion in 'Members Gallery' started by NateS2, Oct 6, 2019.

  1. Tristan Forum Junkie

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    I want to extend gratitude to you Nate from myself and all the people who will do a search for this in years to come, for you going to the bother of posting all the details.
     
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  2. Vinnie

    Vinnie Paid Member Paid Member

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    Do you have a link to the rear protector please Nate
     
  3. NateS2

    NateS2 Paid Member Paid Member

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    No worries! Might as well do something useful with it, especially considering how much info I've got off here!

    He's on instagram, I can see if I can get an e-mail if you like? artemiyyakov
    He does various bits, that cover, and OEM style rain tray, the leaf catcher and a Votex style parcel shelf box. He also sourced the pollen filter for me which was handy.
    If there are a few people interested as I say we can set up a group buy to save on postage
     
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  4. NateS2

    NateS2 Paid Member Paid Member

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    Rear Suspension

    I've already covered part of this but to recap, fetched the rear beam out last year...
    IMG_2738 - Copy.jpg
    Original bushes and brake lines. Previous owner has "painted" the beam, fitted new brake dust shields and calipers. They're from BiggRed and one of them is really nice, looks new. The other(I'll add pictures) has been painted with what I can only assume is rust accelerating paint. Its on various parts of the car is terrible.
    Some closer shots of the beam, bushes and destroyed brake pipes...
    IMG_2850 - Copy.jpg IMG_2846 - Copy.jpg IMG_2851 - Copy.jpg IMG_2847 - Copy.jpg
    The beam, cross member and rad support where sent to a local coating company who blasted with garnet to SA 2.5, Zinc thermal sprayed, epoxy sealed and then coated with two coats of polyurethane gloss @ 50µm. This is the same coating process used for bridges and oil rigs, albeit with far less coats. In its current form its rated for 20 years before failure, so a little bit better than the wisp of black paint VW apply[:D]
    The result..
    IMG_4012 - Copy.jpg IMG_4015 - Copy.jpg IMG_4010 - Copy.jpg
    In these pictures you can also see the new copper nickel brake lines that run in factory routing (anyone know what the big pointless looking bend is for?) and new lemforder bushes. Only thing missing from the brake pipes is the factory green look like @GG. achieved The brake pipe clips are OEM and sourced from Mecatechnic in France. The whole beam has also had a coat of Dynax UB with Dynax S50 sprayed into the ARB. A new Borgeshung bush was also fitted to the ARB.

    Next was the beam mounts which looked like this...
    IMG_0362 - Copy.jpg
    A Deox-C bath and some wire brush action later
    IMG_1401 - Copy.jpg
    There were sprayed with 2 coats of Electrox primer and then enamel paint. I would have had these done with the beam but I didn't think ahead. It will be a good comparison of the coatings :)
    The finished article with new Geomet coated 10.9 bolts.
    IMG_3808 - Copy.jpg

    I'm using XCP rust blocker on all fasteners a torquing lubricant and additional rust inhibitor
     

    Attached Files:

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  5. Vinnie

    Vinnie Paid Member Paid Member

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    Sounds good to me
     
  6. Louis Falco Forum Member

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    Great progress there! That rear beam is going to outlive the human race! I am going to be sending mine off along with all the subframe parts for blast and powder coating this weekend but would rather some more heavy duty like that. The problem is I dont know anywhere in Cornwall that offers this service.
     
  7. NateS2

    NateS2 Paid Member Paid Member

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    I hope so! :) I'm very to lucky that I have that place local to me and the owner is into cars and bikes so he takes on little projects like that! There's a place called "Blastclean" that do thermal spraying and powder coat/wet paint. There website sort of implies they take on smaller jobs so might be worth a look?
    And anything will be better than the whisper thin layer of black paint that's put on from the factory!
     
  8. Savagesam

    Savagesam Moderator Staff Member Moderator

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    And if you think about it, as they’re always on stands, they never get driven it, it’ll never wear off
     
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  9. NateS2

    NateS2 Paid Member Paid Member

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    :lol:Exactly, infinite lifetime, especially with the small brush and black enamel self healing properties when it gets a little storage nick[8D]
     
  10. NateS2

    NateS2 Paid Member Paid Member

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    More work over the last view day, actually got some decent weather for once. Also going to steal the @cupracraig style satisfying list :)

    Suspension and Brakes
    • Rear beam mounted
    • Rear stub axles Elextrox'd and painted
    • Rear Discs fitted
    • Rear Callipers fitted + Brake pipe furniture
    • Brake bias valve hydraulics
    • Brake bias valve mechanics
    • Duralac all fasteners near stainless/aluminium
    • Fit heat shields
    • Fit exhausts
    • Stone chip sills
    • Assemble rear suspension struts + fit (Bilstein debarcle)
    • Assemble drive-shafts
    • Assemble front suspension, loose, Check bearing function
    • Fit front calipers and new flexi's
    • Clean up brake pipe routing using factory clips
    • Final paint on brake booster, fit using new nuts
    • Fit 22 mm master cylinder, new nuts
    • Fill and bleed brake system
    Electrical
    • New ignition switch
    • OEM+ Headlight loom drawings
    • Make OEM+ Headlight loom
    • Re-terminate oil and water temperature sender connections
    • De-bodge immobiliser
    • Source 1 inner spot, and side-light bulb holders
    • Source stainless hardware for fog light mounting
    • Mount fog lights
    • Fit horns
    • Re-fit ECU
    Other
    • Paint interior of rear turret after rust repair
    • Re-fit boot trim
    • Install OEM first kit
    • Source warning triangle and strap
    • Fit boot lip protection
    • Source new boot carpet
    • Source new rear window scraper trim
    • Fit pollen filter and new Mahle LA19 element
    • Change Oil + Filter + Air filter
    • Re-install interior panels
    • Refurbish my own instruments and fit those
    • Make new shift linkage relay shaft bush from Nylon/UHMW
    • Assemble and setup gear shift linkage
    • Re-connect clutch with refurbish brackets
    • Get new PAS hoses manufactured
    • Flush PAS system with CHF and fill
    • Cam belt
    • New V belts
    • New crank bolts and V-belt pulley bolts
    • Source lower airbox section
    • Clean scuttle and source new tray
    Pictures to come :)
     
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  11. davkav

    davkav Paid Member Paid Member

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    Oh we're breaking the lists into groups now are we...
    I'll have to sort mine out.
     
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  12. NateS2

    NateS2 Paid Member Paid Member

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    Yeah moving onto advanced listing now, should get an annual ClubGTi most creative/impressive list award going
     
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  13. davkav

    davkav Paid Member Paid Member

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    Lists and sublists is where it's at, watch this space! :lol:
     
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  14. NateS2

    NateS2 Paid Member Paid Member

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    I'm excited for this, will be waiting intently for the new post notification [:D]
     
  15. NateS2

    NateS2 Paid Member Paid Member

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    Back to the front axle, the original drive shafts were very grotty, started wire wheeling, thought sod that and got them blasted and powder coated instead
    IMG_3850 - Copy.JPEG
    The CV's both inner and outer were fine, no discolouration and just some polishing which you couldn't feel, so I decided to clean them up
    IMG_4006 - Copy.JPEG IMG_4003 - Copy.JPEG

    Someone has clearly got very angry with this inner CV, many times [:D]
    IMG_4033 - Copy.JPEG IMG_4036 - Copy.JPEG
    IMG_4036 - Copy.JPEG
    They were then painted with Electrox and silver top coat, the original inner boots were actually in great condition, but the outer ones were shot so new GKN boots were in order. Re-assembling outer CV
    IMG_4051 - Copy.JPEG IMG_4047 - Copy.JPEG
    I don't have a picture of the full shaft, but I'll get some of them on the car!
    IMG_4178 - Copy.JPEG
    Also have brand new bolts and re-plated spreader plates to go along with them
    IMG_4045 - Copy.JPEG
     

    Attached Files:

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