I started a Hello thread recently after picking up a MK2 GTI and figured I'll start a new thread with the build here. Intro page link - https://www.clubgti.com/forums/index.php?threads/back-with-a-mk2-16v-project.294127/ So, it's been a while since I've had a MK2 but always missed my old one and needed another. This one came up for sale and was worth a look. It's not seen the road (as far as I can tell) since 2006/07 but was fairly decent considering it's been laid up for so long. It's got the usual small dings from lying around and a little crusty here and there but decided it was worth the effort to restore. I've had it around 2 weeks now and finally got some time to get some work done. I noticed there were holes in the floor when I went to view it but wasn't sure how bad it was so wanted interior out to see how bad it was. The amount of Clifford wiring hiding behind the center console and around steering column was more than I was expecting and looks a mess but I was planning to remove it all anyway so will get this tidied up. Luckily I've spoken to someone that can help with this. Reckon I'd be there for days trying to figure it all out. Carpet, seats and door cards are all in pretty good condition with very little wear for its age. Insulation was wet and fell apart so water has been getting in somewhere for a while. There is a hole in the passenger footwell and a larger hole in the drivers side closer to the sill but overall not as bad as I was expecting. Some surface rust in places but pretty solid for the most part. Seat rails, boot and wheel well are good, as are the rear turrets. A little surface rust around the seams at the tailgate but not rotten. The headlining has dropped at the back and on the list of things to take out. I've not had the engine running yet but have managed to turn the crank by hand so doesn't look like anything is seized. New battery fitted but no power to dash so assuming there's a bad earth somewhere or the alarm is causing an issue. Hopefully get a look at that soon.
Your floor doesn't look that bad. I ended up removing all the bitumen with a scraper and heat gun from the top, then thinners and rags to finish (horrible job!). After repairing I used EP 2 part Epoxy Primer to coat it. I found in some parts the water had crept under the bitumen coating.
Short update on this as it's been a while. Not huge amount done but little bits. Got the last of the interior trims out and headlining is out now too. Managed to get the headlining out in 3 biggish bits so reckon I can use fiberglass and get it back in one piece. Fabric is still intact so should be able to reuse that too. I did however, break the pin for adjuster knobs for the seatbelts, both sides. Guessing I need to source a whole assembly for this? Doesn't look like a replaceable pin. Other than that, the dash is still in until the wiring is sorted. Once that's done I can get stuck in to get the dash out and spend more time stripping it down. Hopefully have more done for the next update.
This looks super fresh. Heard it's nightmare job getting it all cleaned up but it looks so worth it and just makes sense doing it properly
Yes I'm glad I did it now, as said there were some parts where the bitumen had come away and there was surface rust underneath. As you say well worth doing.
Yes fiberglass works great did the liner in my 87 GTI but that was more like 8 pieces lol ,however don't expect to get the original fabric back on ,when remove it looses the foam backing when it falls down and over the years the fabric shrinks , my trimmer used Mk5 black fabric that had the foam prebonded not original but looked really smart.
Search on eBay for scrim foam headliner material, and use high temp spray glue. I used this when I did a Quattro sport headliner for a mate. Just make sure the surface your sticking to is flat and smooth as you will see any ridges or bumps, and don’t tape over the joints to smooth out, as the tape glue won’t be high temp. Don’t ask me how I know that one!
Good to see some success stories with the headlining. I appreciate the info. Update time,, Holidays are nearly over, been away for a break in Shetland and getting work done at the house meaning I've had the dog at work on the regular leaving little done. I can't get near it with him there. But what has been done has made so much difference. Thanks to an electrical oracle, we have got all the Clifford kit out, there was loads! He found and sorted more electrical gremlins and now engine starts and runs. Not started in years but idles quite happily. There were issues with the fuel pump not getting power which we think might be down to corrosion in the fusebox. There was wiring torn out from a connector by the throttle sensor/mircoswitch which he managed to re-pin. The alternator doesn't seem to be charging, wiring and bushes seem ok but no output. Dist. cap and rotor arm have movement which is weird and the leads have had a nibble from a critter at some point. All things that can get looked at but main thing is, it runs. All going well, I'll get some time next week to stuck in and get bumpers, trims and wings off to look for any more rust. Hoping to get dash out soon too. Still loads to do but feel like I'm getting somewhere.
That’s a fair pile of wire you have, you’ll be off to weigh it in now Nice to hear you have it running now a big step forward
