davkav's Mk2 Oak Green 8v

Discussion in 'Members Gallery' started by davkav, Feb 6, 2018.

  1. davkav

    davkav Paid Member Paid Member

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    A new updated list, couldn't quite come up with sub-lists.... [:D]
    • Body work:
      • Treat surface rust under driver side A-pillar
      • Fit replacement driver side wing
      • Seam seal wing to chassis
      • Spray wheel arch/inside of wing with waxoil
      • Treat any rust in the engine bay and general tidy up
      • Button up the front end
    • Suspension:
      • Remove subframe
      • Remove wishbones
      • Send part to be media blasted and powder coated
      • Refit subframe
      • Wishbones
        • Insert new bushes
        • Refit to subframe
      • Rebuild driver side driveshaft (passenger was done last year)
    • Steering:
      • Remove steering rack
      • Check steering rack for play/leaks
      • Paint rack
      • Fit new tie rods, tie rod ends, boots
      • Refit steering rack
    • Brakes
      • Disconnect front hard brake lines to allow for engine bay painting
      • Repaint Front calipers as I did a rubbish job the first time
      • Paint hubs of brake discs
      • Cut back and straighten excess brake lines where it joins to T-piece in the engine bay
      • Give the brake booster a lick of paint
    • Electric
      • Modify engine bay harnesses to allow harness to be re routed
      • Cut back excess wires at the plugs at sensors etc and re pin/tidy up
    • Parts
      • Order new Alternator, Power Steering pump, bushes, seals etc.
    • Engine
      • Send aluminium parts (brackets, inlet manifold, throttle body) to be vapour blastedFit all new seals
      • Get head skimmed and new valve guides inserted
      • Paint engine block
      • Fit new oil pump
      • Inspect cylinder bores for wear and roundness
      • Refit engine to car
    • Gearbox
      • Install new input shaft seal
      • Clean gearbox back to original metal
      • Connect gearbox to engine
      • Connect driveshafts
    • Electroplate nuts and bolts
     
    NateS2 likes this.
  2. davkav

    davkav Paid Member Paid Member

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    Yeah, maybe that's the best. It is most likely the original part from factory. If I'm going to the trouble of doing all of this work, I may do it right and replace what I can for peace of mind and to future proof it.
     
  3. NateS2

    NateS2 Paid Member Paid Member

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    Oh yes, I'm not disappointed with this. Going to have to get 4 levels deep of lists on mine now:lol:
     
  4. costel1969

    costel1969 Paid Member Paid Member

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    As a matter of interest - can the pumps be overhauled or are they sealed and as the "T." puts it the only option is to 'bin with extreme prejudice'?
     
  5. rubjonny

    rubjonny Administrator Staff Member Admin

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    they can be opened up by opening the crimped section on the back, but theres not that much you can do except redo the brushes
     
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  6. Tristan Forum Junkie

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    John, do you know if a mk4 alloy pump can be made fit?
     
  7. rubjonny

    rubjonny Administrator Staff Member Admin

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    wouldnt have thought so no, there is a bosch upgrade that fits the kjet swirl pot but dont know of one for the digi version. people have modified high output pumps to the mk2 level sender houisng then done away with under car pump, or you could go mk3 golf fuel tank then can drop uprated pump into that
     
  8. Tristan Forum Junkie

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    Sorry there RJ, crossed wires, Dave/me are talking about PAS pumps not fuel pumps.
     
    davkav likes this.
  9. rubjonny

    rubjonny Administrator Staff Member Admin

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    ah! well there are bolts to split the pumps, but I've no idea if theres anything you'll actually be able to do to the inside. Not seen any rebuild kits for them, though if there are seals those can be replaced. MK4 pumps are the same offset as MK2 Golf just swap the pulley over. There are 2 versions and when fitting 20v engines one of them goes in fine the other can hit the front carrier. Dont think this would be a problem in a MK2 though as its quite low down and further back. then again mk4 pumps may not fit in the mk2 brackets quite right, but mk2 pumps fit in the mk4 pas brackets so dont see that being a problem either
     
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  10. davkav

    davkav Paid Member Paid Member

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    Thanks John, good to know. I've a friend who works in a motor factors so shouldn't be a problem getting 2 or 3 different versions from him to try. I'll report back with the part number(s) that work.
     
  11. davkav

    davkav Paid Member Paid Member

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    Nothing much to report. I cleaned up the power steering rack as best I could last night to get it ready for a fresh coat of paint. I've just the section under the bracket where the gear selector relay ball attaches. I've made a right aul mess too!
    IMG_20210302_223149.jpg

    A few hours work and I didn't even manage to strike something off the list :lol:
     
  12. davkav

    davkav Paid Member Paid Member

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    Bit more progress being made now.

    I'm still waiting for my parts to come back from the powder coaters and a parts order of new bushes etc. But sure there is still plenty to crack on with.

    The steering rack got 3 coats of primer and then 3 coats of gloss black. It came up pretty well.
    IMG_20210310_220642.jpg

    IMG_20210313_160056 (1).jpg

    Built up the rack with new inner and outer tie rods, new bellows, and new clips.
    IMG_20210316_184026.jpg

    I also cleaned up some parts of the engine bay that had some surface rust. A few coats of primer, base coat, and clear coat, and I think it turned out well enough. It was my first time spraying something like this, and I've a few lessons learned. Top of the list is that I should have masked off at natural sections in the panels, in this case I ended up with some lines where the old paint meets the new. Not to worry though, I'll know for next time.

    Prepped
    IMG_20210310_211356.jpg

    Primed
    IMG_20210310_220541.jpg

    And coated
    fe52a13d-7884-4d12-8e6a-8d20039bbde0.jpg

    There is still some rust underneath the battery tray. I'll leave it for now and if I have time I will cut it out and weld in a new piece. For now its painted and sealed so should be fine, if I leave it until next winter.

    So as I am still waiting for parts to arrive, I've started to get a system ready for stripping and plating my brackets and bolts.
    IMG_20210318_133008.jpg
    Tune in at the weekend to see how it all turns out!
     
    dodgy likes this.
  13. costel1969

    costel1969 Paid Member Paid Member

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    I'm liking this Batman :thumbup:
     
  14. dodgy

    dodgy Paid Member Paid Member

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    Great work, and keeping us hanging, wanting more.
     
  15. Tristan Forum Junkie

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    I'll send you all my manky hardware so too, old buddy, old pal, old chum...
     
  16. Savagesam

    Savagesam Moderator Staff Member Moderator

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    I echo this, I was tempted to buy one of these to do all my stuff
     
  17. costel1969

    costel1969 Paid Member Paid Member

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    Ignore him Dave, jealousy is a cruel mistress...
     
  18. Tristan Forum Junkie

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    Dave loves me.
     
  19. costel1969

    costel1969 Paid Member Paid Member

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    Self praise is no praise
     
  20. GTIBOB

    GTIBOB Paid Member Paid Member

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    Fair play davkav. This was a great read and a huge amount of effort and commitment. Couldn’t agree more on returning car to original spec. The Oak greens are lovely. Agree also that the original grille and spots looks so much better than the single lights look. Don’t know why some people visually demote the GTI to look like a GL or a Driver.
    Presume it’s now pristine.
    Fantastic work
     
    Last edited: Mar 20, 2021

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