MK2 Golf GT TDi Conversion 6 speed PD, Dash and Wiring

Good man! I finally bought, drove, broke and subsequently fixed a PD150! I would update mine but i have ZERO photos taken!

 

Apologies John for the MASSIVE quote! lol

The donor is a 2002 150bhp 5 door Golf, with leccy windows all round, remote central locking and electric mirrors. This means I have a 2-plug CCM yes? (and it's going into a 3 door MK2)

I was planning to do something along the lines of Phil Barlow and use the MK4 logic boxes on the window reg (mounted behind the door card somewhere) and cutting the feed to the motor, and wiring the 2 wires drom that to the OEM MK2 electric wIndow regs I have. I hope this would mean that I do not have to cut up perfect Mk2 electric regs is all.

Could you link to an example of the central locking actuators for us, just so I know which ones, some have 2 wires, 3 or 5 etc!

Kav1187 showed how to sort the headlight wiring and said about using the central locking actuators. Luckily I fitted one of them Rightclick boxes into a mates MK2 before and we got it working perfect so it should feel OEM

What do you mean about the interior light? IE use the mk2 one or the MK4 one (I have to do a custom headliner anyway due to the MK4 tilitng glass sunroof I put on mine - fun!)

And about the bulkhead, I'm using the Climatronic everything, and just drilling holes in the bulkhead for things to go through!

Oh and I don't get about wiring the boot and flap to the rear doors - you mean just so the CCM knows if they're open or not for the alarm is it?


OK rant over!!

Sam

 

Wow thanks rubjonny! That's so helpful! I'm sure there will be other areas where i struggle but you have a while before i come to them haha!

Anyway so I'm sorry its been so long since updating, I rebuilt a motorbike to use for summer so that took a couple of months away from the golf then went on holiday which took another couple of weeks away but I am hard back on the golf now!

Here is the before and after of the bike if anyones interested, only a Suzuki GS500 for commuting on:
Before

After


So where to start with the golf project, firstly i bought some winter wheels that will actually fit over the G60 brakes where the Brock B2s wouldn't
BBS RZ





Then I spent hours and hours and hours grinding and heating off underseal


I rang up a shotblasting company and they said they could get the awkward to reach areas and wheel arches so I got it shotblasted






This left a lovely finish for paint to adhere to but didn't remove the underseal from the arches or hard to reach areas as VW underseal is so thick the shotblast just bounces off. If you spend long enough blasting a patch to remove it you will destroy the metal panel around it and possibly distort it.

So back to grinding the rest off and carrying out all the welding required before re blasting.
Both inner and outer sills.










And the other side.

 

For my reference


Various repairs.

Jacking points









Fuel Filler.








Ground all the arches ready for shotblasting.





2nd time at shotblasting.





Then immediately blown off any loose media and coated with Bilthamber electrox zinc rich primer, 2 coats 2.5 hours apart.



Electrox dry



Quick 50/50


So that brings it up to date, it doesn't look like a lot of work but it has been more than I imagined by miles and now i'm nearing the end of the underside the build will get more interesting.

Next up, a few last bits of welding to do then apply electrox to those areas, then epoxy mastic the underside with Bilthambers epoxy mastic, then seam seal, then stone chip. I'm feeling going medium/dark grey with the stone chip. Apparently mixing blue pigment with white stonechip will never get dark enough to match the top colour.

 

Looking top Mike! The photos are better here than on Facebook. I was told that shot blasting would destroy the shell!

 

Cheers mate, I'm happy with it just need to get the last few bits welded and get it all sealed so I can hopefully forget about it for years. Fingers crossed!

Yeh I reckon you could do damage if you let an amateur at your car with something really harsh. If you shotblasted a bonnet or panel you need smooth for paint you will ruin it but for the underside of a car it gives a finish that paint will adhere to better than the original smooth panels. I pulled a few bits of underseal off the arches by hand with a bit of heat, which also pulled the dip primer off. You can see these parts in the arch photos as the metal is smooth and therefore the dip primer didnt adhere as well as it needed to.

 

That should last another twenty odd years!

 

So been coating the underside in epoxy mastic which takes forever as its brush on and so thin! Two coats are meant to achieve 100 microns dry thickness (thinner than factory bodywork paint) so its very runny and time consuming. Finished 1 coat and started the second coat.

Epoxy Mastic



You can see the floor pans are done in this photo but not the boot floor.



Then had to bolt the rear beam on and front subframe so i could drop the golf off of the spit and wheel barrow it onto a trailer to move units!





Her new home



Going to get her back on the spit this week so i can finish off the epoxy mastic, then stone chip the underside white, paint it bodycolour then get all the rear beam/subframe etc powdercoated so i can re assemble the underside and put it back on its wheels permanently!

 

The work you have done is amazing. I am lucky to find this thread. I hope the job continues as well. How has the work gone recently? I don't imagine it's finished yet? John.

 

Thanks, it's still far from finished. I work on average 55 hours a week so I don't get anywhere near as much time to work on it as i'd like to!

Little bit of progress, i have finised coating the underside in epoxy mastic and started seam sealing. One i've seam sealed the arches I have 2 bits of welding to do on the rear panel then i can zinc prime/ epoxy them up and it'll be underseal and paint time.

2 coats of epoxy mastic



Most of the seam sealing done

 

Just read though this project. Top work. Lots of dedication here. Look forward to seeing how you get on over the coming months. When do you hope to have this project complete?

 

Thanks! I've only just seen this, had a fairy bad car accident in december and not fully recovered so haven't touched this since then. I'll go more into that in another thread i need to start now

I want it finished Feb 2015 but thats quickly approaching so hopefully i can get back on it soon and make some decent progress

 

Hope you're OK Mike, I know how that one feels sometimes. Still got the remnants of it 3 years on! I am ploughing into mine, but always too dark to take photos in the shed so haven't updated my thread. Hopefully it will be driving (not finished - note a project is never finished) by the summer.

Sam

 

Hi mate sorry for the delay! I still haven't recovered but am learning to cope as is. Trying to get motivated but it can be hard when still suffering but some progress should help! Hows your build coming along mate?

Small update considering its been nearly 8 months!

So first of all i bought myself a birthday present, GTB2260VK, DSD stainless tubular manifold, braided oil feed and 3" stainless downpipe



Then i figured i'd mock everything up inside and in the engine bay before finishing off the underside as theres no doubt changes to be made, so I started with the front engine bracket.

I used some of the chassis leg from the donor mk4 so make the front bracket fit the 6 speed



M12 Nuts welded on too


Made some longer bolts to hold the front bracket on, will try and find genuine VW ones that are the right length but these will do for mocking up






Then I started on the subframe

Cup removed


02M gearbox mount


Engine in on a knackered front mount and the rear mount


GTB clearance, can clock the cold side a little bit more but it's going to be close



G60 front engine mount arrived


Spot welded the gearbox cup in


Then removed the engine and seam welded the cup to the subframe




Looks like i'm back to square one haha.

Next job is to mount the climate control heater box, but I need the inside mint before i start working in there. So started cleaning.





This is a horrible job, haven't quite worked out a good way to remove the gluey mess from the floor but hopefully the inside will be clean soon so i can start mocking everything up inside and in the engine bay!

More to come sooner this time honest

 

looking good progress there buddy, nice to come back and see some of the threads i used to look forward to seeing still progressing

 

Looks fantastic mate keep up the good work. Makes you feel good when you get a bit done. Progress is getting there but custom fab takes ages. Every time I look at the car I seem to need something buying.

 

Nice work mate - it has come a long way! Sorry to hear about your accident - hope all is well now.

I'm looking forward to seeing this finished! My Syncro has been on the driveway for over a year as I bought a house so probably won't make any progress until next summer.

Keep up the good work!

Kav

 

Any updates on this? Really interested to see how this turned out as ice recently done the same to the underside of my MK1..