MK2 Rebuild

please come and do my car lol

If you weren't so far away I would be happy to help you out.

Thats Megga matey, Want to do this with mine and great minds think alike as i want to paint mine crème. suppose i had better get another idea.

You started all of this in MAY! My God, just what tablets are you taking? Are they legal? Great work, though : )

Right, time for a bit of a catch up after having to take time away from the Jetta.

Next in line for some cleaning up was the front crossmember/s and front grill frame.

As they where,

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Stripped back to bare,

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Primed,

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and top coated.

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also did the same to the rear beam but this time its been top-coated with POR-15.

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Next, rear brake proportioning valve,

For starters, rusted solid.

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I had to drill out the pivot pin as it was corroded into one solid lump, I also welded two washers onto the arm where the pins wore the holes oval, these where then ground back to the profile of the arm.

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after carefully stripping the valves out the seals where found to be in good order so everything was cleaned and painted then carefully put back together, I made a new pin out of a long plain shanked bolt with the head ground down for clearance.

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Before I put the fuel tank back in I had a problem to solve. The earth wire that attaches to the metal filler screw had corroded away. Now there is no way you can use any heat on this to reattach anything so I made up a new band using a CV joint slide clamp and a crimp terminal.

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and this is how it looks on the tank,

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you can see where the wire runs to here,

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and relief as I found out that the replacement saddle lines the filler neck up perfectly with the hole in the bodywork.

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Next, some brake lines, take some of this,

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Add one of these,

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and get busy.

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More update in a day or so.

love this....


some good work going on here....

this thread will be my new winter reading...

keep it coming..

coming along really well

Time for more catch-up.

The exhaust heat-shield that runs under the car was in a bit of a mess and when I took it off two of the mounting lugs sheared off.

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So I brazed these back on with some alloys brazing rods that i`ve had hanging around the garage for years.

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Then gave the whole load a good scrub with gun-wash and a scotchbright pad.

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and back on the car.

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Now for the doors, the original ones off the car had really started to rot out and had been chopped about already from when it was a track-day car so I picked up 4 solid (if not straight) late model doors. The biggest problem with these (aprt from numerous dents and dinks) was the later door moldings where hed on with clips rather than being stuck on like the earlier ones, so I had to fill all the clip holes up with glass fibre and filler as I want the car to not have any more external trim than necessary.

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and now back on the car for some tweaking before topcoat.

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Front wings, these are the original ones and are in pretty good nick apart from a couple of small dents so i`m reusing them, the only change to them is fill the ariel hole and side repeater holes up. I again used cloths soaked in celly thinners to remove the soft paint so I had a good base from which to start.

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Took the stonechip protection off too.

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while I was at it I also attacked the front apron and the grill strips.

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Masked off edges of wings and apron,

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Then sprayed shultz underseal all over the inside.

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Started then filling any little imperfections in the primer.

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Then on with flatting off doors and wings ready for some topcoat.

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This thread is amazing you could use this as a how to on restoration, won't smoothing the side repeaters off cause problems mot time I only ask because i wanted to lose mine when i have the wings repainted and was told its a no go

If ive got my information correct the car doesnt require side repeaters as it was registered before April 1985. Vehicles registered after that need the side repeaters.

Ta

now this is what im talking about!!! genuinely love this thread. please keep it coming!

With the weather turning cold I cant do any more painting so i`ve finished off rubbing down the off side panels, filling any little imperfections then flatting off again.

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My plan when we get a couple of warm days is to do the doors and wings in one go so i`m in the hands of the weather now as goes painting, so I decided to make a start on some of the interior bits.

First thing is to strip down the heater unit as half of it`s seized solid and the control flaps are goosed.

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First job, remove the heater matrix, this is ok to reuse as it was changed about 6 years ago for the new, safer style one.

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next, crack open the two halves of the heater box,

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now we can see just how shot the control flaps are,

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gave everything a good scrub, dismantled all the control rods and gears too,

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After removing what was left of the foam on the flaps I glued some fancy insulated foam back on (its actually laminate floor underlay that i`ve had kicking round for a couple of years). I used high temperature spray contact adhesive to stick the foam to the flaps.

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clipped the two halves back together,

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the slider control unit was then stripped down and cleaned out as it was really stiff to move,

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it`s vastly better now, control cables back on,

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There`s three captive bolts that hold the assembly to the bulkhead and I noticed that two of them had started to strip the threads in the plastic out so I repaired them using some plastic weld epoxy.

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Finally cleaned the fan housing up to and clipped it back on to the heater box.

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Great thread! Makes a good read, some great fabrication work going on.

looking good dude

great work will keep an eye on this...want to see finished product

Ok then, spent the last few days freezing me fingers off in the garage.

Sprayed the floor-pan and inside of the boot with stone-chip paint to seal up all the welding and generally make it look a bit neater.

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Ive put extra sound deadening material onto the door skins,

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spent ages cleaning up the glass and window seals for the doors as they we`re covered in muck and over-spray from lying round the garage for 6 months.

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cleaned and unjammed the door restrictors then refitted them.

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I took me the best part of 2 days on and off to sort out the window mechs and seals as I had 2 complete cars worth of them, 1 set being the older style off the original doors and the other set off the replacement doors. Its surprising the differences between the 2 styles and it took a while to figure out which bit went where when everything is doubled up.

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I made a start spraying up some of the smaller bits to go back on the car, these are the rear arch protectors. I wanted to lose the texture on them so it took over 10 coats of high build primer to get them smooth.

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And now painted in satin black. This is the finish I want for all the exterior trim including the bumpers.

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Started applying sound deadening to the dash/bulkhead area.

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Heater assy back in.

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Made some new joining seals for the air ducts as the original sponge ones had rotted away.

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Fitted these along with more sound proofing on the top of the bulkhead.

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Ive put the door handles back on temporarily so I can get the door pins aligned, they`ll have to come off again to be sprayed though. And just a little teaser to finish with, pick up some new wheels the other day and just had to try one on for size. Perfect.

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love this....


keep up the good work..

Cant wait to see her finished! Your giving me ideas! Who needs a house when I can buy a workshop for the same price!

I like so far !! Well done

Robbie1885! wrote:Cant wait to see her finished! Your giving me ideas! Who needs a house when I can buy a workshop for the same price!

that why i live in a statick van lol

any more progres?.

Ive been doing a couple of bits latley but been very tied up with work. Hopefully a pic update in the next week or so.

looking forwerd to update
ive got opersit pro no work=no money=nothing done