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Old 03-07-2012, 09:24 PM   #1
georgeMK1
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Hey all, though i'd start a thread on stanceworks on my new build, hoping that i can get international help with some issues i may not be able to resolve on my or on my own vw forum. Anyway some of you may recognise my other thread, and remember my car




Seeing as this car was built on a budget and was just put together with a small budget that i had, it always kept falling apart on me :P So im starting to sell of the wheels, coilovers and other bits to fund my new project.

I bought this golf a couple of months ago with the mentallity of a full restoration. Now dont get me wrong, im no proffesional or expert, and neither do i work on the automotive industry, im just a 19 year old that goes to school and works a part time job. So everything im doing here, is from past experience on the orange golf, and also through the willingness to learn. Something may be done shitty, but sometimes as long as they do the job, id be happy. - Now the plan is to have this thing as my daily, but have some plans to make it stand out like dogs balls, which i wont reveal yet hahaha. Time will show :P

Ok enough talking shit hahaa. It was an apsolute mission to get the car home, we had a huge trailer, it was raining hard on the day, the guy lived 60kms away, and he lived in the mountain ranges of Victoria -.- Left the car untouched for a while, then i finally got the motivation. So here we go ;

This is the car, and how i got it.




2.0L engine and fuel injection from a golf mk3 GTI i beleive, with 5 speed gear box, sway bars, and a half cage.






As you can see the floor pan was completely shagged




So i started stripping everything, and i mean EVERYTHING. Called a mate and he brought over a engine crane to the rescue.
















Heres the two together a couple of months back




So this is what i had to work with. I knew that i would have to cut the rust out, and well new sheets of metal in. Cutting? Yeah cool i could do that, but fuck, i've never welded before LOL. So i saved up and bought a small mig gas welder, which was cheap and perfect for waht i needed.




Ok, so let me get people up to speed on my plans. Yes, the golf is fuel injection, and thought would be awesome in such an old car, as well as effiecient. However the ECU and management system this car used is old, outdated and unreliable. So i thought, ill go to carby, and ill do a complete engine bay shave, as well as wire tuck !!
So i started stripping things off, battery tray was out, all the wire tabs were removed, holes were welded and plugged, and so forth.

Rust cut out






This is the tiny space i have to work in lol (and yes thats a engine in a trolley - dont ask LOL)




This is all the cancer, and probs heaps more i havnt taken pics of yet








Ok so i hired gas and these were the results. Firstly, criticism is always welcome, as it helps to improve, but this time i dont care haha. Its ugly, but its strong, and thats all that matters. There will be carpet over it, so i didnt want to spend hours and hours for perfect welds. Like i said, i have never welded, so this was my very first time.






This is the donar piece for the other side, as well as cut out donar bits i have cut already







Welded



Thats all i can be bothered with right now haha, i'll upload some more later on today
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Old 03-07-2012, 10:00 PM   #2
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hosier lane!
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Old 03-07-2012, 10:14 PM   #3
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mmmm....swallowtail!
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Old 03-07-2012, 10:58 PM   #4
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wow great so far! good luck man!
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Old 03-07-2012, 11:28 PM   #5
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love this already. cant wait to see what you do with it!
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Old 03-07-2012, 11:53 PM   #6
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hosier lane!
Hahahaha yeah dude, how'd you know?

And thanks guys. Well its not going to happen overnight as i work very little due to school, but it will happen at a good pace. I've got some sick ideas for it.
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Old 03-08-2012, 12:07 AM   #7
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Ok, so i had a feed and a nap and its time to post up to where i am currently.


This is just a few pics over the last few weeks of me working on the golf. I've been really motivated in the last month and have acheived heaps (i think so anyway). Its really hard to mix in a restoration, school, social life, and work at my age, as theres no much things i want to do, rather than stay home and work on the golf haha.






And heres my awwweesome welding mask :P :P (and yes i know, the gloves, the long sleeve top etc etcc it was just done for a quick pic )




So anyway, i welded all the holes up on the radiator support, and made it look clean. Ill get more in depth with that when i have the time to






Also stripped out the whole car. Petrol tank out, suspension out, windows out, everything is out. Car is just a bare shell. In the pic below, i will flip the car on its side this weekend, clean everything, and paint it all in bitumen. I love that stuff and think it works great.




On monday i started grinding down all the metal and painting it in a Rust preventative primer. I just hope it fucking works, and i never see rust agian !!!!!!!!










I have then used an angle grinder with a flappy disc, and a drill with wire brush to get rid of remaining rust and paint. This took me from 11am yesterday, to 10pm lastnight, including painting. That was honestly the most exhausting thing i've ever done.










I also managed to pick up a new fuse box over the weekend, as mk1 fusebox's are notoriously shitty haha. So i got on off a cabby, and i just have to re-wire it to work with my loom.

So thats where im at currently. I have a few more rust issues to do this weekend, and i have to shave the engine bay, then its ready for paint. Ill leave you with a picture of the fusebox, and just a small teaser for now :P





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Old 03-08-2012, 12:19 AM   #8
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Great progress! Props for keeping Swallowtails alive!
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Old 03-08-2012, 12:34 AM   #9
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very nice job
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Old 03-08-2012, 01:45 AM   #10
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You should reorganize the pics so the description matches. Props for going all out even without having the background for it.
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Old 03-08-2012, 02:57 AM   #11
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word to the mki, great project

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Old 03-08-2012, 03:11 AM   #12
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props for all the work u put in it
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Old 03-08-2012, 06:27 AM   #13
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Cheers fellas, haha yeah im basically learning as i go !
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Old 03-08-2012, 09:04 AM   #14
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Good luck!

You have a long path in front of you, but you have the stance with you... :P
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Old 03-15-2012, 05:41 AM   #15
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So lately its been raining and i've been a bit lazy haha. Cleaned the garage completely and it was fucked after just 3 hours hahaha.

Anyway, i was contemplating for ages whether i should cut the rain try out or not, seeing as its going to be my daily, but i thought feck it haha, take it out for a proper shave.







I have already though of a way to re-route the heater, but not sure if it will work lol. Also found surface rust in the rear and attacked it with power tools till i couldnt move any more. Then painted it.. i just hope it works !!







And now i have stumbled on this, and am confused on how to proceed. Its a very tricky corner, and istn really easily cut/welded in with a replacement. It has a tiny hole into it but im unsure of how to proceed as i dont want to rust to come back





Anyway thats it for today till the weekend. I hoep to get motivated more lol, the rust is depressing me badly
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Old 03-15-2012, 01:31 PM   #16
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hit it with the flappy, weld in a little metal from the backside and leave it up to bodywork imho.
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Old 03-19-2012, 03:39 AM   #17
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Spent some time today to clean all the surface rust around where the rain try was previously. It was soo hard to clean everything while remaining the curve. Thank you flappy disc

Also, what do i do with this deeply stained rust? I couldnt clean it anymore. Treat it, or cut it?






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Old 03-19-2012, 07:45 AM   #18
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Your best bet would be to cut it out or you could put some fibreglass filler over it, then your normal filler.

The fibreglass will act like a barrier(Hopefully) against the rust, it will also help build up any low spots and use your filler just to finish off
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Old 03-20-2012, 05:17 AM   #19
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So i got sick of waiting around for whenever my mate isnt using his gas bottle for me to take it. So i got my uncles one and filled it today. Also with pete's advice, i got .06 wire, which works alot better. Anyway, the golf had a roll cage and was bolted to the floor. So today i cut out tiny peices to fit the holes and i plugged them all up. My welding skills are a bit better then when i started haha. Ground down the welds and it turned out great !!

Also paid my rego today, god damn $641 apsolutely ripped my heart in two haha. Fuck there goes all my money haha





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Old 03-20-2012, 05:19 PM   #20
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dang! doing work!
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Old 03-20-2012, 08:23 PM   #21
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I wish I had something like this to work on. Great work.
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Old 03-21-2012, 06:40 AM   #22
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I've been reading this dudes resto on his mk1 and have been looking at how he has shaved his engine bay and it has got me quite motivated. So today after work i got to work. Welded up tons of little holes, and bigger ones too. I made little plates and stuck them behind the hole and welded from the inside, if that makes sense?

Anyway plugged up one of the vent holes for the fan/heater system. The other one will be left there so i can re-circulate the heater. Im going to make a small bottle and hide it for the wind screen squirter thingo, and also hide the expansion tank for the radiotor somewhere as well. Anyone know if there is a way i can completely remove the heater and all pipes, and have another way of having a internal heater of some sort?


Very very novice welding skills haha, who cares as long as it works !




The red is increasing in the engine bay, i have to start body fillering soon, which will be a fucking headache hahaa




Thanks to my old man for giving me a hand after work today to start stripping the rest of the car !!

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Old 04-14-2012, 05:20 AM   #23
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Alright so i finally stopped working on the orange golf, and had time for the swallowtail today. Felt like a productive day. Uncle borrowed the gas bottle (its hit bottle but my gas) and i got it back today. Last night i fab'd up some tabs for the wiring harness to re route. Ill put picks of that later. I made L shapes and welded them to the body, and drilled holes in the so that i can cable tie the wire loom on to. Should work great !

Here they are, with the crappy pic




And here im putting it to the test, looks cool 8-)




Also started with the heating system. Theres no chance in hell im spending $250 on a universal heater, and i love to be innovative and make shit work, so i started modding my heater today so that it doesnt pro-trude into the bay. Im going to get a smaller fan, probably from a motorbike and drop the whole heater box by a cm so that theres enough space for the fan to get air. Basically im only going to use it for heater, so re-circulating the air in the cabin will be fine.
However i really have noooo clue what to do with the de-mister yet, if anyone has some ideas please share. Heres the heater




Also grinded down the heater box hole, and made a cover up sheet for the hole. I think its 1.2mm which is pretty thick, but i got it for free, which otherwise is $60 something from bunnings, feck that. DIY FTW !!







Ive started welding in the sheet already, pics soon.
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Old 04-14-2012, 05:42 AM   #24
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love it! going through very similar work with my BMW at the moment. Love MK1's. What is the difference in a "swallowtail"? Never heard of that before.
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Old 04-14-2012, 06:07 AM   #25
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This looks promising. Will be following
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