Projekt Golf Zwei

[uzumati]

Geez . I thought I was lucky to set eyes on it in the metal yesterday lol .the attention to detail is scary.the opportunity was much appreciated and great to put a face to the name.this build is next level.

[80 Vert]

Finishing detail always takes forever and certainly no exception here. Most of the engine bay finished and sorting out the last of the wiring I realised there wasn't really any room for the mk2 washer tank.
Wanting to keep the engine bay as clutter free as possible I decided to make my own and hide it in the rain tray where the stock ecu used to be and it even has a handy cover over it to hide it away completely.
Made one out of cardboard to play with sizing etc and placement to clear the wiper motor arms.

Folded it up out of scrap sheet aluminium and tig welded it together, had to make a neck for a Mk5 cap to clip on to and used the stock mk2 washer pump.
Uses the stock clips and tray mountings which used to hold the ecu to keep it in place.
Coat of wrinkle black from a spray bomb completes yet another little detail, doesn't hold much water but plenty for wofs and the odd screen wash. Never going to daily this car in winter or anything so will be just fine.

[80 Vert]

Johnnytron you absolute legend, contacted me out of the blue to say he'd found the original owners books and wallet for the Mk2 from when he used to own it. Nice to reunite these with the car after a 10 year absence.
Thanks bud, appreciate it.

[rambo_005]

That's so cool

[80 Vert]

On wards with the interior, both front floors were super solid but did have surface rust starting and the bitumen sound insulation was cracking and falling apart. Now was the right time to take all of it off, treat the rust and apply new material.
Heat gun and scraper worked wonders, passenger floor was the worst compared to the driver floor which still wore most of its factory primer.
Wire wheeled the minimal rust and treated it with Brunox, once dry new sheets of Bostik tar board went down heated and pressed in to all the recesses of the floor panel.
Rear floors were in great shape so I decided to just leave them alone, before and after.


Time to start thinking about the front end and bumper. New / used grille restored and inside of the lights cleaned a nice easy job.
The bumper not so much, obviously had fog lights as the switch and wiring was there but no lights. Bought some Ebay re pop lights which are very average in quality but do the job for now. At some stage I'd like to find some originals somewhere.
The bumper, well that was a complete mess. Every single clip and tab holding the steel reinforce to the cover was broken. Crudely screwed together with some self tappers and wood screws. Some real geniuses have worked on this poor car.
This turned in to a 2 day job to straighten out the reinforcement bar and make new brackets to attach the cover so that it fits tightly together and to the body again.
Ideally it needs a new bumper but little chance of finding a nice one here, let me know if anyone has something.
Looking at it now you'd never know how poked it was.

Using the factory Mk6 airbox I wanted to retain the oem plastic intake pipe as well but due to placement being slightly different the 2 would not meet. Looked at joining 2 pipes together but that didn't really work out.
In the end just a simple extension machined from some intercooler piping did the trick nicely.

[le mans]

Great score getting those original books and owner’s wallet. So good of the previous owner to get in touch and send those to you. And as for the rest of it, a truly epic resto-mod. Such a cool car.

[dubstar]

That engine bay really does look OEM

[80 Vert]

Front end on for the final time or so I thought at least, that was until solving the A/C became a problem.
The engine ecu has full control over the cooling fans speeding up and slowing down as it deems necessary to control coolant temps and on a Mk5/6 the Canbus handles the A/C on messages turning on the fans.
There didn't seem any way to break in to turn the fans on when the A/C was switched on, this became a real headache to solve in the end. I did get to a point where disconnecting the outside air temp sensor would turn the fans on so I thought about the A/C switch simply breaking this contact and the fans would run.
Problem with this was that the fans would run full bore.....not ideal.
The more I thought about it the more it wasn't for me, at that point I remembered I had a single factory fan from a late Mk7.5.
This could work, use the 7.5 fan for the engine and the Mk5/6 slave fan (normally driven by the mk5/6 main fan) for the A/C.
Cooling pack needs to come out......again...

Took the Mk5/6 main fan and control unit out and swapped in the 7.5 one, had to pretty much re make everything at this point including the attachment for the fan blade.
Rewired everything to suit and now the engine ecu just controls one fan however both are connected to coolant temp so that at high temps both fans can run.
Found that the Mk3 Cabriolet had the simplest wiring for A/C so I would use that.

Had to make room for some extra sensors which would go in the coolant pipe I made to run under the front engine mount, at the same time I made and added a centralised coolant drain as I was tired of the mess it created pulling a hose off to drain the coolant.
New Mk3 sensors for coolant and A/C these were wired up to a separate Mk3 coolant fan control module to run the A/C and fan for it.
This way if coolant gets too hot with A/C on its cuts the A/C off as well, nice safeguard.
Although a huge amount of work this is a 1000% better solution, besides we were in lockdown....what else am I gonna do!

[coons]

Nice one. Coolant drain plug is great, why don't they do this from factory. I remember I never got the AC figured out on my Mk3 - I kind of gave up. But being a bit of an OEM freak it always annoyed me that I knew it didn't function..