Projekt Golf Zwei

Started by 80 Vert, June 28, 2020, 12:08:36 PM

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the phantom

that's a lot of sanding by hand!  8)
Land Transport New Zealand, taking the fun out of driving since August 2008

80 Vert

You're telling me, as of yesterday I've got about 200 hrs in it doing body repairs and paint prep.
Still not ready to paint.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

GLIDN

Quote from: 80 Vert on September 19, 2021, 05:24:42 PM
You're telling me, as of yesterday I've got about 200 hrs in it doing body repairs and paint prep.
Still not ready to paint.

Great work John, the more effort is put in at this stage (as you know), will result in the better the final product. I also know how you feel. Done much the same with mine.
Audi A4 DTM - K04 NZ New | All bolt-ons | Carbon Clean done
2012 MK6R Golf |Stage 3+ | Stage 4 DSG | Tuned & Built by HSP Tuning

dave

Is the ppg primer your using the epotec 408 epoxy primer?

80 Vert

2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

dave

It?s good stuff aye. Pretty cheap and sands super nice

80 Vert

I've used a lot of different products but this is one of the best, especially like the fact it's a surfacer as well as an epoxy.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

Working towards priming the main body, there are the never ending amounts of small repairs to do, treat all the bare metal areas and then masking everything up.
Since my engine bay and under body are pretty pristine I do not want over spray of any kind on those areas so masking absolutely everything every time any priming is done is essential.
This was my main area of concern when I was thinking of leaving this stage to a body shop but then lockdown came along.
Also with so many different colour layers on the body I find it difficult to get an accurate feel for how things are looking, shoot an even coat of primer on making it all one colour the problem areas show much easier.
Masking I actually quite enjoy, did the engine bay first followed by all the holes for fixtures in the body followed by window and door openings.
Put a couple tarps down and taped a skirt from the body down to the floor, I have a set of boards that go between the floor and roller door with a big hole in it for a large extraction fan. All works quite well.
When you don't have a booth you gotta be creative.



2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

With the main body primed I could move on to the panels, doors, tailgate and sunroof panel.
Doors I got as good as I could for now and all the lines will be fine tuned once back on the car, tailgate had no prior damage so that cleaned up nice.
I'll need to remove the doors multiple times for different things and I didn't want to waste time aligning them each time so I drilled a 2mm hole through each hinge to take an alignment pin. This way the doors go back on in exactly the same place each time and once the car is painted it will be a huge help in assembly & alignment of the doors.



2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

le mans

Looks good. I?m quite digging that primer colour.

80 Vert

Thanks, yeah I like it as well. Should just leave it and put it back together now.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

spooln

Hah the primer is like a 60s fiat green color
77 CS1 Fiat Spider. 78 Mk1 Scirocco. 83 Mk1 GTI. 12 Abarth 595C Competizione. 18 Golf R. 20 Kodiaq vRS

dubstar

Would be a good colour for a 911??
"I am so clever that sometimes I don't understand a single word of what I am saying."

80 Vert

Inside of the doors next, years of crud and old wax rust proofing to be degreased first and cleaned off. Thankfully the hinge pins seem pretty good so I decided to leave them even though I'd bought new ones.
From all accounts they are a bit of a mission to change ideally needing a press tool to force the old ones out, with minimal play in mine I didn't feel it was worth the headache.
180 sanded the inside of the doors to prime them, hard to believe but there's nearly a whole day in each door. by the time you degrease, clean, sand, feather out all the chips and edges and prime with 3 coats the day is pretty much done.


My drilled alignment holes in the hinges paying dividends already making it a snap to line the doors up, started out 220 blocking from the 1/4 across to the door. No panel roll in allowed here.
The sides of the body, especially 1/4 to door and door to front guard will at least need another prime but even at this stage things are starting to look pretty good.
There's probably easier ways to do it but I don't know them so I'll just keep chipping away one bit at a time.

2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

#154
Finally, my big box of new and NOS parts arrived today from my parents place in Germany.
Been collecting parts there for close to a year and adding bits here and there as I found them.
NOS pair of smoked Hella fogs are the shizz nizzle, pretty happy to have all this stuff here now.
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

liv

just read through this entire thread from start to finish.  WOW!  This is absolutely amazing!
2016 Audi S4 (B9)
2019 Mercedes Benz B180 AMG (W247)

80 Vert

I've said it before and the same is true here, these projects always become much bigger than intended. Looking at the boot area I removed all of the wiring and other components to scrub it clean.
It actually came out really good but here's where it starts, hmm well while everything is like this I could paint it right?
Yeah why not, I have base coat and clear so....see where this is going?
Feathered out the worst of the chips, not intending for perfection in any way but just a tidy up. Primed the spots where I went through to metal and had deeper scratches then wet on wet base and clear. Tidy again.


2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

le mans

Like new! And yeah, famous last words eh... "while I'm in there..."

80 Vert

It's a dangerous thought process to get in to Jon  :laugh:
2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration

80 Vert

Time for a change, sanding bumpers!! haha.
These would prove to be a boat load of work, the rear one I thought wasn't too bad actually wasn't good at all. Been hit at some point bending the inner reinforcement. With the metal parts straight and fitting the car properly again attention could be turned to the bumper cover.
Block with 120 grit reveals how wobbly it is, I don't know how these things end up like this but same as the body its a case of reprime, fill, block, block, block. At least the upper textured part hadn't been painted but that also needs repairs before I can re texture finish it.

The front bumper is a mess, that I already knew. When I did the engine swap I already invested 2 full days in just making it useable and creating a rough intercooler opening. I should have called it quits then and found another.
I didn't realise at the time it would take over 30 hours to turn this junk in to something I'm happy with, not a good use of time.
There were 100's of cracks in the paint, top part re texture painted littered with cracks, once I started sanding I realised someone had sprayed it with spray filler and the filler was cracked down to the plastic.
The 3 lower vertical fins I cut when making the intercooler opening needed extending to make it look like its supposed to be that way, plastic welding and then shape it to suit.

Sanding the spray filler down to plastic to eliminate the cracks just so you can re prime it is pretty soul destroying, little did I know the worst was yet to come but at least the lower part is starting to look better.

2010 T5 Transporter TDI  Tuned by Superior Tuning NZ
2003 Jetta Coupe soon to be R36TT
1991 Golf GTI 2.0 TSI swapped
1963 Type 34 Karmann Ghia, turbo 2.0
1990 Porsche 964 911 Carrera 4
1980 1303 Beetle vert, under restoration