Projekt Golf Zwei

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

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Period_Correct_

Christmas has come early mate... It looks great!
1971 Porsche 911T | 1990 Audi Quattro Turbo | 2003 Audi RS6 Avant | 2009 Renault Megane R26

80 Vert

Sure has Nigel, first thing was to drag all my boxes of new parts out of hibernation.
The urge to start bolting it together was pretty high but also realise from past experience that is a bad idea due to paint being pretty soft for a while. Therefore leaving the paint for a week is the best thing to do while I chip away at the inside and other things that can be done.
I started with the core support and grille etc, reassembled the lights with the metal parts that were re plated.
Cleaning parts you re use before re fitting is also one of those things, some of my stuff had overspray on them from previous repairs but a paint stripper made for plastic takes care of that pretty easily.
So stoked to have it back, will work towards getting the panels on and glass in so that it can go back for its polish up in the coming week or so.


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

the phantom

completely off topic, but I've recently tried to reduce my google dependence and Firefox loads this pic heavy post much faster than chrome
Land Transport New Zealand, taking the fun out of driving since August 2008

gti vr6

That car is looking 🍒 
Nice work John.
1986 Mk2 Scirocco
2021 T6.1 4M LWB Transporter Trendline

le mans

One of the best restomods out there.

Period_Correct_

you're a legend John. cant wait to see it again
1971 Porsche 911T | 1990 Audi Quattro Turbo | 2003 Audi RS6 Avant | 2009 Renault Megane R26

80 Vert

Assembly is always enjoyable and with the exterior paint still needing to have debris removed I started on the interior, most of it is just a matter of reinstalling but since its all apart I thought I'd clean up each part as much as possible and try to find better parts for the few items that are not so nice.
Starting at the back with the carpet, seat belts and the new interior cards I'd made previously. Rear seats in as well this is going together faster than I thought it would.
Oem+ car stickers came through with a set of reproduction stickers that I've been waiting to install, quality is awesome. Just like original.
Glad I went with red stitching on the panels in the end, matches the seat belts nicely and ties in with the whole GTI red trim.
Trying to do a bit each day, no matter how small its progress. Goal is to have this done and back on the road by the end of the year as I actually miss driving it.


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

Thanks Jon, I'm pretty happy with them. Certainly much better than my first attempt.
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

Period_Correct_

those seat belts are a bloody good touch!
1971 Porsche 911T | 1990 Audi Quattro Turbo | 2003 Audi RS6 Avant | 2009 Renault Megane R26

80 Vert

#190
Sometimes you just have to laugh at how out of hand things can get, my last situation like that was my door handles. I'd bought brand new Febi ones and my plan was to drop my lock cylinders in to those and done......but no. Wasn't that simple.
Lock cylinder fitted fine but when I came to put the handle gaskets on they were too small and didn't work, comparing them it turns out the handle bases are a different shape (bigger) and the gaskets will never work or fit.
My old handles mechanism were worn out but the plastic handle itself was in good shape so now what?
That's right, take all the handles completely apart and put all the new parts and re keyed lock cylinders in to cleaned original handles.

Even half way through I'm thinking wtf am I doing this for but once I had one together with NOS gaskets and on the door the reason was clear. Looks and works like a brand new one. That old lesson of nothing fits like genuine parts is very true.
Was it worth 4 hours of my time? probably not. Would I do it again, yep probably  ;D

At this point it seemed like a good idea to fit the doors before there's any weight in them, my little trick of drilling 2mm alignment holes through the hinges made that a very simple task. Used a couple small nails as pins to align them going back exactly where they had been.
Lined up the striker pin to have them open and close correctly, you can literally spend hours on lining stuff up but little tricks like that make this job a lot simpler.
Starting to look mighty fine.

Going for the black out look means Hella Tresers, these things look epic against the Caprigruen. Will tie in well with smoked NOS fogs, front blinkers and NOS Hella smoked side repeaters.
Can't wait till final polish is done to assemble the exterior.

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

slowburn

this is easily my fave build i'm watching anywhere. super slick
99 B5 S4 Avant
85 coupe quattro
72 fiat 124 coupe
97 corolla wagon

le mans

Yeah that back light looks great. Can?t wait to see this thing in the flesh.

80 Vert

Getting closer all the time Jon, should be done by years end. Well, done for now that is as I still have some things I'd like to change / get working 100% but then project cars are never truly finished are they.
Onwards with the bumpers, re texture coated and NOS smoked fog lights and indicators installed. Quite a faff in the end getting the fog lights to sit where they should. Probably due to the bumper being so beaten over its lifetime but managed to get there after 6-7 goes at it.

Started at the back with the tail gate, rear lights and wiring. As usual lots of cleaning and repairing previous hack jobs.
Tail gate on and assembled ready for the glass to go in.
I did have Novus come out and polish all of the old glass as it was pretty scratched in places, though it looks much better the cost vs result probably wasn't really worth it but then buying all new glass wouldn't be cost effective either.
New OE windscreen on order from VW Classic through Giltrap was yet to arrive and that's really the thing that makes the biggest impact.

I'd ordered all new badges and warning label decals of course but my vin plate was very tatty looking also, the supplier for the decals was also able to make me a new one and the difference is quite astounding and 100% correct on every detail.
Little details that no one else will probably notice really stand out to me and make such a massive difference to the over all project.

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

That vin plate is a very nice touch.

Pristle

Have to agree on the VIN plate.

As for the 4 hours on the door handles? I recall going through the same process and thinking the same, until I stood back end then walked around the car opening each door. Totally worth it.


If someone tried to described the mint green tartan with red accented trim, I would've said no. But now that I've seem it, it works. Where did you get the belts done?

80 Vert

Thanks yeah I'm loving the red accents. The belts are actually MK6 ED35 ones adapted to fit the MK2 but I left the sewing on the one end to a seat belt specialist.
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

Slowly but surely its coming together, back from polish the exterior bits can go back on now.
Started on assembling the doors, new parts where ever possible, clean, detail or restore the rest.

Onwards to fixing more stuff, by this stage I'm pretty tired of fixing things someone else has broken or ruined but had no choice as I'd not been able to find replacements.
Both door rub strips were no good, broken clip mounts, bent and cracked trim just some of the issues. These were stuck on with huge globs of urethane prior to me stripping the car.
I made aluminium brackets to hold the clips and epoxied these in to the rub strip which seemed to work well, painted them in the same texture paint as the bumpers and installed new 16V badges I had made for them.
Unfortunately they are still not very straight and don't really fit the doors all that well so I'm still looking for a better pair to replace them as soon as I find some.


The arch trims also had to be painted to match everything but these had been painted before and although they looked fine I thought it best to strip them to bare plastic first.
Paint stripper worked well on this, I've had mixed results with paint stripper on plastic but seemed to work well on this type of plastic.
With a lot of this stuff you can't buy new its a matter of finding the best used ones you can and making do.

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

#198
Time to tackle the door membranes, I've tried a bunch of stuff over the years and some successful but most of it not.
Last time round I used EVA foam sheet 3mm thick and contact glue, while this worked well its impossible to get off without creating a huge mess if you ever need to get inside the door again.
On that thought I tried a bunch of different tapes that would stick to metal as well as the foam, Aluminium tape seems to be the answer.
Last discussions with Rambo005 were to use a plastic sheet to deflect most of the water back inside the door and as it turns out aluminium tape sticks well to polythene as well. That's what I decided to do here, not that this car will see lots of rain but anyway.

The foam sheets cut to fit I initially did them in one piece for a nice tight fit but realised that the arm rest of the door card needs a bit of clearance so I cut them in half to make allowances for that.
I'll need to remove these again once my replacement door rub strips arrive so that will be a good opportunity to see how the tape has stuck to the foam and also how its all held up in general.
Door membranes on mk2's have always been a pain so hopefully we're on to a system that works.

Last but certainly the most exciting, the new door cards go on completing the doors for now. I had huge amounts of hassle with getting the door rub strips to stay on, and to be honest don't look all that great against straight doors.
Mostly down to the fact they are so beaten and repaired clips etc so I've found replacements that hopefully are better and are coming from the US.
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

Oh yes, love the door card.