VASK Forum (VW Audi SportKlub of NZ)

VOLKSWAGEN => Mk1 Golf - Jetta - Scirocco => Topic started by: dubstar on April 23, 2012, 04:57:43 pm

Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on April 23, 2012, 04:57:43 pm
I've been hanging out for a project car for a year+ now and I finally found a Mk1 3 door.  The search has been long, with a few near misses, but it's complete!

(http://i287.photobucket.com/albums/ll148/golfworx/76%203dr/P1010983.jpg)

(http://i287.photobucket.com/albums/ll148/golfworx/76%203dr/P1010979.jpg)

(http://i287.photobucket.com/albums/ll148/golfworx/76%203dr/P1010996.jpg)

(http://i287.photobucket.com/albums/ll148/golfworx/76%203dr/P1010994.jpg)

There's tidying up to do, but overall its in great condition.  I'm about to head on holiday so I don't pick it up until June, but it's all mine....

Plans are:

1) I managed to find one of these body kits, which are really rare and should look grouse. http://www.gumtree.com.au/s-ad/marsfield/auto-body-parts/vw-golf-body-kit-for-mk1-mk2-golf/1001271379 (http://www.gumtree.com.au/s-ad/marsfield/auto-body-parts/vw-golf-body-kit-for-mk1-mk2-golf/1001271379)

2) That should allow me to cut the fenders to run some 17" BBS, I'll try for 7" wide, but may have to settle for 6".

3) I'll leave the engine as is, because its original.  I may add a 36 Weber carb down the line.





Kidding.....

In reality the plans are:

1) Keep the outside minty fresh/period patina
2) Good suspension and some wider 14/15's with sticky rubber.
3) I want to go 2.0L crossflow 8v and run some Weber DCOEs, but use programmable ignition.
4) Interior needs a full strip out.  I want some oldschool race seats, like on the early 911s/minis/fiats.

Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: GTI's on April 23, 2012, 05:01:00 pm
thats damning awesome!  What a tidy MK1 score!
dunno about the body kit mate!
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: The Truth on April 23, 2012, 05:07:09 pm
That is a minter, probably opening a can of worms here, but I don't know about the kit  :-X
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: nacnud on April 23, 2012, 05:12:26 pm
Tidy!

What about some 17" Enkei g zeros for it?

(http://www.tyreking.co.nz/G-ZERO.gif)

They would look good with that bodykit.

 ;D
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on April 23, 2012, 05:17:42 pm
In reality the plans are:

1) Keep the outside minty fresh/period patina
2) Good suspension and some wider 14/15's with sticky rubber.
3) I want to go 2.0L crossflow 8v and run some Weber DCOEs, but use programmable ignition.
4) Interior needs a full strip out.  I want some oldschool race seats, like on the early 911s/minis/fiats.

Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: M M on April 23, 2012, 05:28:56 pm
That looks like a nice one!
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: AndyGti on April 23, 2012, 05:36:52 pm
that thing is beutifal!!!
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: spooln on April 23, 2012, 05:52:10 pm
Nice!! How rare are mk1s over there? Post some picks of the interior please!
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: Filx on April 23, 2012, 06:48:57 pm
Awesome - looks like a pearler. Definitely needs a dose of lowness though - hahhaaa. Also a little black sticker at the bottom of the F to turn it into an E would epic school boy humour!
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: coons on April 23, 2012, 09:30:08 pm
That's a minter! All it needs is a drop and some 15" BBS RS and it's a winner
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: sifty on April 24, 2012, 12:32:15 pm
I love it...  8)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on April 24, 2012, 10:58:01 pm
That is SFX on wheel Dubstar!
 How much did it cost over there if you don't mind telling?
 Its so cool being small lights and chrome bumpers
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on April 27, 2012, 02:19:43 am
It cost me $3000, which is about average here. There has been one or two 1000 bargains, but they are generally in need of more bodywork

Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: RS ZWEI on April 27, 2012, 07:48:35 am
What suspension are you thinking Bryce?
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on April 27, 2012, 09:15:14 am
It cost me $3000, which is about average here. There has been one or two 1000 bargains, but they are generally in need of more bodywork

 That is worth $3000 all day long its just beautiful, Im so glad its in your hands and you won't make a meal of it.
 Keep it clean and original.
 Except for the ABF........believe me an ABF will make you way way happier than farting around on a 8v tho I know you love your 8vs ;)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: chis on April 27, 2012, 02:44:31 pm
one to watch
choice!
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on May 03, 2012, 08:08:42 am
What suspension are you thinking Bryce?

I'd like to go height and rebound adustable.  What did your old man end up using?  I'm in Berlin this week so may try to get to tm tuning
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: RS ZWEI on May 03, 2012, 08:18:32 am
I'd like to go height and rebound adustable.  What did your old man end up using?  I'm in Berlin this week so may try to get to tm tuning

Dad had the same as what you had in your Mk2. Ive got the rebound adjustable ones.
It might be worth looking into KW as well?
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: 80 Vert on May 03, 2012, 09:53:18 pm
looks like a cracking little car Bryce, someone has looked after that one!
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on June 22, 2012, 10:39:47 am
So, I'm back from Europe and on Sunday I went to Geelong to pick up my new car.  I was tempted to drive him home, but with 120km to travel I opted for a car trailer. Em has named him Andy. (there has be a toy story joke there about owning other cars at a racetrack and writing Andy on their tyre tread)

Anyway, Andy is in nice solid condition, not mint, but definitely workable.  I have ordered all the manuals I need, so will start pulling bits off over the next few weeks.  There are 3 bits of rust to deal with and a very badly cracked/wavy dash to replace (anyone got one of those black plastic ones?!?).

The suspension (I have driven it around the block a few times....don't tell the po po) rides like a boat.  I think it stopped rocking this morning after my drive last night (maybe it was the earthquake).  I've found a great deal on Spax RSX fully adjustable coilovers.  Anyone had any experience?  They seem like a really good deal and have features that match the KW V3, etc?

Pics will come soon....once it stops raining.




Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: RS ZWEI on June 22, 2012, 11:44:43 am
So, I'm back from Europe and on Sunday I went to Geelong to pick up my new car.  I was tempted to drive him home, but with 120km to travel I opted for a car trailer. Em has named him Andy. (there has be a toy story joke there about owning other cars at a racetrack and writing Andy on their tyre tread)

Anyway, Andy is in nice solid condition, not mint, but definitely workable.  I have ordered all the manuals I need, so will start pulling bits off over the next few weeks.  There are 3 bits of rust to deal with and a very badly cracked/wavy dash to replace (anyone got one of those black plastic ones?!?).

The suspension (I have driven it around the block a few times....don't tell the po po) rides like a boat.  I think it stopped rocking this morning after my drive last night (maybe it was the earthquake).  I've found a great deal on Spax RSX fully adjustable coilovers.  Anyone had any experience?  They seem like a really good deal and have features that match the KW V3, etc?

Pics will come soon....once it stops raining.

When you would have seen my MK1 it ran Spax suspension, a spring and damper kit though. I really enjoyed it.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on June 22, 2012, 11:59:11 am
I love mk1s.
 Im working on kevadventures cabby right now and its so easy and mostly well made.
 Well its still going and will still go for 30 more years if its looked after.
 Remember KISS? Keep it simple stupid.
 
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: GTI's on June 22, 2012, 01:26:54 pm
I'm running spax rsx in my mk2  Awesome ride!    >:D
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on June 22, 2012, 01:58:38 pm
I'm running spax rsx in my mk2  Awesome ride!    >:D

That's good to know.  It seems they are popular with other car makes, but not so with VW guys? 

Just had an email back and they are AUD890 shipped to Australia.  Bargain considering I think I paid $850 for the Patec's I had on the Mk2.

God, I've missed man shopping for my car....
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: spooln on June 22, 2012, 02:36:39 pm
Interior pics please
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on June 24, 2012, 07:32:58 pm
(http://i2.photobucket.com/albums/y39/kiwidubstar/10910e79.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/50b246d1.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/c0828288.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/5d454d5b.jpg)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: coons on June 24, 2012, 08:44:16 pm
That interior looks mint! Looks like your picked up and absolute score there
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on June 24, 2012, 10:54:29 pm
The interior is actually pretty ratty.  Will need new dash, front seats and parcel shelf.  I was thinking about going to some of those black door cards from old skool vw.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on June 25, 2012, 03:03:44 pm
I have opening vent windows and I need the latch for the ledt side as it has dropped off at some point and the window is just taped shut.  It looks like this (apparently the same as some transporters).

(http://i2.photobucket.com/albums/y39/kiwidubstar/59788227_01_med.jpg)

It is the glue on type

Any help?
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on June 26, 2012, 09:48:31 am
I may have the latch and I also just got given some two door black door cards with the handles etc your welcome to them. Not perfect but good for the age.
 I think I gave a very good black plastic old dash to the guy who bought my ABF mk1, Ill see if it can be got.
 You have to keep those seats tho! Just get em redone I love them.

 Your dash is ok as well really, if you have the money you can do it all but really they are old and can't be perfect......... 8) Can they?
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on June 26, 2012, 11:56:05 am
I think the car can be pretty damn good with a little effort.

The dash is completely f**ked, as it sat for another 18months afetr those photos were taken.  Its got more cracks then a plumbers convention and is all wavy and horrible.

The seats will stay for the time being, but my goal is to make it a bit of a weekend racer.  I'll keep the exterior stock looking, but interior will be more stripped out and the engine/suspension played with.

It's always a fine line as to 'leave stock' for the historic value or modify for fun.  I think I hit the right balance with the Mk2 and will try to get the same result with the Mk1.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: rambo_005 on June 26, 2012, 12:23:26 pm
Not sure if this car has them or not: http://www.vask.org.nz/index.php/topic,28781.0.html
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on June 26, 2012, 09:41:27 pm
Doesn't have the opening vent windows
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: 80 Vert on June 26, 2012, 09:45:10 pm
Looks like a really tidy little car Bryce, I'm sure you'll do it justice.
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on July 19, 2012, 09:04:21 pm
I need a new battery and I'm weighing up whether to spend $250 on a odyssey 'race battery'.  Small, light and mountable upside down.

Or

Spend $130 on a standard battery.

Leaning towards a std battery unless someone comes up with a fantastic argument for the race car.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: 80 Vert on July 19, 2012, 09:38:48 pm
Odyssey batteries are awesome, the tiny battery starts my R32T with ease and since its under the floor in the boot being small counts for quite a lot.
One problem is that it seems to drain down if left for more than 1-1.5 weeks so I'll probably end up getting a bigger one as modern cars seem to have more stuff draining the battery when not in use.
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on July 19, 2012, 10:05:58 pm
What one are you running John?
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: 80 Vert on July 19, 2012, 10:24:37 pm
Dunno, I'll see if I can find the blurb on it tomorow.
Bought it in the US, guy told me that a lot of the Honda drag guys use them as they are about half the weight of a normal battery however I think its a little small on the capacity side for my car.
Will use it for the Ghia and buy a bigger one for the Jetta.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on July 20, 2012, 11:14:51 am
Get the Koba brand battery if you can.
 Partmaster haas been selling them for a year now and zero returns! The old brand had 100s of returns ::) Supercharge= supercrap.

 All VWs seem to drain battery's when left for a week or two ??? My vert mk1 is the only golf Ive ever owned that can sit for 2 weeks and then still start and thats with the alarm set.
 My friends had a mk1 and 2 out at Piha and constantly had flat batterys even though they were new batterys and the charging system worked and they were tested for drains.
 Went to Nissans and never had a problem since..... ???
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: bigbumper on July 20, 2012, 02:33:29 pm
Just fit a battery kill switch if the car is going to sit regularly?

(http://ecx.images-amazon.com/images/I/31-DNV8aMRL._SL500_AA300_.jpg)

These ones are easy to fit (and remove), and all of about $10 from Ripco... I have one on my Abarth, it works a charm
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: GTI's on July 23, 2012, 07:18:17 pm
awesome!  I need 3 of those!
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: rambo_005 on July 23, 2012, 10:10:50 pm
Grabbed one from Repco today - $12.49 8)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on July 25, 2012, 05:01:34 pm
Going to move the discussion about seats from the rocco thread to here.

My ultimate seat would be a pair of Recaro Rally 2 (http://www.weinkath-carwheels.de/recaro/recaro_classic/recaro_rally_2_nr_741000.html/)

However, short of winning lotto, I will have to settle on something similar.  My current favourites are:

Mini buckets (http://www.ebay.co.uk/itm/CLASSIC-MINI-BUCKET-SEAT-BLACK-COOPER-AUSTIN-MORRIS-/390368225406?_trksid=m7&_trkparms=algo%3DLVI%26itu%3DUCI%26otn%3D3%26po%3DLVI%26ps%3D63%26clkid%3D848905349171511982&_qi=RTM687476)

OMP Donningtons (http://www.ebay.com.au/itm/HA-764-M-OMP-DONINGTON-CLASSIC-CAR-RACING-SEAT-SALE-PRICE-SAVE-10-RRP-/330660844947/)

Cobra Classics (http://www.ebay.co.uk/itm/Cobra-Classic-RS-Seat-Black-Vinyl-Outer-Black-Cord-Centre-/221061166687?pt=UK_CarsParts_Vehicles_CarParts_SM&hash=item337845b65f/)

The OMP Donnigtons are on sale at the moment and I could get them landed here for under $500 for the pair, brand new.  Only problem is that the picture makes them look ugly and out of shape and I can't find any pictures where someone has actually fitted them in a car.

I'm open to any old school bucket style seat as long as it has a head rest and is not too big that it would look out of place ina little Mk1.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: RS ZWEI on July 25, 2012, 05:12:59 pm
I think the OMP ones look good.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on July 25, 2012, 06:30:29 pm
+1 on the OMPs and I did look at all of them :)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: spooln on July 25, 2012, 06:39:42 pm
I like the cobra ones. I also really like you existing setup. Are they to far gone to keep?
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: 80 Vert on July 31, 2012, 02:32:30 pm
Same as Neil on the Cobra, they look quite a lot like his Opel GT's
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: Filx on July 31, 2012, 03:24:03 pm
Shame you can't sit in them up front as that makes the most difference. I would probably vote OMP except it would be nice if they didn't have the OMP logo stenciled on the headrest. The OMPs in the Vento are suprisingly comfortable and well made for relatively inexpensive seats.
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on August 05, 2012, 10:54:23 pm
New battery and homebuilt tray.  Went with a Full River battery in the end.  Exactly the same as the Odyssey, but only $120.

(http://i2.photobucket.com/albums/y39/kiwidubstar/7a518805.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/a8b943a7.jpg)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on August 06, 2012, 09:31:05 am
Nice tray ;)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on August 06, 2012, 10:44:16 am
It still needs some cleaning up and a coat of black paint, but its secure, so that's the main thing.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: RS ZWEI on September 02, 2012, 08:21:03 am
Did you decide on a seat Bryce?
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on September 02, 2012, 10:11:35 pm
Nope, not yet.

Last weekend I pulled all the old boat-like shocks out.  I have decided to switch to later style top mounts on the front, but unfortunately, the mounts I got didn't have the correct spacers and washers included, so I've spent the week tracking down the correct ones.

Today I got the rear shocks in.  Prothane top mounts and coated in lithium grease to protect the threads.

(http://i2.photobucket.com/albums/y39/kiwidubstar/fe1bb05a631db56c6e5db501c1ca323e.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/81fa8cbd98b7068714e02c93c7bd306c.jpg)

I also found some of the old underseal peeling off in the front arch.  So i ground it back and, using the por15 etching solution and por15 top coat, corrected the little bit of rust that was the present.  Then coating it in underseal, which looks like a cat with explosive diarrhea backed up to my car and let loose.

(http://i2.photobucket.com/albums/y39/kiwidubstar/4ef56a209edf0bfb4bbdaee75e861d85.jpg)

Finally, i used my homebuilt pressure bleeder to bleed the brakes.  It worked amazingly, managed to bleed all 4 corners, by myself in under 20minutes.  Build one, if you haven't already.

(http://i2.photobucket.com/albums/y39/kiwidubstar/bac2e2679f51ee2f75b5cb439c27cd5a.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/956862c9d8a5510273cfaae99fab07f3.jpg)

Also, what's this? Some kind of diagnostic hub?

(http://i2.photobucket.com/albums/y39/kiwidubstar/06e83b4a3614f2d7101e00eeab074e10.jpg)



(http://i2.photobucket.com/albums/y39/kiwidubstar/8d4e79d7c3653997cfb58ddcd3fab017.jpg)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on September 03, 2012, 09:24:43 am
Nice shed.
 I have a sales brochure of a mk1 golf and they show it at the VW service garage and they do have a diagnostic machine they plugged into a port where your one is.
 God knows what they can diagnose on an old points driven mk1 ???
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on September 03, 2012, 10:56:59 am
I know! Plug it in...umm...yes, we can confirm your battery is flat.  Seems a waste of 450g of wiring.  Will see if I can hide it or I'll trace it back and get rid of it completely.

For anyone interested, this is the build instructions for the brake bleeder:

http://faculty.ccp.edu/faculty/dreed/campingart/jettatech/bleeder/index.htm (http://faculty.ccp.edu/faculty/dreed/campingart/jettatech/bleeder/index.htm)

Mine came in $11 (sprayer), $6 (hose), $15 (brass fittings), $2 (tyre valve) = $34
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: 80 Vert on September 03, 2012, 11:04:17 am
Yep thats a diagnostic of sorts, checks lights etc..........bit of a gimmick in the day really. Came out on Beetle's first.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on September 03, 2012, 05:58:51 pm
Don't delete It dubstar! Its part of its charm!
 Find an old "diagnostics" machine to plug into it!
 I will scan in the brochure.....
 I am so dumb I am bad at doing pics on here and I could do so many good ones :-[
 I will try now....
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on September 03, 2012, 06:19:22 pm
Here!
 (http://i636.photobucket.com/albums/uu86/jellymeat/Diagnosis001.jpg)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on September 03, 2012, 06:23:05 pm
You will be able to suss stuff from it like Alt voltage etc with a multi meter. Bit like you can by touching one on the battery terminals but that's no fun is it.
 It was all about smoke and mirrors. Always has been and always will be ;)
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on September 03, 2012, 10:25:33 pm
Wonder where I could get the plug and analysis tool........
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: RS ZWEI on October 21, 2012, 11:18:38 am
Any updates Bryce?
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on October 22, 2012, 12:01:29 pm
Will have some updates on Wednesday.......just little bits and pieces, but they shoudl all add up
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on November 02, 2012, 12:43:48 pm
I wanted to have a nice big update about roadworthy certificate/re-registration, but I've been painting the house (we are on a deadline for the new baby).

I have got it completely ready for the check, so its just a matter of finding time to book it in and do it.

On a side note, I found these very cool 80's seats.  They are HOIP which is a German company that made lots of cool accessories for BMW, Mercs , Audis and VWs in the 80's.  I think they would look great when recovered.

http://www.ebay.co.uk/itm/Second-Hand-HIOP-Sports-Race-Seats-Complete-/321014007931?ssPageName=ADME:B:WNARL:GB:1123
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on November 02, 2012, 02:18:24 pm
Nice period seats for sure.

 This baby has shown up very quickly after the marriage hasn't it Bryce? :)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: spooln on November 02, 2012, 02:50:29 pm
Nice period seats for sure.

 This baby has shown up very quickly after the marriage hasn't it Bryce? :)

+1  ;)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on November 02, 2012, 02:58:05 pm
Easy there fella's.  2 year wedding anniversary next week, but, not bragging or anything, it took 4 days. :laugh:Too Much Information?
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: RS ZWEI on November 02, 2012, 02:58:51 pm
Easy there fella's.  2 year wedding anniversary next week, but, not bragging or anything, it took 4 days. :laugh:Too Much Information?

Gold.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on November 02, 2012, 09:22:25 pm
Two years already!
 You make me feel old Bryce.
 Your baby is gona be the cutest kid on the block I know it ;)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on November 20, 2012, 10:43:29 am
Sorry for the delayed updates.

I finally got my Roadworthy Certificate yesterday which means I can get regoed and on the road!

They picked up on 7 little things:

- The Seal around the boot/hatch had a 10mm gap at the end.
- Exhaust hangers were knackered
- Steering rack boot is ripped
- The rubber boot under the car that protects the gear lever was cracked.
- Windscreen washers weren't aimed correctly
- The underside of the engine needed a degrease
- Spare wheel strap wasn't done up


All sorted now!
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: RS ZWEI on November 20, 2012, 11:23:16 am
Sorry for the delayed updates.

I finally got my Roadworthy Certificate yesterday which means I can get regoed and on the road!

They picked up on 7 little things:

- The Seal around the boot/hatch had a 10mm gap at the end.
- Exhaust hangers were knackered
- Steering rack boot is ripped
- The rubber boot under the car that protects the gear lever was cracked.
- Windscreen washers weren't aimed correctly
- The underside of the engine needed a degrease
- Spare wheel strap wasn't done up
 :-*

All sorted now!

They are fussy compared to NZ.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on November 20, 2012, 02:32:44 pm
Well those things are quite easy to rectify and they stop fumes into the cabin so I can understand them pointing them out.
 Good work Bryce.
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on November 26, 2012, 09:10:03 pm
Here's the Golf at the weekend sporting its new plates.

(http://i2.photobucket.com/albums/y39/kiwidubstar/1716bfec83e5d3fe9144a45b076a85cb.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/efb65135720707d78ba46643a54445ba.jpg)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on November 27, 2012, 08:53:05 am
Slammed! :)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: spooln on November 27, 2012, 12:55:36 pm
Nice one, any side pics?
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on January 03, 2013, 09:45:45 pm
(http://i2.photobucket.com/albums/y39/kiwidubstar/2d937815d247a5d1bf2d17e8378b3fcf.jpg)

Finished the majority of the house painting so I pulled Andy out the garage for a quick clean and side shot
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on January 03, 2013, 09:58:52 pm
Looks nice and green there in stralya.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: sifty on January 04, 2013, 09:08:33 am
Did you buy this car off a guy named Tim in Victoria? 
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on January 04, 2013, 10:48:03 am
Yes I did....... ???
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: sifty on January 04, 2013, 11:10:00 am
Small world huh. Did you see his 4 door turbo Mk1?  That thing hauls, or hauled, some serious ass.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: 5-pot on January 04, 2013, 06:26:15 pm
They are fussy compared to NZ.

Well, you only get a roadworthy done when you buy/sell a car.  There are no other inspections over the life of the vehicle, unlike NZ's Warrant Of Fitness. 
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on January 15, 2013, 11:15:02 am
I've been doing a little bit on ANdy over the past week or so. 

The dash that came with the car was completely fcuked.  I managed to get a mint, plastic dash from Lane and so set about fitting it.....

I didn't really find any full instructions on removing an early mk1 dash, lots on removing the instrument cluster, so heres a quick help guide:

1) remove instrument cluster and steering wheel as per Haynes/Bentley.

2) remove the 2 screws at each end underneath the dash (4 screws in total)

3) remove the 3 screws from the centre console and slide the console out of the way (no need to remove the whole thing)

4) This gives you acess to the centre screw that is holding the 2 sections of the heater together.  Remove this screw.

6) Remove any wire clips/ties that may be holding the loom to the dash

5) Now just give the dash a damn good tug backwards and it should come free.

Location of 5 screws and picture of fcuked dash

(http://i2.photobucket.com/albums/y39/kiwidubstar/Dashscrews_zpscfd9037b.png)

When I installed the new dash I also took the opportunity to update the stereo.  I wanted something with a slight retroi feel to it, so I went with the Retrosound Model One "Becker" style unit.  Pictures....

(http://i2.photobucket.com/albums/y39/kiwidubstar/e8683f12e22b9b59b0b7a7b706916593.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/e53c6e18946242511312cc9bd9793c7d.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/44a270e85fcd09605787c40c810823fc.jpg)


The only problem is that there is only 1 4x6 speaker in the centre of the dash and I don't want to hack up the car to fit any others.  I found a simple wiring diagram (see below) that apparently can convert stereo into mono, however I have found that it distorts the sound and also really limits the volume.  Can any of the electronics experts here tell me another way to get around this?

If I read the schematic correctly, I put resistors on all 4 wires (R+, R-, L+, L-) and then 1 big one between them.  I have used std type resistors rated at 1W.

Schematic:
(http://i2.photobucket.com/albums/y39/kiwidubstar/stereo20to20mono20circuit_zpse702f57f.png)

My wiring:
(http://i2.photobucket.com/albums/y39/kiwidubstar/ad08e115771b677cace31b680cc7baac.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/97766bc7c72fc53b3a47ff2fcdc8af1a.jpg)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: Trofeo on January 15, 2013, 05:37:06 pm
There's a simpler version on this page. http://www.gearslutz.com/board/geekslutz-forum/634214-mono-stereo-passively-help-sought.html

Your one shows what looks like coils on the inputs?
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on January 15, 2013, 06:25:21 pm
Just chuck one speaker in the middle place and then put the other one hidden under the dash a bit and she will sound fine.
 That's what I dun anyway.
 Then get some other speakers and make little pods that slide under your front seats and you get 4 sensible sized speakers going unseen.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on January 16, 2013, 03:17:05 pm
At the moment I just have it connected to one speaker output (Rear Left) until I can work out a good system.

I don't want to just stash speakers around the car.  I'd like to keep it all looking original if possible
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on January 16, 2013, 05:24:02 pm
Well can you see a speaker hidden under a dash or under a seat? No and your not cutting into anything.
 Having one speaker in the dash would never do it for me.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on March 12, 2013, 01:19:48 pm
I haven't had much time to do anything recently, but managed to fit in a few hours to correct the brake light set-up that was in Andy when I got him.

The set-up looked like this:


(http://i2.photobucket.com/albums/y39/kiwidubstar/P1080428_zpsf490b06c.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/P1080429_zps335f924c.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/P1080430_zps6d7b3af5.jpg)

However, what is really funny, is that the wires were connected in such a way that this switch did nothing!  The car was running off the original hydraulic brake light switches that are connected at the master cylinder.  I guess someone put it tiogether, figured the brake lights still worked and left it at that?!?!?

Anyway, I plan on running a later master cylinder without the hydraulic switches and, since I went ahead and purchased a replacement brake light switch anyway, I thought I might as well correct the issue now.

I actually found a motorbike universal brake light switch that would work much better in the Mk1.  Here's a pic:

(http://i2.photobucket.com/albums/y39/kiwidubstar/P1080431_zps18842e4c.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/P1080432_zpsa409dad1.jpg)

You can buy them from ebay here (http://www.ebay.com.au/itm/270973311150?sPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649/).  It is made by K&S and has a part number 12-0001

The Mk1 pedal cluster is set up perfectly for this switch.  All you need to do is drill a 10/12mm hole (mine was already there for the previous switch), bend the activating wire so that it can loop through the existing hole in the pedal and Roberts your Mothers Brother.

(http://i2.photobucket.com/albums/y39/kiwidubstar/P1080436_zps1255f3b5.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/P1080440_zps09e43dac.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/P1080437_zpseb3ade12.jpg)

Now on to the wiring. 

Whoever set up the previous switch had connected one wire to ground and one wire to the red/yellow in the pic below.  This doesn't work (at least on my car).  For the switch to work it needs to switch between the red/yellow and pink/black wire.  I believe the blue/brown wire is part of the low pressure warning system. 

(http://i2.photobucket.com/albums/y39/kiwidubstar/P1080446_zps36a5ed9a.jpg)

For the moment I have the hydraulic switch hooked up and the pedal switch running as a parallel 'back-up'.

And here's the 'engineering' of the old switch.....

(http://i2.photobucket.com/albums/y39/kiwidubstar/P1080441_zpse5967eb1.jpg)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on March 12, 2013, 10:01:10 pm
You appear to have the usual mk1 accelerator hook just hooked through the pedal hole with no rubber bung left.
 For some insane reason they had a large hole in the pedal a rubber grommet and that hook on the cable.
 The grommet breaks up and disappears and the hook just ends up hooking vicariously through the hole, until one day when you go to pull in front of a bus and then go oh no and lift off quick and then think oh crap I have to go now and stomp again only to find the hook falls out.
 Not good.
 I cut a bung out of rubber and then also got a large electrical chocolate connector and screwed it over the end of the hook so it can't fall out the hole. 
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on March 13, 2013, 12:10:10 pm
Thanks Jem, I'll get onto that.  It is very loose feeling so it was on the list.
Title: Re: DUBSTAR'S PROJECT - Wei� Hase - 1976 Golf LS
Post by: 00quattro00 on March 13, 2013, 12:15:57 pm
I had it happen to me in one of my mk1s and in the old audis, luckily had enough speed to roll across the intersection

Sent from my GT-N7100 using Tapatalk 2

Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on June 17, 2013, 09:59:34 am
Getting ready for the next big upgrade.....

I'll be replacing the brakes with the following set-up:

1) Front girling 54 calipers, rebuilt with ss hoses and Greenstuff pads.
2) Rear 200mm drums from a mk3.
3) mk3 9" booster and 22mm master cylinder

I'll also be adding the front cross brace John made, GTI swaybars, poly bushes and new balljoints, etc.

Some pics for clicks

Calipers and swaybars:

(http://i2.photobucket.com/albums/y39/kiwidubstar/GOPR0028_zps8f1a43f5.jpg)

Rear drums:

(http://i2.photobucket.com/albums/y39/kiwidubstar/GOPR0030_zpscec818db.jpg)

I also ground down the old bearing races so that I can use them to press in the new bearings

(http://i2.photobucket.com/albums/y39/kiwidubstar/GOPR0032_zpsfacf4fad.jpg)
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on July 09, 2013, 09:02:07 pm
Started the big brake and suspension refresh.

Here's the majority of parts to go in.

(http://i2.photobucket.com/albums/y39/kiwidubstar/c7c658fe19763ed2368750a8e1f72e8c_zps7fd3d8da.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/a228a9dd3adb936c5310a6f268238854_zps97142b5b.jpg)

Front:
- girling 54 calipers, rebuilt
- early Audi caliper carriers.  These allow 256mm brakes to bolt straight on.
- DBA slotted rotors
- EBC Greenstuff pads
- Goodridge hoses
- prothane and Superpro bushes (pain in th arse to buy all the different swaybar bushes)
- new control arms and ball joints
- x-brace from vert.
- 17mm swaybar

Rear
- 200mm Mk3 drums with new cylinders
- Prothane bushes
- Goodridge hoses
- 20mm swaybar

Brake booster
- 22mm m/cyl
- 9inch booster

Wheels will be a surprise...nothing too exciting.

Over the past few days I have done the front suspension and brakes.  Brakes all installed.  Shiny new suspnsion parts.  All bushes lubed up, 'cause noone likes squeaky bush.

(http://i2.photobucket.com/albums/y39/kiwidubstar/96a4920c979ebe4cca96f0b0efc634e6_zps675ace6f.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/64dc5f26218a9c66187aaab5b8e0b2bd_zps3b1a402f.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/4566ecda520c3ec96f7c065ca114f8f4_zpsb0957fd0.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/6863c40d077567cc66149906a6fd6fb2_zps40461d52.jpg)

And I've also removed the booster....

(http://i2.photobucket.com/albums/y39/kiwidubstar/cbccf7dfa639832848478678d0471455_zps754bf597.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/5269594e34724c9aa0f230f2372a0778_zps5596a09e.jpg)
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on July 12, 2013, 05:59:10 pm
I got the booster and master cylinder all sorted.  It's amazing how much you can get done if you don't watch TV for a few days.

I modified a mk3 booster to work as per this link:

http://www.vwwatercooled.com.au/forums/f20/how-mod-late-booster-mk1-11689.html

(http://i2.photobucket.com/albums/y39/kiwidubstar/3848422011f51cf4b849fd663512f617_zpscd02a8b3.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/1fed750159bc0f76be7f24dc53c0f838_zps5b796c4e.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/0f0cb05d453c6f4d33e2c964f0404c6d_zps45bea9aa.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/e10e7063547ac8fddd0c45f4b4e22b88_zps349ae254.jpg)

The lines have been bent a bit by some previous owner, they now clear everything, but when the engine swap happens i'll bend up some new ones.

Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: spooln on July 12, 2013, 06:22:41 pm
What engine re you planning?
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on July 23, 2013, 09:06:20 pm
Got Andy back on his wheels on the weekend.

I forgot to snap some pics of the rear beam before I re-installed it, but here's a few fuzzy/dark photos....

Prothane bushes

(http://i2.photobucket.com/albums/y39/kiwidubstar/7bab7183c7c2942bf7538e2146a14745_zps3343f9e9.jpg)

20mm sway bar

(http://i2.photobucket.com/albums/y39/kiwidubstar/945dc3fdec4d89a373a75f383f49cf37_zpsf21d3b45.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/f169dc48e617da7cc20a72a8b3ddf7ec_zpsebaea9ec.jpg)

200mm drums

(http://i2.photobucket.com/albums/y39/kiwidubstar/7858a6e497dfb3a8ef095a31e5820e6b_zps70dd67d4.jpg)

Front strut bar

(http://i2.photobucket.com/albums/y39/kiwidubstar/cdab1e844b2ee8fcee93adc6debfd31a_zps27b50fd8.jpg)

Sneaky pic of the wheels

(http://i2.photobucket.com/albums/y39/kiwidubstar/15a3114d13afb6ff1572a3999511485c_zps2925b817.jpg)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on July 25, 2013, 07:10:13 pm
If you run low get the ball joint extenders.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on July 26, 2013, 12:31:40 pm
Hey Jem, you've been quiet recently.

I thought about balljoint extenders, but my car runs the really early 15mm balljoints and no-one makes 15mm extenders.

Title: Re: DUBSTAR'S PROJECT - Wei� Hase - 1976 Golf LS
Post by: 00quattro00 on July 26, 2013, 12:46:23 pm
Looks good, ill be doing the same for my mk1, swapping out the brakes on my mk3 for vr6 so the mk3 drums can go on the mk1
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: watercooled on September 02, 2013, 09:38:51 pm
What engine re you planning?

Wanted to ask this myself,so far the car is overbraked,there must be a bigger motor on the way,reckon 3a or 2e would be the nuts.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: watercooled on September 09, 2013, 08:50:54 pm
No answer ,? hope theres no offence taken by my reply but have done full mk3 brake conversion on 87 mk2 3a 2 litre block and dijifant head and well speced motor (plenty of power),never changed the master cylinder as stock is fine,I have powerful brakes.
Nice to see this car very tidy and good luck with the project.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on September 16, 2013, 12:18:44 pm
Sorry for the delay in response.  I've been working on resolving an exhaust/subframe interference issue.

When I fitted the front X brace to the underneath, it was clear that the old standard convoluted flex joint/section was going to rest on the frame.  I decided that I would upgrade the entire system (downpipe back) in preparation for future developments.  I found a guy who was recommended by a bunch of people and dropped the car off with the clear direction to get rid of the interference in the front and also allow a bit more room at the back, where, on occasions, the tailpipe hit the bodywork.

I picked up the car and found that he had done the tailpipe, but he swore black and blue he couldn't clear the front brace and that I would be better modifying the brace.

I went home and jacked the car up to take took some measurements and found he had replaced the system from about halfway along the transmission tunnel, leaving the front flex section.  To me it was really clear that he could simply install one of those 100mm long woven flex joints just after the front flange and this would be well away from the X brace.

So a quick call and he admitted that what I suggested was possible, but it was going to cost extra for the joint......anyway, I now have a full 2" downpipe-back system with clearancce where needed.  He also replaced the flanges for easier to access ones, so I can change/adapt future changes easier.

The car sounds a lot less 'tinny' and is actually quieter than before.

Pics to follow....

I'm also having issues with bleeding my brakes.  The symptoms:

1) When car is off, it takes 2 pumps and the pedal goes hard.
2) When the car is on.  The pedal has quite a bit of travel before it bites.
3) Once the pedal bites, the brakes are fantastic.

To me this points to air still in the system.  I am using a pressure bleeder and have gone through about 1.5L of fluid.  I am going to get Emelyn to give me a hand and try bleeding the old fashioned way.  If that doesn't work then it is off to the mechanics and they can try bleeding.  Any other thoughts?

Finally, engine plans......I would love an ABF, but at the moment cost is kind of prohibitive.  I priced up getting one from NZ and the freight is about $6-800 all up.  So I will probably go down the tried and tested 2L 8v route, which was pretty good in the mk2.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: GTI's on September 17, 2013, 08:41:33 am
How old is the M/C?  I had one leaking in the diaphragm
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on September 17, 2013, 10:49:19 am
Brand new MC
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on September 25, 2013, 10:49:01 pm
Are the rear shoes adjusted right? you can get a bit of travel if not.
 Hit the brakes without the motor going and see if you can hear the rear brakes squeak as they take up the slack.
 Where the wedge drops down can get worn and they never adjust up properly.
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on October 16, 2013, 04:53:31 pm
 10points to Jem on this round of "what the bloody hell is wrong?"

The adjusters were not moving freely on the rear shors.  Eventually coaxed them further down through the bolt hole.

Does this mean a new set of springs, levers, adjusters when the pedal travel next gets too bad?
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on October 26, 2013, 10:51:20 am
A quick pic from DoVW. 

Finally got the brake issue sorted.  Turns out that the 'automatic' adjustment wedge was not automatically adjusting.  We forced the wedge down through a wheel stud hole and that solved the issue!

(http://i2.photobucket.com/albums/y39/kiwidubstar/4c3125f4b18e319e4ab860965f6da9dc_zpsbc2ba7f3.jpg)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on December 02, 2013, 11:05:11 am
My project on ANdy for the past few weeks has been to make new set of interior boot cards and also repair the parcel tray and its supports.

The boot area was in pretty bad shape as you can see here:

(http://i2.photobucket.com/albums/y39/kiwidubstar/P1040196_zps786573ac.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/P1040196_zps786573ac.jpg.html)

The parcel tray was broken and ripped and didn't stay in place, it just dropped off the supports:

(http://i2.photobucket.com/albums/y39/kiwidubstar/P1040199_zps0158dd2c.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/P1040199_zps0158dd2c.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/P1040200_zpsc04f1eba.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/P1040200_zpsc04f1eba.jpg.html)

I used some 4.2mm masonite to reconstruct the panels, using the old ones as a template.  With a lot of primer-sand-paint-repeat, I got the boards pretty smooth:

(http://i2.photobucket.com/albums/y39/kiwidubstar/P1040202_zpsadd03208.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/P1040202_zpsadd03208.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/6a4b75a868b955ac9cd486d64b861407_zpse25ee87a.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/6a4b75a868b955ac9cd486d64b861407_zpse25ee87a.jpg.html)

I also used the masonite to add some strength and repair the parcel tray:

(http://i2.photobucket.com/albums/y39/kiwidubstar/d900854a7d63c5875c7e6b6f1ec2da23_zps49431cad.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/d900854a7d63c5875c7e6b6f1ec2da23_zps49431cad.jpg.html)

The parcel tray supports were pretty bowed and also had some broken tabs/cracks.  I added strength and straightened them out by using some Auminium U bar.  This fits perfectly into the channel where the parcel tray rest and with some JB weld and concealed rivets (clamped for 3 days) I managed to get them straight and sturdy again.

Before:
(http://i2.photobucket.com/albums/y39/kiwidubstar/2c3cb868e26fd7610b359cc81fe07fb6_zps30aac97c.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/2c3cb868e26fd7610b359cc81fe07fb6_zps30aac97c.jpg.html)

During:

(http://i2.photobucket.com/albums/y39/kiwidubstar/0f6d26b9d991a608caa5f6b39ee7a7ae_zps2ef81a41.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/0f6d26b9d991a608caa5f6b39ee7a7ae_zps2ef81a41.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/639894a31fe92471143bcc448b487b5c_zpsbc9bb753.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/639894a31fe92471143bcc448b487b5c_zpsbc9bb753.jpg.html)

After:

(http://i2.photobucket.com/albums/y39/kiwidubstar/775bdf35bb8999e90480883f9ad46e2a_zps202835f3.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/775bdf35bb8999e90480883f9ad46e2a_zps202835f3.jpg.html)

The parcel tray on a Mk1 connect to the backseat.  It has an excess length of fabric that is screwed into the top of the back seat.  Over time the fabric rips and frays.  Obviously this was a known problem and on the later Mk1s, VW added a length of aluminium bar to fold the fabric more evenly.  This bar is NLA, so I had to choose a profile from stock and used that.  I also had to break out the needle and thread to repair the rips.:

(http://i2.photobucket.com/albums/y39/kiwidubstar/d2f2dd1ef7228874e42aeb97a194f615_zps6a3b0377.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/d2f2dd1ef7228874e42aeb97a194f615_zps6a3b0377.jpg.html)

And fully completed:

(http://i2.photobucket.com/albums/y39/kiwidubstar/26083647a9e7649dde3962349066aabb_zps7a878b62.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/26083647a9e7649dde3962349066aabb_zps7a878b62.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/2c2e306d93db04dd227daee858c1c233_zps68fe9c65.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/2c2e306d93db04dd227daee858c1c233_zps68fe9c65.jpg.html)

A few things I would do differently:

1) I'd look at using slightly thinner board (the originals are 2.5-3mm). 
2) I'd also look at getting ABS plastic sheet, I think that could work wuite well, but cost is the issue ($15 vs $140)
3) I hate trim clips, they are the s**ttest invention next to clam shell packaging (which is what mine came in!)
4) I need to clean my camera lens.



 
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on December 11, 2013, 01:03:06 pm
Basically, I had to take the mk1 to work yesterday when we had the huge downpour in Melbourne (there's a longer story here, but lets stick to teh topic).

I got home and felt the carpet and it was a little damp, which I expected.  So I lifted up the carpet and underlay to let it dry out.  However, I found some rust that will need treating. 

I plan on doing the full POR15 3 step process (I know some people don't like it, but vert used it, so can't be all bad ;D).  What I would like to know is, what are people doing for sound deadening/underlay?  The OEM stuff is quite thick, but I think it would be best to throw in some new stuff.  Thoughts:

1) Use this stuff.  Two layers of sound absorbing underlay separated by a noise barrier of mass loaded vinyl:Sound Deadening Underlay Offcut Suits Replacement Moulded CAR Carpet Fitting | eBay (http://www.ebay.com.au/itm/Sound-Deadening-Underlay-OFFCUT-suits-replacement-moulded-car-carpet-fitting-/141096716867?pt=AU_Car_Parts_Accessories&hash=item20da050a43#ht_1757wt_1203)

2) Use this stuff.  A layer of butyl bonded to traditional jute underfelt:  Soundproofing Felt - Knox Auto Carpets (http://www.knoxautocarpets.com.au/underfelt-soundproofing/soundproofing-felt/)

3) Use Dynamat/Extrememat/etc and then std underlay on top.

I'm no a fan of number 3 as it seems counterintuitive to stick something to the floor of the car that could trap moisture and condensation.

On the good side is that most of the bitumen sealer crap is easily chipping off, most came off easily, but there are some further parts that will require a heat gun.  The rubber pads on the front wheel wells, to the right of the pedals, are going to be pain in the arse

(http://i2.photobucket.com/albums/y39/kiwidubstar/64ce913cb4548227f307d78778c9b960_zpsfcd2eb22.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/a1acb75a4ca740e9200925805a5e8ffc_zps9ab5441a.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/f00006c08301b133b7261ff99c99b2ad_zps1ca8890a.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/40f3244f3b9f5059a01e220e1b87731d_zpsabbc4eba.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/41ca46bebf0b4d3f847e171f6bfbd7ea_zps4e7f8bf5.jpg)

There's no holes, which is good, but will take some work.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: 80 Vert on December 11, 2013, 01:26:28 pm
Por15 has it's uses and is very tough but I wouldn't use it to "paint over rust" per say, ideal on your floors but use the metal ready first and de rust it before top coating.
I used it on the inside of the Ghia roof but that was after sandblasting first and since the sunroof is a "wet" area its quite ideal for that.

Chip off the old stuff and treat the rust underneath it as well, even going over it with a wire wheel in a grinder before metal ready will give better results as well.

That first sound deadening material is great, I would use that!
I have used similar stuff from Forman Insulation before and works really well, quite heavy due to the bitumen in between but you'll only need relative small pieces.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on December 11, 2013, 01:59:10 pm
Thanks John

I've used POR 15 before.  I always wire brush and then 3M-strip-disc the area to get rid of all visible rust, then follow the marine clean - Metal ready - POR procedure.  I would maybe consider epoxy primer, but if you miss even a small rust speck you are in trouble.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: 80 Vert on December 11, 2013, 02:12:29 pm
I'd agree, if you were to sandblast it I'd go 2 pack epoxy but since that isn't an option go the Por15 route.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: watercooled on December 16, 2013, 11:12:38 pm
Nice work so far ,well done,the Por15 is often applyed over heavy rust scale and thats not what it is designed for,don't put it on clean steel also because it won't bond to it also,many home restorers are now finding this out after a while.
I've used a sound deadening material that is for sale on TM,it is bitumen based product but has no odour,way cheaper than Dynamat,it profiles to the panels with a deadblow hammer and sticks real good.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on December 21, 2013, 10:49:24 pm
Been cracking on with removing the rest of the bitumen and rubber from the firewall.  The best method is to keep the heat gun on the area and the use your chosen craper to peel it off.  The best scraper i found was the 'crevice type', as it conforms to most angles.

I'll go get some dry ice to do the rear floor, as I also want to try making sorbet Heston-style.

(http://i2.photobucket.com/albums/y39/kiwidubstar/ed68c0a996596153f32f31424dcedac1_zpsae26f452.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/5249ed6ac5f4344f580308a57969371a_zps45be22d6.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/12bcc0731d03ead8c796def7729e273e_zpse71aec11.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/819ca16f139a9f38e9d3465ca8d6a0a1_zps4d963d79.jpg)
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on December 27, 2013, 12:35:10 pm
Question for the day.

There are holes pressed into the footwell plate (circled in red).  Can anyone tell me if the cavity underneath has a drain?  Where does it drain to on the underside?

(http://i2.photobucket.com/albums/y39/kiwidubstar/cdd6e7e0a2da802cef4aa842010b37db_zpsfe82a911.jpg)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: 80 Vert on December 27, 2013, 04:32:40 pm
I don't believe so no, if there is it will be a little hole at the end of the rail.
Can't quite recall from the Scirocco.
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on March 03, 2014, 10:08:19 pm
Been a while since I updated.

I have POR 15'ed the floor now.  I actually found a spot that needed a weld, so cut it out and got it welded.  Then I followed the POR guidelines:

1. Scrub with Marine Clean and rinse well.

2. Wire brush everything and then scour the surface with green 3m pads to 'key' the surface.

3. Marine Clean, scrub and rinse again.  Then dry everything with a heat gun.

4. Soak in Metal Ready for a minimum of 30 minutes. Rinse and then dry really well with a heat gun.

5. 2 coats of por 15.

It looks good and solid, ready for putting back together

(http://i2.photobucket.com/albums/y39/kiwidubstar/dedf65613eed137fdbad712a56ff3417_zps584090a7.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/dcb8cea5e602f14024883f43158e90d0_zpsf52d7d80.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/fdd3e47b5db0e3aca8df07123d95c1c7_zps8ddb3bae.jpg)

I wish the budget would allow for some better seats, but I'll just put the originals in for the meantime.  I'll have to keep my eye out for that elusive 'free to a good home' GTI interior....
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on March 27, 2014, 09:28:00 pm
Finally all wrapped up and back together.

I ended up cutting out the manky parts of the foam underlay and cutting replacement parts from the new vinyl/foam underlay I bought.  I also found that the factory misses a few areas where I added extra underlay.  I also put aluminium tape over the holes that were taped up by the factory

(http://i2.photobucket.com/albums/y39/kiwidubstar/4c362b9755cc71b09fc59b6f4f72708e_zps1a449bcd.jpg)

Seam sealed the portholes in

(http://i2.photobucket.com/albums/y39/kiwidubstar/5a24af51b0957f97e2db73d0ff25d840_zpsb312385f.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/a55cfb6bff2425f07a2f8995a12bfcf8_zpsf8d61b4f.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/8f2121303115bcf64f2e849608d130fc_zps2dadbcc3.jpg)

And my little helper

(http://i2.photobucket.com/albums/y39/kiwidubstar/301b8d0b411e801ab4208b40f56430f1_zpsd70e7cd5.jpg)


(http://i2.photobucket.com/albums/y39/kiwidubstar/e1ad7c1c7ef70c59b10528fd35afc6c7_zps106b55ae.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/35083477989108ddcf4287eb6da959a0_zps6e79e0db.jpg)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on March 29, 2014, 10:13:42 am
Nice work, but have you sealed where it was leaking in? Usually around the windscreen and it drips all over the fuse box. I would have the screen removed and clean up any rust and then have it refitted with a good window rubber sealer, which can be even just some candle wax or a lube stick tho there may be better products?
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: spooln on March 29, 2014, 12:14:17 pm
Tan interior goodness.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on March 31, 2014, 11:40:59 am
The interior looks clean, but theres lots of rips and tears on the seats and little holes in the door trim.

I haven't pulled the windscreen yet.  I will, but for the time being it is a dry weather car.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: BB on April 06, 2014, 06:27:51 pm
They are easy to pull out and refit. Just spray lube around the rubbers etc as you push it out if you break it buy a new one a new screen is so nice on an old car and only about 280 here, not sure there? And then just rub a lube stick or two all around it if its good, scrub up the rubber and don't forget some lube on the glass side and refit with sash cord rope. easy and the dripping on the fuse box is a real pain. But yea Im sure you will when you feel like it.
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on May 07, 2014, 08:24:31 pm
Just repaired another little issue.  The speedo was working, but the odometer had stopped.  Pulled the cluster apart and repaired the cracked gear with 2 tiny circlips and jb weld.  Google the vortex for the full DIY.

When I put it back together I had a part leftover.

The inter web says its a 'dash support' but I can't see where it goes?  Any help?

Pics

(http://i2.photobucket.com/albums/y39/kiwidubstar/AA0BA29C-2E2B-4BA6-A358-E2D7B06D478F_zps7ttdyijp.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/2BCEA675-7552-40D6-90E4-7509FC8E38FA_zps2hwphswg.jpg)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on August 08, 2014, 03:55:32 pm
This week I have been doing two things to Andy

1. Getting all the parts ready for the 5 speed conversion.  I have purchased a linkage kit, 90mm drive flanges and a few other bits and pieces needed to upgrade.  I am just cleaning up the box now, I was thing about painting it, but the aluminium has come up looking fresh and clean after a little kerosene and toothbrush action, so that will be all that is needed.

2. The odometer stopped working randomly a little while ago so I pulled the cluster and set about repairing the issue.  Here is a write up with photos to help others and also for my own reference:
Once you have the gauge cluster removed from the dash (refer to Haynes or Bentley) this is what you are left with:

(http://i2.photobucket.com/albums/y39/kiwidubstar/Andy/D22487A1-EDD6-41C1-9267-FB9C84D419B8_zpse8lgo7lu.jpg)

Set yourself up on a nice flat surface, you will need Philips and flat screwdrivers of various sizes as well as a set of sliding jaw pliers and some little picks/tweezers.
Undo the 6 screws circled below:

 (http://i2.photobucket.com/albums/y39/kiwidubstar/7_zps77b73dc7.jpeg)

You need to remove 4 bulb holders to free the printed circuit board (bulbs shown in next 2 pictures).  This will allow you to remove the tach and speedo from the cluster housing.

 (http://i2.photobucket.com/albums/y39/kiwidubstar/9_zps9540eca6.jpeg)

 (http://i2.photobucket.com/albums/y39/kiwidubstar/Andy/3925A7D8-0D14-4732-80B3-719BEA1965C4_zpsuuca90yq.jpg)

Now you need to remove the speedo from the tach.  This requires the removal of the 2 screws highlighted below:

 (http://i2.photobucket.com/albums/y39/kiwidubstar/5_zpsec0690d3.jpeg)

Now you should have the speedometer free from everything else.  Be VERY careful not drop it or lose any screws, etc…..

This is what you should have in front of you now:

(http://i2.photobucket.com/albums/y39/kiwidubstar/Andy/1414F9DA-2E01-41E9-A511-015832D71D51_zpsdpw0uqcp.jpg)

Remove the needle by sliding the tweezers/picks under the base of the needle and pulling up gently.  It will come free with some persuasion.  The needle will fall apart into 3 pieces, like such:

 (http://i2.photobucket.com/albums/y39/kiwidubstar/Andy/239425FD-E79E-4FC4-9853-210A67244C0E_zps0sbjym55.jpg)

Now undo the 2 screws on the gauge face, make sure you don’t scratch it!!

(http://i2.photobucket.com/albums/y39/kiwidubstar/Andy/C19E2BC2-940C-4AF3-810D-CE3C7362E85A_zpsjaxl2odc.jpg)

You now have access to the inner workings of the odometer and speedo.
To allow you to access the gears and tumblers, remove these 3 screws CAREFULLY.  A white gear will drop out and you will also have to be careful of the speedometer flywheel thingee.

(http://i2.photobucket.com/albums/y39/kiwidubstar/Andy/968AE870-C5BD-4970-A3AA-D3A6595985ED_zps0xm4shw7.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/2_zps252535c1.jpeg)

The way the odometer works is that the little white gear on the end (covered in grey snot in this photo) turns the shaft which turns the big metal tumbler.  This in turn drives the odometer through a series of small gears and black numbered tumblers, as well as driving the trip meter via the tiny white gear.
The common issue is that the white gear on the end (the one with the grey snot) cracks and spins freely on the shaft.  I also found that the big metal tumbler was spinning free on the shaft, thus nothing was happening when the speedo drive turned.
To fix the small white gear you need to start by levering the gear off the shaft.  I used a small screwdriver and it came off quite easily.  I used 2 tiny star washers that I pressed  over the sides of the white gear and then covered them in JB Weld and let it dry. 
To fix the metal tumbler I slide the shaft out just enough so the tumbler dropped out.  Don’t remove it completely otherwise the black numbered tumblers will fall out!!  I added a smidge of JB Weld to the centre of the metal tumbler and then slide the shaft back through.  Make sure no JB Weld is on any of the other components, otherwise the whole thing won’t work.
Once the white gear is dry and the metal tumbler is dry (i.e. it won’t spin freely on the shaft) you can start reassembly.  I used the sliding jaw pliers to press the white gear back on the shaft with a little JB Weld to keep it locked on.
Everything else is just the reverse of dismantling.  I would take the time to install some T5 LED bulbs in the cluster so you never have to pull it apart again to change the incandescents.
Further pics for detail

(http://i2.photobucket.com/albums/y39/kiwidubstar/Andy/E080107C-1F32-4E82-9659-BAD2231CC67B_zpsm3gdveh3.jpg)

(http://i2.photobucket.com/albums/y39/kiwidubstar/Andy/01F144A2-3156-4FB3-86AB-1555BD7D919D_zpsl6hwhmta.jpg)

Sorry for the wordy post, hopefully someone finds it useful.

Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on September 25, 2014, 12:15:51 pm
After a year and a half of driving on a 4 speed box, I decided to upgrade to a 5 speed.  The box I have is an AMC with ratios 3.45, 1.94, 1.28, 0.97, 0.80, 3.67 (1,2,3,4,5,Final).  I believe it came off a Mk3, but may also be found on SEATs.  The big difference about this box is that it has a 24mm input shaft, instead of the ‘standard’ 22mm input shaft.
There’s a few things that are needed for a 5 speed conversion:
1)   5speed gearbox mount.  This is the mount that bolts to the left hand chassis rail.  I received a genuine one with the box.

(http://i2.photobucket.com/albums/y39/kiwidubstar/0ABFD5E8-F22F-4EF1-9472-7FE0D1846EA0_zpsuc3si34a.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/0ABFD5E8-F22F-4EF1-9472-7FE0D1846EA0_zpsuc3si34a.jpg.html)

2)   5 speed linkage.  You can either find the full 5 speed linkage from a mk1 (cabby would be the most abundant in Aus) or you can buy an adjustable set-up and 4 speed extension from MissingLinkz.  You can see the setup all bolted in to my car here:

(http://i2.photobucket.com/albums/y39/kiwidubstar/2B279E1D-45E0-4C58-B633-C4CAE3A9BE10_zps5srdwoqx.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/2B279E1D-45E0-4C58-B633-C4CAE3A9BE10_zps5srdwoqx.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/E755EF8B-86CB-4DB1-B146-85E5C7A4AE80_zpsbiqcn8na.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/E755EF8B-86CB-4DB1-B146-85E5C7A4AE80_zpsbiqcn8na.jpg.html)

3)   100mm drive flanges.  I want to retain the 90mm driveshafts and uprights that I have, so I switched the 100mm flanges in the AMC box for brand new 90mm flanges from GAP.  Note: your old 4 speed flanges will not fit.

(http://i2.photobucket.com/albums/y39/kiwidubstar/9A281FFE-A6C8-458B-8414-904507A23DF5_zpsdaakryjg.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/9A281FFE-A6C8-458B-8414-904507A23DF5_zpsdaakryjg.jpg.html)

4)   Clutch.  I am using the full 24mm clutch setup (flywheel, pressure plate, disc) that came with the box.  There are lots of options to mix and match.

5)   Speedo drive.  You will need to match the speedo drive to the final drive ratio of the gearbox.  Mine is a 3.67 final drive which means a ‘red’ speedo gear is needed.

One thing that wasn’t an issue was the reverse switch.  Some boxes have a bigger threaded switch, however, the AMC has the same thread as the old 4 speed, so I could just use the 4 speed switch.

(http://i2.photobucket.com/albums/y39/kiwidubstar/59C00519-0CA2-4045-B1BB-64B9FB1679A2_zpsdv1y4c4d.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/59C00519-0CA2-4045-B1BB-64B9FB1679A2_zpsdv1y4c4d.jpg.html)

I’m using all new gearbox mounts and also the OEM style dampening rings that Mk1autohaus sell.  I’ve spent a bit of time scrubbing my nuts (and bolts and hardware) with kero and a toothbrush so that everything is nice and clean.

At the moment it is now ready for the box to be lifted into place, just need some quiet time when I don’t have my 18-month old ‘helper’ around.
Title: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on December 01, 2014, 12:39:51 pm
Been a while since my last update.

At the beginning of the month I completed an 8 week panel restoration course at the local polytech.  My goal was to pick up a couple of tips for repairing panels and maybe actually repair a couple of parts on my car.  It turned out that another vw watercooler had the same idea.

Anyway, after a few weeks of the basics, like beating out a hubcap, oxy and mig welding, we got to start bringing our own panels in.......

First up was my bonnet which had two little holes by the washer jet.  After making the hole bigger myself, the instructor took over and welded them up.  Ground down and painted, it looks spot on. No photos as it was done in a single session

Next was a part I had been dreading.  Just on the boot lip there were 2 sections that were like Swiss cheese.  I was allowed to bring my car into the class.  We cut out the sections, folded up new metal and then it was welded in.  I've just finished grinding it and painting it.  Pretty pleased with how it came out

Old metal:

(http://i2.photobucket.com/albums/y39/kiwidubstar/54FB29F1-2EEC-4F7D-8749-31264D50F15D_zpshuy04f8k.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/54FB29F1-2EEC-4F7D-8749-31264D50F15D_zpshuy04f8k.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/78B1C473-BAFD-4737-A37A-811149E65528_zpszbidolo3.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/78B1C473-BAFD-4737-A37A-811149E65528_zpszbidolo3.jpg.html)

And finished:

(http://i2.photobucket.com/albums/y39/kiwidubstar/CF8DF471-F196-463C-8B60-BD0AD8327631_zpshqpj1irx.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/CF8DF471-F196-463C-8B60-BD0AD8327631_zpshqpj1irx.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/EC7838AE-6E19-42D4-B668-FFEFD20062B2_zpsobpdvsmo.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/EC7838AE-6E19-42D4-B668-FFEFD20062B2_zpsobpdvsmo.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/9958684D-792A-4357-814B-7C744514BCBB_zpsy5qucgta.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/9958684D-792A-4357-814B-7C744514BCBB_zpsy5qucgta.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/223A811D-BE54-4721-88A7-DDABF1A655D4_zps3enmphir.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/223A811D-BE54-4721-88A7-DDABF1A655D4_zps3enmphir.jpg.html)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: sifty on December 03, 2014, 03:20:03 pm
Nice work.  :)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on September 19, 2015, 01:08:44 pm
Wow, it's been a while......just finished a house renovation, so can finally get back to the car. 

There's two jobs I've been saving up parts for.  The first is an interior update.

I bought a TMI seat upholstery kit earlier this year.  I've started fitting the covers over the past week.

I finished the rear bench and the backs of the front seats.  Unfortunately, the lower front seat is wrong, so I've had to order the correct one which will take 2 weeks to arrive.

Photos:

(http://i2.photobucket.com/albums/y39/kiwidubstar/C7D378FF-7799-44CA-99DD-405780121BC6_zpszcr6vxp7.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/C7D378FF-7799-44CA-99DD-405780121BC6_zpszcr6vxp7.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/92E2B80A-C906-47AF-9172-02ADA1D300A2_zpsygxcch2l.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/92E2B80A-C906-47AF-9172-02ADA1D300A2_zpsygxcch2l.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/511DA8B8-122B-4E70-A0D1-28769F2E21B7_zpszyvvj5s5.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/511DA8B8-122B-4E70-A0D1-28769F2E21B7_zpszyvvj5s5.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/C206E52D-7C7A-4A28-9658-89531A69D1E2_zpsndrwogov.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/C206E52D-7C7A-4A28-9658-89531A69D1E2_zpsndrwogov.jpg.html)

Some progress shots:

(http://i2.photobucket.com/albums/y39/kiwidubstar/F7948D66-6C5B-478F-87D9-5E0BF4D3630E_zpsezswqzpk.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/F7948D66-6C5B-478F-87D9-5E0BF4D3630E_zpsezswqzpk.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/FE40ED1D-AE48-4136-AF98-A1387448F320_zpsjmolot6i.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/FE40ED1D-AE48-4136-AF98-A1387448F320_zpsjmolot6i.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/ECC347CD-31CC-49FB-844A-5076916D270E_zps0mar2qrn.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/ECC347CD-31CC-49FB-844A-5076916D270E_zps0mar2qrn.jpg.html)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on September 19, 2015, 01:11:47 pm
Also updated the boot panels with abs sheet.  If you want a set I have some of the sheet left.

(http://i2.photobucket.com/albums/y39/kiwidubstar/E1754450-E75C-42BB-9628-5729235D2F6C_zpsbp98ejzo.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/E1754450-E75C-42BB-9628-5729235D2F6C_zpsbp98ejzo.jpg.html)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on September 19, 2015, 01:13:34 pm
Here's the back of the front seat:

(http://i2.photobucket.com/albums/y39/kiwidubstar/7644E0F7-CFE0-4A3B-A1B3-090965228106_zpsnwoirlzu.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/7644E0F7-CFE0-4A3B-A1B3-090965228106_zpsnwoirlzu.jpg.html)


(http://i2.photobucket.com/albums/y39/kiwidubstar/DD54DF4A-7E0E-4F77-B79E-5D7778A67B24_zps474rcwrf.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/DD54DF4A-7E0E-4F77-B79E-5D7778A67B24_zps474rcwrf.jpg.html)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dave on September 19, 2015, 05:58:11 pm
Seats look tidy as. Was it hard to do?
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on September 28, 2015, 10:20:30 pm
No, not too hard, just take your time

Finished off the front seats.  Pretty happy with how they turned out.  I need a couple of little pieces to finish them off, if anyone can help.

(http://i2.photobucket.com/albums/y39/kiwidubstar/DE4C54A3-0F83-43DF-98B3-98C1A737CC7D_zpsvd06sruz.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/DE4C54A3-0F83-43DF-98B3-98C1A737CC7D_zpsvd06sruz.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/FA27A6FF-5A33-4CBF-9D7E-D7371BC9067D_zpsjyygcrno.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/FA27A6FF-5A33-4CBF-9D7E-D7371BC9067D_zpsjyygcrno.jpg.html)

I need the passenger side fold forward handle. Like this:

(http://i2.photobucket.com/albums/y39/kiwidubstar/F4273988-0A52-43A4-A215-D127235AB68A_zpsbd71jujn.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/F4273988-0A52-43A4-A215-D127235AB68A_zpsbd71jujn.jpg.html)

And I also need one of the special little circlips,  like this

(http://i2.photobucket.com/albums/y39/kiwidubstar/E5935417-561E-4730-B2A7-9B84092EB7CB_zpssb4kyqdx.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/E5935417-561E-4730-B2A7-9B84092EB7CB_zpssb4kyqdx.jpg.html)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: rambo_005 on September 28, 2015, 11:27:28 pm
Looking good Bryce
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: M M on September 29, 2015, 07:16:40 am
It does look good. Nice work.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: GolfJon on September 29, 2015, 08:23:10 am
No, not too hard, just take your time

Finished off the front seats.  Pretty happy with how they turned out.  I need a couple of little pieces to finish them off, if anyone can help.

(http://i2.photobucket.com/albums/y39/kiwidubstar/DE4C54A3-0F83-43DF-98B3-98C1A737CC7D_zpsvd06sruz.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/DE4C54A3-0F83-43DF-98B3-98C1A737CC7D_zpsvd06sruz.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/FA27A6FF-5A33-4CBF-9D7E-D7371BC9067D_zpsjyygcrno.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/FA27A6FF-5A33-4CBF-9D7E-D7371BC9067D_zpsjyygcrno.jpg.html)

I need the passenger side fold forward handle. Like this:

(http://i2.photobucket.com/albums/y39/kiwidubstar/F4273988-0A52-43A4-A215-D127235AB68A_zpsbd71jujn.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/F4273988-0A52-43A4-A215-D127235AB68A_zpsbd71jujn.jpg.html)

And I also need one of the special little circlips,  like this

(http://i2.photobucket.com/albums/y39/kiwidubstar/E5935417-561E-4730-B2A7-9B84092EB7CB_zpssb4kyqdx.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/E5935417-561E-4730-B2A7-9B84092EB7CB_zpssb4kyqdx.jpg.html)

Pretty sure I have the circlip thingys somewhere, from a Mk2 seat but am sure they are the same. I'll have a look for it tonight.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: black16v on September 29, 2015, 09:13:15 pm
I've got two old MK2 front seats here (ex Golfjon) with those clips, you're welcome to them (or the seats) , sorry no handles.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on October 12, 2015, 04:25:26 pm
Final interior shot with new door cards, etc

(http://i2.photobucket.com/albums/y39/kiwidubstar/E86E7802-125A-4AAA-BF63-7652E629CA73_zps52sxtvwt.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/E86E7802-125A-4AAA-BF63-7652E629CA73_zps52sxtvwt.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/9B5BF693-5C54-4351-B35A-31C872A46AE2_zpsmws8b0h2.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/9B5BF693-5C54-4351-B35A-31C872A46AE2_zpsmws8b0h2.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/6EA34260-841E-4723-8956-9CA53BFB02ED_zps8uqigfhh.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/6EA34260-841E-4723-8956-9CA53BFB02ED_zps8uqigfhh.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/F2D23771-0549-4A1C-82B9-8C30D0C3504F_zpsufo77v9i.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/F2D23771-0549-4A1C-82B9-8C30D0C3504F_zpsufo77v9i.jpg.html)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on November 12, 2015, 01:45:12 pm
With the arrival of son number 2 (Hamish), progress has been slow.

I have upgraded to a Weber 32/36 which had made the car a lot more lively

(http://i2.photobucket.com/albums/y39/kiwidubstar/DE7738FD-1CE7-4A35-9A4D-F47F2421DEDD_zpstrz55vtn.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/DE7738FD-1CE7-4A35-9A4D-F47F2421DEDD_zpstrz55vtn.jpg.html)

I also made a bracket to attach the fire extinguisher.  I didn't want to drill holes in the floor so came up with this:

(http://i2.photobucket.com/albums/y39/kiwidubstar/BF624922-78FB-4840-BB29-A06A820CE0C1_zpsaht6dsoq.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/BF624922-78FB-4840-BB29-A06A820CE0C1_zpsaht6dsoq.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/7C962C37-F49F-4F3A-B948-963E644ACFDC_zpsdp4myzhq.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/7C962C37-F49F-4F3A-B948-963E644ACFDC_zpsdp4myzhq.jpg.html)

Finally........I picked up a 2L 8v.  It is an AGG with a nicely worked Mk2 40mm valve head.  I will be working this one up slowly, along with a close ratio ACD gear box I sourced.  Final goal is to fit the bargain DHLA45s I scored.

(http://i2.photobucket.com/albums/y39/kiwidubstar/77EC4E50-4AC3-47BF-B8FF-661261FAE98B_zps4lgadiuv.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/77EC4E50-4AC3-47BF-B8FF-661261FAE98B_zps4lgadiuv.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/873AC6D2-2095-4AB4-8DF2-47A4637E58AF_zpskytovf6a.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/873AC6D2-2095-4AB4-8DF2-47A4637E58AF_zpskytovf6a.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/177AE521-A533-4118-847A-89D35210EA61_zps607o85vu.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/177AE521-A533-4118-847A-89D35210EA61_zps607o85vu.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/BE04F1F0-1E76-4629-99A7-EF0BA82E530D_zpsm9rt4jpx.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/BE04F1F0-1E76-4629-99A7-EF0BA82E530D_zpsm9rt4jpx.jpg.html)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: M M on November 12, 2015, 03:03:00 pm
That interior looks good, nice work.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: RS ZWEI on November 12, 2015, 07:33:37 pm
What are you using for a distributor?
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: spooln on November 12, 2015, 08:34:11 pm
Congrats on no2!
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on November 13, 2015, 10:09:29 am
There's a company up the road, 'Scorcher,' who modify vac advance dizzies into pure mechanical advance dizzies.  They re-curve them to match your engine.

I was thinking about programmable ignition, but need to consider that a bit more before investing
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: 00quattro00 on November 13, 2015, 12:55:32 pm
You are probably  going to find those 45's are going to be far too big
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on November 13, 2015, 05:43:54 pm
With the cam and the headwork I'm hoping to push peak power out to 6000rpm (std AGG is 5500), then using the calculations for venturi size and subsequently barrel size (best described in the link at bottom), 45 should be almost perfect.  I will need to re-jet them as they were on a fairly modded 2000cc fiat 124.

http://www.s262612653.websitehome.co.uk/DVAndrews/dellorto.htm (http://www.s262612653.websitehome.co.uk/DVAndrews/dellorto.htm)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on February 17, 2016, 11:32:50 pm
So it's been a while.  I have decided to give the 020 rebuild a go.  I have basically printed off the entire BrokeVW rebuild instructions and am using them as my guide.

I started by making up some of the tools required using various steel off cuts.  The first pic shows the input shaft support bar, the second shows the shift fork release tool. 

(http://i2.photobucket.com/albums/y39/kiwidubstar/5BCFF618-46B8-479A-B187-90056B944BEC_zpssuuz1mzm.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/5BCFF618-46B8-479A-B187-90056B944BEC_zpssuuz1mzm.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/79D6E5BC-2B06-4EDB-9EE8-9719144B86A9_zpsv01gsqo4.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/79D6E5BC-2B06-4EDB-9EE8-9719144B86A9_zpsv01gsqo4.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/116ABA49-D0DE-4E7D-9B56-280E969ED455_zpshs5puavu.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/116ABA49-D0DE-4E7D-9B56-280E969ED455_zpshs5puavu.jpg.html)

I also got a nice shiny new press for my Birthday

I have removed the 5th cover and shift forks, but my old pullers are too 'fat' to fit under the gear set.  I've ordered a new puller set, so will crack in when that arrives
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on March 04, 2016, 04:55:30 pm
So, I got a few hours in today.

I used my homebuilt case splitter to split the case

(http://i2.photobucket.com/albums/y39/kiwidubstar/98AEFA9D-879A-4348-974D-24F955DA1E6B_zpsuaje2snx.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/98AEFA9D-879A-4348-974D-24F955DA1E6B_zpsuaje2snx.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/B6002767-B360-4327-B8FA-ADDC629F52C4_zps7ecpqccd.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/B6002767-B360-4327-B8FA-ADDC629F52C4_zps7ecpqccd.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/88D5B625-4CF8-4A06-9D4C-4F00914F845B_zpspdpt8qmu.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/88D5B625-4CF8-4A06-9D4C-4F00914F845B_zpspdpt8qmu.jpg.html)

The internals look pretty good.  A few little marks, but no missing teeth (in my initial inspection).  The downside is that the diff is still riveted, not bolted.

Now I need to decide what parts I will replace.  Bearings, gaskets, etc, etc….any expert thoughts or should I just replace the low?

(http://i2.photobucket.com/albums/y39/kiwidubstar/935AC2C7-20E8-463C-8183-2F813960DB9F_zps7ckiuueq.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/935AC2C7-20E8-463C-8183-2F813960DB9F_zps7ckiuueq.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/C8A90716-EA26-46AC-A556-5C9F46B35437_zpsl9vozk19.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/C8A90716-EA26-46AC-A556-5C9F46B35437_zpsl9vozk19.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/16EE8B72-F3AF-43CD-83D2-1423F2E48A79_zps5sas85ri.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/16EE8B72-F3AF-43CD-83D2-1423F2E48A79_zps5sas85ri.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/70E29951-4076-4831-BACF-6708B3FAD660_zps9skplblz.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/70E29951-4076-4831-BACF-6708B3FAD660_zps9skplblz.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/24A7FDB2-4618-46DC-8DE5-DB06CEB070AD_zpsaybdficw.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/24A7FDB2-4618-46DC-8DE5-DB06CEB070AD_zpsaybdficw.jpg.html)

Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on June 06, 2016, 11:08:22 pm
Quick update, if you can call it that.

The gearbox is all together now and I am now finishing off the engine.  A few bits to go.  The DHLA's are all overhauled and ready to go on the manifold, which just needs some porting

(http://i2.photobucket.com/albums/y39/kiwidubstar/D839B4F8-32C3-4B46-A325-B162918DE78B_zps0hhhokhr.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/D839B4F8-32C3-4B46-A325-B162918DE78B_zps0hhhokhr.jpg.html)

(http://i2.photobucket.com/albums/y39/kiwidubstar/820A1CD6-6188-4EC8-847B-1B3055489AC0_zpsm1tb9uh0.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/820A1CD6-6188-4EC8-847B-1B3055489AC0_zpsm1tb9uh0.jpg.html)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on January 16, 2017, 01:09:09 pm
Been another long break between posts, but there has been significant progress.
I have been ripping everything I can out of the engine bay in preparation for lifting out the engine and gearbox.  I will be posting a bigger summary and possibly a timelapse soon, but in the meantime I need some wiring help as I am trying to remove/update some of the 40 years old wiring in the engine bay.

Here is where the engine bay is at.  Wires labelled and almost everything out of the bay.

(http://i2.photobucket.com/albums/y39/kiwidubstar/7010C485-B124-47CF-9A4E-D2AC579687B6_zps29rqqtvy.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/7010C485-B124-47CF-9A4E-D2AC579687B6_zps29rqqtvy.jpg.html)

My question relates to the alternator wiring.  I will be upgrading to a 90amp alternator with the bolt down posts (the old one was the rubber plug type).
I just want to know about the blue/white wire that originally went to the B+ terminal on the alternator (the other blue wire is the excitor wire).
It plugs into harness spot A4.  On the ‘1976 Golf’ wiring diagram in the workshop manual it says that it should terminate in the C plug on the harness….it doesn’t……..anyway question is.  What does this wire do?  I have a feeling that it is part of the diagnostic circuit and doesn’t do anything else.  Can anyone confirm?  I am removing the diagnostics, so if it is, I won’t run a new wire for it.

(http://i2.photobucket.com/albums/y39/kiwidubstar/CC6223C7-A68C-41B6-9271-ADAC5727738B_zpsnbfntcx5.jpg) (http://s2.photobucket.com/user/kiwidubstar/media/CC6223C7-A68C-41B6-9271-ADAC5727738B_zpsnbfntcx5.jpg.html)

I will be redoing the power wires as they are fatigued and I really don’t like how ‘light’ they are for the main charging circuit.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on February 20, 2018, 11:12:33 am
It has been a looooooong time since my update, however, a lot has happened in that time.

I originally took Andy off the road on 28-Dec-2016 and, as life gets busy, only go him back on the road on 8-Nov-2017, just under a year.

Here is the how the engine bay looks now

(https://i.imgur.com/0OChfL6.jpg)

The specs are:

2L AGG bottom end
Mk2 ported/polished head
270deg cam
45 DHLA carbs
Purely mechanical dizzy
Raceland headers
ACD gearbox

It runs beautifully and is an absolute hoot to drive.  i have 2 problems that still need fixing.  Firstly, there is a bit of smoke on start up, so I think I will need to change the valve stem seals (maybe they sat too long?) and secondly, the headers are touching the steering rack.  This is really annoying as I have tried 2 different manifolds and this is the one that touched the least.  I am going to give up and take it to an exhaust shop to sort it out, but very annoying!!

Also whilst the car was off the road I painted the engine bay.  I have reverted to the original colour code, so it doesn't quite match at the moment, but eventually there will be a fresh respray on the outside which will bring it all together.  I also raised the suspension by 15mm all around, just for some comfort and compliance.  Finally I got some new tyres and a GTI duckbill to add the final touch.

Pics after first clean (I am painting the badges at the moment)

(https://i.imgur.com/r1ecUSs.jpg)

(https://i.imgur.com/vBnBEg1.jpg)

Other engine pics:

(https://i.imgur.com/FAsWUEX.jpg)

(https://i.imgur.com/TXTSVu2.jpg)

(https://i.imgur.com/eScTLO8.jpg)

(https://i.imgur.com/mdbMeQ5.jpg)

PS, if anyone does have a 6-bolt Mk1 GTI exhaust manifold they will sell, this could be another option for my exhaust woes.


Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: sifty on February 20, 2018, 11:43:56 am
Looks freakin awesome! Tidy.  8)

What cambelt and idler did you use? I'm building a similar engine - 2E with a DX head.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dave on February 20, 2018, 01:13:35 pm
Weird my  raceland headers have good clearance with the steering rack, but the dont fit well with the twin carb manifold.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on February 20, 2018, 07:04:23 pm
Weird my  raceland headers have good clearance with the steering rack, but the dont fit well with the twin carb manifold.

Maybe its because I have the very early, solid mounted rack.  The extra height of the AGG block just pushes the headers too far back.  I think a GTI manifold+spacer would sort it, but it is really hard to find a GTI manifold!
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dave on February 20, 2018, 07:07:31 pm
Yea the early rack could make the difference. Did you need die grind the intake and exhaust manifold for them to fit nicely together?
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on February 20, 2018, 10:36:10 pm
Yea the early rack could make the difference. Did you need die grind the intake and exhaust manifold for them to fit nicely together?

Yes I did.  Had to grind a bit off the intake manifold.
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: deedub on February 21, 2018, 02:33:11 am
Every time you add pictures of your Mk1, I go for a little trawl of the local classifieds to see if there are any clean 3 doors up for sale!
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on February 22, 2018, 12:27:17 pm
Every time you add pictures of your Mk1, I go for a little trawl of the local classifieds to see if there are any clean 3 doors up for sale!

do it.

Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on March 08, 2018, 12:28:08 pm
Went to a local car show on the weekend (very local, as it is 300m down the road!).

(https://i.imgur.com/bCaJX65.jpg)

When I was painting the engine bay I also restored and matched a vintage chilly bin which I got from my wife's Grandma.

(https://i.imgur.com/U4bep1c.jpg)

(https://i.imgur.com/sl1MaCy.jpg)
Title: Re: DUBSTAR'S PROJECT - Weiß Hase - 1976 Golf LS
Post by: dubstar on April 17, 2018, 12:33:13 pm
First time on a track for Andy.  I entered the Maserati Trident Day at Sandown which was on Sunday.  It was also Round 2 of the Victorian Supersprint Championship.

The day was SO WET!  Still managed to get 4 good sessions on track.  There was a total of 6 laps where it wasn't raining/drying and my best lap was 1.47 which placed me provisionally 3rd in class.

I missed the last session as the joint between the headers and the rest of the exhaust came undone and it sounded like a tractor.  Its annoying as that is the one part of the car where I paid someone to do the job and it is the part that failed.....I also didn't have it on my pre-race checklist as something to check, but will definitely add it now.

(https://i.imgur.com/qYS3GT8.jpg)

(https://i.imgur.com/zEuQV9l.jpg)

and some car porn.....can't believe this was in the same class

(https://i.imgur.com/uBEosmY.jpg)