My Golf Project

L1J · 7 Mar 2007 at 21:03

Will look into the fiat airbox, thanks

Right, things didnt exactly go to plan with the welding today

I cut a plate out for the area that needed reapair

Marked all the areas that needed to be welded

We thought we'd try TIG welding it to try and minimise any sparks etc that would fly about and land on the bodywork and it looks tidier. It didnt work, lots of seam sealer still in the seams that cant be removed but caused havoc with the welding arc. Welder is going to come back on the weekend and blast it with a MIG.

Managed to secure the battery tray and weld some clean seams, but then we ran out of gas!

Nothing seems to be going to plan at the moment, I even managed to bang my head on one of the Konis that was hanging up in the garge!

Can't refit anything until it's painted!
Can't paint it until it's welded!

Can't do anything to the engine until a cambelt tensioner thats on back order arrives in 7-10 days from Germany....

Plus the deadline for finishing might be 6 weeks from now dependant on how something goes next Monday which I cant mention at the moment.

Argh!

Going to create a to do list and take it from there I think!

-Mike- · 7 Mar 2007 at 22:33

Don't lose heart in it

There are plenty of us on here very keen to see the finished project

paradigm · 7 Mar 2007 at 22:59

Would it have not been easier to have just rented a welder? Or is it something you aren't comfortable taking on yourself?

Amazing progress non-the-less though

L1J · 7 Mar 2007 at 23:11

-Mike- said:
Don't lose heart in it There are plenty of us on here very keen to see the finished project

Havent quite got to that stage yet

Thanks for the reply, Im quite keen to see it finished also

The to do list:

Get engine bay welded
Get engine bay painted
Trial fit engine
Measure up all pipework required for engine
Rebuild front and rear suspension
Fit new wheel bearings to front hubs
Swap over passat steering arms to golf steering rack
Finish off engine bay wiring loom
Refit dash
Refit interior trim
Refit exterior trim
Build up doors (they are bare at the moment)
Fit new cambelt and water pump

Stuff to source/buy

4x Road tyres
ECU and engine wiring loom
Silicone hoses for air intake/intercooler
280mm brake disks, pads and carriers
Front cross memeber bushes
Rocker cover gasket
Peloquin diff
KO3S Turbo
Fuel pump
Drive belt from a non AC golf/leon

Should be able to do quite a bit of that list in the next week.

L1J · 7 Mar 2007 at 23:17

paradigm said:
Would it have not been easier to have just rented a welder? Or is it something you aren't comfortable taking on yourself?

Amazing progress non-the-less though

It will look a lot better if I get someone to do the welding, mine is more function over form

He has about an hour of welding work to do then the wet and dry comes out to prep for paint.

Lopéz · 7 Mar 2007 at 23:28

L1J said:
It will look a lot better if I get someone to do the welding, mine is more function over form

He has about an hour of welding work to do then the wet and dry comes out to prep for paint.

Llyr welds like me. Messy and over-engineered

L1J · 7 Mar 2007 at 23:30

Lopéz said:
Llyr welds like me. Messy and over-engineered

My stainless steel TIG skills are fine thank you

The rest is exactly as described

L1J · 9 Mar 2007 at 21:47

Slacking here, no update for two days....

Did a few bits tonight after work:

As mentioned somewhere in the thread I needed to make a 'tab' for the throttle cable to attach to the inlet manifold. Marked on an offcut of alloy

Cut out and ready to be welded

Started to clean the engine block so I can paint it in the next few days

Old front suspension removed, the top nuts were FT, lots of heat and leverage required!

Plans for tomorrow:

Take springs to be powder coated
Get tensioner and rocker cover gasket from VW
Fit bearings into passat hubs
Start painting block

Bri · 9 Mar 2007 at 22:18

What a project, just read it from start to finish. My dad had a 1990 8v GTi in Tornado red, I loved that car

Lopéz · 9 Mar 2007 at 22:35

L1J said:
top nuts were FT

Hehehehe, haven't heard that in ages

"How tight do these nuts need doing up?"

"They're FT specials mate

"

L1J · 10 Mar 2007 at 15:57

L1J said:
Plans for tomorrow:

Take springs to be powder coated
Get tensioner and rocker cover gasket from VW
Fit bearings into passat hubs
Start painting block

Springs done and bits here from VW

Fitting the bearings was a pain as the press didnt work some reason, we had to use a vice and be very careful as we didnt want to damage the powder coating!

Got there in the end

Going to start painting the block and wheel hubs later on

L1J · 10 Mar 2007 at 20:54

Tonights update

Managed to give the block 2 coats of paint

Hopefully it will be welded sometime soon so I can carry on with it!

Away for another 2 days tomorrow so next update will be Tuesday night.

Just realised I've missed a bit by looking at the pic, back to the garage I go!

Faithless · 10 Mar 2007 at 21:38

WOW, just read from start to finish. Awesome work and a neat little project.

Glad you're keeping the progress updated.

4ndy89 · 10 Mar 2007 at 22:23

This is amazing stuff, just read from start to finish!

This is my first ever subscribed thread!

L1J · 13 Mar 2007 at 16:29

Quick update on the parts to source list!

L1J said:
Stuff to source/buy

4x Road tyres - Ordered F1s from mytyres
ECU and engine wiring loom - Loom being sent away today
Silicone hoses for air intake/intercooler - Need to wait until engine is in place
280mm brake disks, pads and carriers - Disks and pads ordered, still looking for carriers
Front cross memeber bushes - Ordered from VW
Rocker cover gasket - Picking up from VW tomorrow
Peloquin diff - Emailed, awating reply
KO3S Turbo - Ordered a new one today, should be here tomorrow!
Fuel pump - Sourced one from ClubGTi, should arrive next week
Drive belt from a non AC golf/leon - Ordered

Welder should be here tomorrow to carry on with the welding

I've also ordered the following:

Parts washer, lots of bits that need to be cleaned before reassembly
Some deox-c and dynax s50 from bilt hamber

Update to follow tonight on actual car progress.

tbz_ck · 13 Mar 2007 at 16:32

A new K03s turbo!!!

How much was that then????

L1J · 13 Mar 2007 at 16:37

It was.......

£440 for a brand new unit, I thought that was quite reasonable, closest quote to that was £480 for a recon unit, but I didnt have an exchange unit so a surcharge of £150 would apply!

tbz_ck · 13 Mar 2007 at 16:48

Thats better than I would have predicted. I've heard four figure sums for some replacement turbos !

L1J · 13 Mar 2007 at 16:50

tbz_ck said:
Thats better than I would have predicted. I've heard four figure sums for some replacement turbos !

I did price one up from VW, £1032 for an outright purchase :eek:

Once it arrives and I know it's the right one I'll post some details of the company!

Lopéz · 13 Mar 2007 at 16:52

L1J said:
It was.......

£440 for a brand new unit, I thought that was quite reasonable, closest quote to that was £480 for a recon unit, but I didnt have an exchange unit so a surcharge of £150 would apply!

I thought you said you were skint