Mk2 1.6 the longer term project

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Ebies
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Re: Mk2 1.6 the longer term project

Postby Ebies » Fri Feb 02, 2018 6:42 pm

So I'm really leaning towards doing some like this;Image
This is a picture of a Rocco with a completely flat rear, I think it looks great and very practical however I want to go a step further.
ImageImage
A tail gate, It would make the rear so much more accessible and look pretty awesome as well.

And in other important news, I've just picked up these.
Before,Image
And after,
Image
So much of an improvement

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BlackGTX
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Re: Mk2 1.6 the longer term project

Postby BlackGTX » Fri Feb 02, 2018 8:08 pm

Hows that tailgate gonna work?

The lights take up most of the rear so are they on folding down too or just fhe number plate section



Ebies
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Re: RE: Re: Mk2 1.6 the longer term project

Postby Ebies » Sat Feb 03, 2018 9:39 pm

BlackGTX wrote:Hows that tailgate gonna work?

The lights take up most of the rear so are they on folding down too or just fhe number plate section
The natural line of the boot goes down through the lines right at the end of the indicators, so I would cut through there, so the whole back end drops down.
Here's roughly where it would be, the blue part being the tail gateImageImage

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Jack92
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Re: Mk2 1.6 the longer term project

Postby Jack92 » Sat Feb 03, 2018 11:00 pm

Ebies wrote:
BlackGTX wrote:Hows that tailgate gonna work?

The lights take up most of the rear so are they on folding down too or just fhe number plate section
The natural line of the boot goes down through the lines right at the end of the indicators, so I would cut through there, so the whole back end drops down.
Here's roughly where it would be, the blue part being the tail gateImageImage

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Seems like a challenge be good to see how it comes out though!


Jack
South East

www.motorsportdiscounts.co.uk
Seat Leon 1.8T 20V - Track Car
VW Scirocco Scala 1.8 Inj - Toy
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Jack
South East

http://www.motorsportdiscounts.co.uk
Seat Leon 1.8T 20V - Track Car
VW Scirocco Scala 1.8 Inj - Toy
Ford Transit 2.0 - Work Horse

BlackGTX
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Re: Mk2 1.6 the longer term project

Postby BlackGTX » Sun Feb 04, 2018 9:24 am

Interesting project, hope it works out.

Look at the bulb holders as they have metal all the way along to channel current and something to seperate the indicators would need to be made



Ebies
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Re: Mk2 1.6 the longer term project

Postby Ebies » Wed Feb 07, 2018 2:26 pm

I hate rust. I hate having to repair rust even more so, however MOT is due at the end of the month and it was never going to pass with this hole in the drivers rear wheel well.

Image

Did I say hole? I meant holes.Image
This repair just got significantly harder

(Here's another pic for the sake of it)
Image

Now that top part of the rust was a right pain to cut out due to lack of access as the rear speak shelf is just about it, I could get a little better acres going through the speaker hole. But not much more.

After melting my Lidl special Dremel and resorting to old school method of using tin snips I had this hole.
Image
Now I just needed to fill the hole
Image
After trimming the metal down by eye and then by trial and cut, I had thisImage
Cleaned up the hole to get a decent weld;
Image

Image

Here it is in place. Uglyist bit of welding I've probably ever done, for ages I couldn't get it to weld nicely, I adjusted wire speed, gas flow, power level etc, just was not playing bull. Was driving me insane as normally it's pretty okay (it's a cheap welder,it's very going to be jaw droppingly pretty weld)
Turns out the issue was the lead for the gun was at to much of an angle and the motor struggled to push the wire along it. Slightly readjusted my position and boom, back to normal consistent type welds, just a shame I was pretty much done.
At least I no for next time.

It's not quite a finished repair, I've put some filler over the welds yesterday to help it be less of an eye sore, I just need to sand this back and spray it so it looks semi decent

Image

In conclusion, not overly happy with finish quality of the repair, but it is repaired strongly and importantly the rust as gone

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Ebies
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Re: Mk2 1.6 the longer term project

Postby Ebies » Wed Feb 28, 2018 9:42 pm

So prior to the MOT, I took my car into work for a pre MOT check. To spot any obvious faults. All was looking good till I got to the rear arches and saw this;
Image
Image
Well shit. Have i mentioned I hate rust?
(Both sides were identical so I only took pictures of one repair)

There was no way I was going to let this defeat the car so I set to repairing it.

As with any repair, you start out with some flat metal.
Image
Then comes the fun part, figuring out to turn said bits of metal in to a curved complicated 3d shape.
Image
I really do enjoy this bit but lack the skill/experience to do beautiful job of it. So out comes the hot metal gun;

ImageImageImage
Now got the basic shape, just need to refine it. Which involves lots of loving taps with a hammer. After a while I got my curve and step
Image
Image
ImageImageImage
Then just trim of the rest to get a nice fit.
Image
Image

Cut away the Rot, clean up the metal and start welding the patch into place.

ImageImageImage
Found some old under sealant in my dad's garage and applied it liberally. Quite happy with the finish tbh.
Image

Had some slight issues gluing the skirt back down afterwards, but thankfully another one of my projects came to the rescue.
Image

So after doing all this work, I confidently put my car in for its mot.

Here's the result;
Image

There rust was two very small holes (one each side) that I had missed due to the angle I was working at. I've fixed that.

The seats rocked forwards a bit to much, a combination of pivoting on the Audi frames and scirocco frame. Some welding has sorting that.

The lights are an easy fix and will do that on the retest.

The Brakes I didn't know about and am actually glad they got picked up when they did. One of the wheel cylinders is leaking so have purchased completely new rear brake assemblies (cylinders and shoes) which should fix that problem.

Whilst inspecting the brakes, I found out that both the rear hub nuts were only finger tight. That's was not something I expected to find.

Some what pissed about the buckled wheel. But have managed to source one on eBay.

Hoping to have her back on the road next week. Fingers crossed.


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mark1gls
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Re: Mk2 1.6 the longer term project

Postby mark1gls » Wed Feb 28, 2018 11:09 pm

I get rear wheel play sometimes on an MOT as the nut is only just nipped up as that’s how it’s meant to be, the split pin holds the nut on.
I do now do up the nut so I can just move the big washer then put the rear wheel on and feel for play and do the nut up just enough to stop the play.
To loose and you wear out the bearing, to tight and you wear out the bearing... it’s a bit of practice to get it right.

That’s a good bit of home made patch panel on the rear arch, such a common problem for rust in that area.


Mk1 78 Scirocco GLS 1.6 FR, weekend toy.
Mk1 88 Golf GTi cabriolet 1.8 DX. Daily drive.
Membership No. 323

BlackGTX
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Re: Mk2 1.6 the longer term project

Postby BlackGTX » Thu Mar 01, 2018 7:17 am

Alot of work gone on there, fabricatoion takes times



Ebies
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Re: Mk2 1.6 the longer term project

Postby Ebies » Sun Mar 18, 2018 6:19 pm

So I fixed (at least thought I fixed) all the faults. only for it to fail again on the retest.
I had changed the wheel cylinder & shoes on the weaker side (drivers) in hope that it would sort the axle balance and increase the over all efficiency. I only did the one side for retest for two reasons.
1- I had working on drums brakes, they are a pig of a job at the best of times
2- I felt like the pipe union was going to snap on the drivers side, took alot of careful undoing to free it off. I didn't want to try my luck on the other side.

But it failed all the same, so I changed the wheel cylinder and shoes on the passengers side. And guess what, the union into the cylinder snapped the pipe clean off.
Making new brake lines is no big deal, but who ever picked the location for joining the hard line to the Flexi line needs a high five, to the face, with a brick.

Another stupid idea by Volkswagen were the Allen key bolts holding the wheel cylinder on to the brake plate. My Allen keys just rounded the heads. But thankfully a colleague has a set of these. Turbo sockets, they bite into any stud,bolt etc rounded or not and unscrews it.
Made quick work of my bolts.


Image
Image

That left the issue of finding replacement bolts. Couldn't find any identical replacements. So a quick stop at euro car parts produced these:
(Small bit of hacksawing was required)
Perfect replacement
Image

All the effort, blood lose and swear words were worth it though as it passed the MOT.

Image
Some very small minors that I'm not worried about

Now the modding can properly begin.
Starting with the flat boot build.


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mark1gls
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Re: Mk2 1.6 the longer term project

Postby mark1gls » Sun Mar 18, 2018 10:40 pm

Good news on MOT, you can at least enjoy driving the car now. :-D
With the rear wheel cylinder bolts I coat mine in copper grease to stop them rusting in place and coat the head of the bolt as well.


Mk1 78 Scirocco GLS 1.6 FR, weekend toy.
Mk1 88 Golf GTi cabriolet 1.8 DX. Daily drive.
Membership No. 323


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