As title really. This is my Jade Green 16v 3dr project. It's going back to a bare shell and I'm hoping to order a rollover jig in the next few weeks. Once it's up on that it'll get pretty much every panel that you can buy welded in, plus a few body cuts from donor cars if I can get some decent ones. But, it'll be worth it, right?
(https://i.ibb.co/GRLYmcf/1-BEC023-E-DD10-4-C5-C-8386-AABA7-BE740-E1.jpg) (https://ibb.co/PgnXkws)
(https://i.ibb.co/xjfybGB/127364-C0-ADD5-4788-8056-BA894-A38683-E.jpg) (https://ibb.co/85dJw2f)
(https://i.ibb.co/1KhjR7Q/D3-E7-DE80-9-B3-A-473-D-A9-AF-D258-CB2-E06-B8.jpg) (https://ibb.co/VDr5MJ9)
(https://i.ibb.co/9GVPFgh/600-D0-C2-B-0789-4109-A1-C4-3-B13-C186-AB50.jpg) (https://ibb.co/x3fZpLY)
The project came with two 2.0 engines. A 9A Corrado engine and a Mk3 ABF engine. I've got a couple of matching gearboxes also.
I've budgeted around 2 years and about £5k for the project. Both of those might be wildly conservative though.
First small patch repair. Klokkerholm part from VW Heritage.
(https://i.ibb.co/8sbv3TC/0-E1241-F3-4206-4-BC0-96-B5-C05-FFD8-DBA0-F.jpg) (https://ibb.co/nmBd2ZG)
(https://i.ibb.co/w0Xf112/D7-F8-F4-DF-F4-D2-41-CE-9-C5-D-B57-C2799-AA55.jpg) (https://ibb.co/X2gqTTG)
(https://i.ibb.co/ynbrNtb/5-AD51-A62-1237-4-BE9-877-A-D45-F73-B6-E626.jpg) (https://ibb.co/wNxfdVx)
(https://i.ibb.co/rwQpWrt/F0-A66-F2-E-9-D7-D-431-D-98-DD-BB8-D030-C59-C1.jpg) (https://ibb.co/5R1j7H9)
(https://i.ibb.co/ZNqFG5z/8-EFEC188-AFF9-424-F-B66-E-29073-AE341-E5.jpg) (https://ibb.co/V3fzJRY)
Threw some (badly matched) Jade Green paint on it because I'm impatient.
(https://i.ibb.co/2NdCYRh/43-AAD800-F8-F1-4242-9916-4-E19428157-FF.jpg) (https://ibb.co/HdqbpR4)
Then seam sealed it because I'm sensible.
(https://i.ibb.co/VMFcfmT/A462-E2-FE-8297-47-E4-ADE8-0-E9703434-AD7.jpg) (https://ibb.co/1RCtF6T)
Forgot to take a picture after I put more (badly matched) Jade Green paint back on top of the seam sealer.
Had to make and let in a little repair for the chassis leg. I've not got a picture of it dressed, so here's what my ugly welding looks like.
(https://i.ibb.co/ZmyGcFp/189-A9-CD7-F4-DA-4749-AE69-576-B60490632.jpg) (https://ibb.co/PQBF1Pv)
I love watching projects like this.
I'm doing a very similar thing to a red 8v, it's definitely worth doing.
5k might be a bit conservative, maybe more like 6 or 7, but I'd say you're not far off the mark.
I'd budget more with the idea of £7k. Obviously the more you can do yourself the better but looks like you have a handle on that.
As for the engine, the Corrado 9A runs on K-jet injection so since your 16v is already that my personal preference would be to keep that set up and use the Corrado engine, you already have the correct fuel pump etc. It'll also look more similar to the original 16v with the fuel metering head ad fuel lines etc in the engine bay. K-jet is generally more tunable, however it's of the age now where unless everything is in good condition it can be problematic, not many people these days know how to set it up and many chose to just swap out. A 9A conversion would make for a nicer completed package if you ask me. But looks like you might be a while off from making any engine decisions.
I'd budget more with the idea of £7k. Obviously the more you can do yourself the better but looks like you have a handle on that.
As for the engine, the Corrado 9A runs on K-jet injection so since your 16v is already that my personal preference would be to keep that set up and use the Corrado engine, you already have the correct fuel pump etc. It'll also look more similar to the original 16v with the fuel metering head ad fuel lines etc in the engine bay. K-jet is generally more tunable, however it's of the age now where unless everything is in good condition it can be problematic, not many people these days know how to set it up and many chose to just swap out. A 9A conversion would make for a nicer completed package if you ask me. But looks like you might be a while off from making any engine decisions.
I'd go for the best of both worlds, get the ABF engine and stick it on the K-Jet.
You get to keep the oe look, but benefit from the better engine.
The ABFs make 150 out the box, by the time you have ditched the cat, stick on a four branch and get the k-jet setup right, you'll probably see nearly 170. A friend of mine had that exact setup on his and it was great.
hmmmm.... I thought conversations with Kerly suggested the 9A was better?
Other than the original tank and hard plastic lines fitted to the car still I don’t have a fuelling setup for either engine.
I haven’t researched enough about it but I was wondering if it would be easier/cheaper to go MK3 tank and pump etc. and this would lend itself more to running the ABF engine. I’ve got a hydraulic pedal box and the engine/gearbox mounts I need. Plus I have an ECU and engine loom for it.
Some random pictures.
The start of the strip down.
(https://i.ibb.co/BZGWbvC/194-DB7-F3-9817-4-B11-9257-DB20-C3-FF2-FFD.jpg) (https://ibb.co/XsD016C)
9A engine
(https://i.ibb.co/fxzwpGH/E6611556-C58-E-4-A9-A-801-F-B65-B5-E5-EE382.jpg) (https://ibb.co/d5wY2JD)
ABF engine
(https://i.ibb.co/m9TRN3r/E4-C8692-F-E256-4-A74-8-E43-793-BC66-E580-C.jpg) (https://ibb.co/48tF1Hw)
Started to strip some parts off it before putting it on an engine stand for storage.
(https://i.ibb.co/NLz2JD2/EC1-DE57-C-4169-4-D5-A-919-F-A14-EBCC34-D2-F.jpg) (https://ibb.co/P58GPXG)
Other than the original tank and hard plastic lines fitted to the car still I don’t have a fuelling setup for either engine.
I haven’t researched enough about it but I was wondering if it would be easier/cheaper to go MK3 tank and pump etc. and this would lend itself more to running the ABF engine. I’ve got a hydraulic pedal box and the engine/gearbox mounts I need. Plus I have an ECU and engine loom for it.
In which case, yes the ABF probably wins. I was thinking along the lines of converting an already K-Jet car. My old one was an 8v K-Jet and I had toyed with the idea of 2.0 16v, and had come to the conclusion if that's what I was going to do I would have gone down the 9A route. I however no longer have that car and the current owner is in the process of fitting an R32 engine.
My current one is a later, 8v Digi.
(https://i.ibb.co/Z2Q1Dd0/079-DE27-B-D9-E5-49-EC-80-A4-92495-E2-CE6-F0.jpg) (https://ibb.co/Z2Q1Dd0)
The looms are out
Had a few hours on the car over the last couple of days.
Got the looms and wiring removed, boxed up and labelled.
(https://i.ibb.co/g4PHtVp/B72-C087-F-01-FA-4202-B7-E8-E2500644-FF04.jpg) (https://ibb.co/sW6ksHG)
The fuel tank and hard lines removed
(https://i.ibb.co/mH8NSFk/C7777-F07-8500-4658-95-DB-F3-E3-C0-FD16-C4.jpg) (https://ibb.co/4jd1Jgz)
(https://i.ibb.co/wCwxZG1/49280-B55-F3-B4-403-F-86-F3-A9082006-EBE6.jpg) (https://ibb.co/0ZFdp43)
(https://i.ibb.co/S35snFM/16-C5226-A-9246-4-F16-A73-A-30768-E47832-F.jpg) (https://ibb.co/d5jW28V)
(https://i.ibb.co/L0Qzfvq/640967-C6-2-F1-B-4-D2-E-81-D0-93-A7-DA3-E0026.jpg) (https://ibb.co/10sfxbp)
(https://i.ibb.co/CPRQZGy/0-FD14-B8-B-6817-4777-B3-FF-676-D5-BEF64-C1.jpg) (https://ibb.co/MBF740H)
With the looms, servo and hard fuel lines removed from the bulkhead it meant I could get busy removing the chassis leg closing plate that needs replacing.
(https://i.ibb.co/GVGFXw8/1-C8-C9-AEB-1324-4877-A06-C-F361914-EE19-C.jpg) (https://ibb.co/zSCN1cB)
(https://i.ibb.co/gJf4bqx/E602-AB91-22-A5-43-CA-88-E5-C4-FF4-EB9624-B.jpg) (https://ibb.co/89fYnvH)
(https://i.ibb.co/zn0Czcw/8289-DAC0-A4-B8-4-FDE-B314-A49-FC2841-CE6.jpg) (https://ibb.co/PmfJdp8)
(https://i.ibb.co/dMY298L/E279-AC04-2-F8-C-43-C1-959-C-05-F319287-FE7.jpg) (https://ibb.co/sRYwS86)
(https://i.ibb.co/cwmPZQH/037-BFA92-A5-FA-42-F2-B7-DF-CBDFB4-AB8841.jpg) (https://ibb.co/PMSRPgn)
I need to get all that cleaned up and rust treated ready to start welding the new panels in place.
Great work, I'm enjoying seeing all the progress.
I'm in Covid jail until Thursday so I might have time to get all that chassis leg and inner wing cleaned up and prepped ready to be welded. I bought a new finger sander which is proving to be ideal for spot weld grinding.
My initial plan was to get the front chassis legs repaired ready to order up a rollover jig. Still on with removing all the bolt on panels. Got the bonnet and drivers door to go. Turns out I've pushed the car too far over towards the wall to get the drivers door open far enough to get access to the hinges. Might need to do some moving later. Should manage it with a trolley jack or my engine hoist.
Lower screen surround and scuttle need a few repairs.
(https://i.ibb.co/mHJG7m1/F7-C755-E3-24-D7-415-E-904-C-083-FB2194-DF4.jpg) (https://ibb.co/Wcn61Qq)
(https://i.ibb.co/WcQDKKQ/494795-F9-7-CC6-40-C3-9657-A9-EE40-A33339.jpg) (https://ibb.co/P5RTCCR)
Interior has been stripped out a bit more. I already knew about the drivers floorpan hole (you can put your hand through it from the outside!)
(https://i.ibb.co/vkTrdjM/31-E225-A5-D1-E8-4484-9-AF5-184-BD8-F3671-D.jpg) (https://ibb.co/2dCLMkp)
(https://i.ibb.co/LrMznmZ/ABA3-B251-2-A93-44-DA-BBE4-0-F4-E70-F81370.jpg) (https://ibb.co/Sc2XRb3)
(https://i.ibb.co/nz4ZrGH/6-E7-CDBDC-FEB6-488-C-80-BF-3-AD26-BAB71-D4.jpg) (https://ibb.co/pJNG27t)
I've got the Klokkerholm repair panel ready to go in here once it's all mounted up on the rollover jig and I get it cut out and cleaned up.
(https://i.ibb.co/55qzpwW/28-E1-C095-BC85-4580-891-F-38325152-E8-D8.jpg) (https://ibb.co/gDsXqhM)
My tidy garage didn't stay tidy for long! I need to tidy my tools up and get a load of stuff moved to my storage unit!
(https://i.ibb.co/JxTSnDg/F1-FD5-FF7-F150-4649-A7-DD-F9-DCE9470600.jpg) (https://ibb.co/rbhXkDN)
If anyone has some clear pictures of the scuttle showing the hole the accelerator passes through and the hole for the heater fan air intake it would be much appreciated. Looking to remake those pieces myself.
If anyone has some clear pictures of the scuttle showing the hole the accelerator passes through and the hole for the heater fan air intake it would be much appreciated. Looking to remake those pieces myself.
Does this help:
(https://eddypeck.files.wordpress.com/2017/07/2014-03-16104628_zps878faa34.jpg)
(https://eddypeck.files.wordpress.com/2017/07/2014-03-16143746_zpsfbdb69a3.jpg)
If anyone has some clear pictures of the scuttle showing the hole the accelerator passes through and the hole for the heater fan air intake it would be much appreciated. Looking to remake those pieces myself.
Does this help:
(https://eddypeck.files.wordpress.com/2017/07/2014-03-16104628_zps878faa34.jpg)
(https://eddypeck.files.wordpress.com/2017/07/2014-03-16143746_zpsfbdb69a3.jpg)
Yes! That helps a lot. Thanks.
Steering wheel and pedals are now out
(https://i.ibb.co/f9CQx8w/5119-DB73-319-C-4042-98-A3-FCE2503383-D7.jpg) (https://ibb.co/pQ3nLWF)
Scuttle is in pretty bad shape.
(https://i.ibb.co/VNPBpqT/DC1-C77-D2-E743-4-FBE-887-B-5-E7113283-C88.jpg) (https://ibb.co/DbSKgRQ)
The beauty of working from home means I can sometimes spend my lunchtimes working on the Golf.
This lunchtime I cut another piece of the lower screen surround out. I knew it was going to be rotten behind it and sure enough, it was! The pictures do the talking but after 20 minutes with some power tools I found some shiny bits. A bit of fiddling around with some 1mm steel sheet and I've got the start of a little repair patch. A bit more fiddling with that and I'll have some about right to weld in.
(https://i.ibb.co/xD61fwh/847-B970-A-F397-48-AD-A99-E-1-F399701-C18-A.jpg) (https://ibb.co/NsK9mfx)
(https://i.ibb.co/cF8JpZP/F8-CB04-D5-A690-451-B-82-F0-E70838-F51127.jpg) (https://ibb.co/hWdsn4k)
(https://i.ibb.co/FWMyk7V/BBC9572-C-5-C36-4-F48-8-D21-12-A4498-A3-D04.jpg) (https://ibb.co/cvHZKTL)
(https://i.ibb.co/WxPpX4j/17-F63383-D753-4437-A7-CB-109-C2-F278118.jpg) (https://ibb.co/4mYgLn3)
(https://i.ibb.co/r638sP5/52498795-36-E6-4-B4-A-B963-F50436-A00-B3-A.jpg) (https://ibb.co/G29YTwC)
Once this piece is in I can move into the corner and repair that. There's about 3 or 4 panels that meet here so it'll be done in little sections rather than a massive repair piece.
I've got a lower screen repair panel on it's way from Heritage too so not fussed about trying to stitch weld that piece back in.
New panel arrived from Heritage. They are mega fast at shipping.
(https://i.ibb.co/jhJ5vxX/4273-A08-B-EB59-44-FC-9773-3-F962800733-E.jpg) (https://ibb.co/gy47MXK)
Dropped it on the car, early signs are good. It doesn't look a million miles away. Needs a bit of grinding/bashing (plus of course a hole drilling for the wiper spline (they ship as LHD and need converting to RHD)) but nothing serious.
(https://i.ibb.co/Dz6HBCX/C7945718-13-A2-4-BF2-BEEB-898-F2-A9-B549-A.jpg) (https://ibb.co/wBbFnWH)
I've been playing around knocking some patches up to repair the inside of the windscreen lower surround. There are 3 or 4 panels that meet here and I'll need to patch every panel before shaping them and welding them together then welding the new scuttle panel over the top.
(https://i.ibb.co/XV5bWdt/6600-B2-F2-19-E1-4779-8-AB5-B23824-F4-F420.jpg) (https://ibb.co/x3gD2c6)
(https://i.ibb.co/rGhzsfJ/AA08-F1-BD-B241-439-A-B99-F-3449-A6068-B61.jpg) (https://ibb.co/DDFvpgn)
That's a decent start. More cutting, welding and grinding to go though.
Just got to admire the fact you are doing such massive repairs. I don't think many would be prepared to tackle it.
scs
Just got to admire the fact you are doing such massive repairs. I don't think many would be prepared to tackle it.
scs
Thanks.
I bought the car as a long-term project. I definitely don't yet have the skills required to complete it, but learning them was the aim of this whole thing. I had a Mk2 Golf as my first car and I think this will be (one of) the last petrol engined cars I'll ever buy. It doesn't matter if it takes me a year or five years to finish it, the fun for me is in the escapism that the project gives me.
Life has fast forwarded recently, but today I spent an hour reacquainting myself with the Golf
(https://i.ibb.co/RY0JhhM/CB4-CA444-6765-42-FD-9-BEF-1-C71784-D4-AF5.jpg) (https://ibb.co/jbMjVVx)
(https://i.ibb.co/XWK6j56/A107-A41-A-C70-E-41-B4-806-E-99582-AFC8-E15.jpg) (https://ibb.co/JcG8mp8)
(https://i.ibb.co/nnH5T2S/BEF847-B1-E3-DA-4204-A49-E-F7845-A070-BD5.jpg) (https://ibb.co/ww9xTH1)
Had another few hours at it
(https://i.ibb.co/VvR6NMZ/3-C356-EF5-7-D3-B-470-D-AF66-35-ECF55-D43-DF.jpg) (https://ibb.co/191cnR5)
(https://i.ibb.co/Qn7DRvr/DF4797-F0-26-FD-4-D8-E-9-E96-749-B7053-C599.jpg) (https://ibb.co/ctKYHhD)