Mk1 Golf (lots of pics)

  1. paul_c Member

    Messages:
    42
    I've taken on a little bit of work welding/repairing the front bodywork of a Mk1 Golf, for a friend. The rest of the car is remarkably rot-free, basically what seems to have happened is most of the usual rusty areas have been addressed before, including sill repairs, rear panel, underneath. But they obviously didn't look at the front, except a bodged repair which I've found, where they slapped a plate over a dodgy area, leaving it to rust underneath even worse!

    Anyway, here's the (lots of) pics so far.

    Car arrives:

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    Count the cars!

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    Front part of inner wing is cut off and previously spot-welded areas carefully ground off:

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    The front panel needs repairs to its flanges. Cut out rusty area:

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    Small repair piece:

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    Ready to weld:

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    Tacked in place:

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    Remaining welds done (butt welding):

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    Welds ground neat (yellow in appearance, due to reflection from other areas on car!):

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    Another area needing repair:

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    And another. Cardboard template for this more complicated shape:

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    Transfer to sheet metal:

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    Cleaned up:

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    Bent into shape:

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    Trial fitting:

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    After some adjustments, more/less ready to weld in:

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    And welded in place:

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    Then painted in primer for now:

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    So, now its ready for the large repair panel. 1st fitment:

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    Drilling, to allow plug welds to front panel and battery tray:

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    And front panel drilled for plug welds:

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    Trimmed accurately, ready to weld:

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    And its secured:

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    Next area. Yuk!:

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    After the sealant was removed (which needed high pressure degreaser and toothbrush assistance, it could be seen a repair panel had been crafted and slapped over rust:

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    Eventually, this was removed. Tricky access meant disconnecting suspension:

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    Previous welds now smoothed down and in primer:

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  2. paul_c Member

    Messages:
    42
    Template for area near the suspension turret is made from cardboard:

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    Cut out and cleaned up (wire brush) but not bent lip yet:

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    It needed a lot of fettling to make fit. The dimensions were a little off, because I'd based it on the cardboard template but when made from metal, the bend of the lip has to be radiused. So it was trimmed approx 3mm. But I'd rather trim it than make it twice! Also the main section is almost flat but there are 2 subtle bends to incorporate too.

    Trimmed, bent to shape and ready to weld. It fits so well it only needs the one clamp to hold it nicely:

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    Welding done:

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    This area was a problem. The metal is so rusty and thin here, it flapped around and I couldn't drill holes for plug welds. So I compromised with an overlap weld on 3 sides, it can be ground down and made neat though:

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  3. scotb

    scotb Member

    is that shell from falkirk area mate?
     
  4. paul_c Member

    Messages:
    42
    Bit random?

    Its not my car, so I can't tell, except to say that the owner is not from Falkirk.
     
  5. scotb

    scotb Member

    thought i recognised it as a car from about 7 years back, maybe not.:whistle:
     
  6. what engine is going back in to it?

    wish i could park all that in the back garden ;) I was watching a cheep truck on ebay but mum would not let dad get it because it was to tall to fit in the garage and it would have to be parked on the drive, shes a bit funny in that way lol
     
  7. bill_gj

    bill_gj Tired and irritable

    Messages:
    1,390
    Hockley, Essex
    Nice work Paul. Patient man.

    Yes bucko, most wimin are a bit that way.
    They also ask questions like "Why do you want that?" and "What's it for?"

    And sometimes they say things like "Yes, dear, it's very nice"
     
  8. scotb

    scotb Member

    :laughing::laughing::laughing::laughing::clapping:
     
  9. paul_c Member

    Messages:
    42
    The friend's asked me to move the engine mount to allow a big block (1.5 upwards) engine to fit (its currently a 1.3) although I'm not involved in the engine conversion side, apart from moving the engine mount to allow it.
     
  10. scotb

    scotb Member

    just drill out the welds on the current mount and turn it upside down,make sure the centre of the mount is in line with the groove on the chassis leg;)
     
  11. paul_c Member

    Messages:
    42
    I know....just need to find my spot weld driller, I want to make it look pretty much stock. I've seen it done before and the welding looked like a right dog's dinner. Just need to wait for some more sunshine to progress!
     
  12. TurboShed

    TurboShed Member

    Messages:
    115
    Liverpool
    Looking good, I like that :)
     
  13. paul_c Member

    Messages:
    42
    Time to address a couple of corroded areas lower down on the left inner wing:

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    This area was easy enough to cut out:

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    Cutting out the lower area was awkward due to the corner, and wanting to keep areas of good metal on the car:

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    Delicate going - it took a while and here are a selection of the tools used for it:

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    Finally done:

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    Note the lines drawn, to assist in accurately cutting the shape of the cardboard template:

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    So, the cardboard template is made:

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    And then the shape transferred to metal:

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    Welded up:

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    Using the overlap technique, the welds are strong and I was also able to gain access to the other side, in the footwell of the car.
     
  14. zardoz

    zardoz Old school Socialist

    Messages:
    2,219
    Location:
    Chetser, UK
    All good work well done. I too know what a pain it is to be working outside, i sympathise.
    Is that a Dremmel (sp?) i spy there. what are they like, any good ?
     
  15. paul_c Member

    Messages:
    42
    Yep, well a cheaper version of a Dremel, in fact it was a bit of a bargain from Maplin, it was the only one on the shelf and it was a massive case of loads of attachments and tools with the tool itself, all for about £15 or something. The genuine Dremels (and attachments) are much more expensive! A bit of a price premium, I think. I was scratching my head on how I'd cut the awkward area out until I thought of it, they're really invaluable. It will also be used for grinding awkward/inaccessible areas, although when you use a grinding stone in them, the stone wears out at the same rate as the metal! Its not like a proper grinding wheel in a mini angle grinder.
     
  16. TurboShed

    TurboShed Member

    Messages:
    115
    Liverpool
    Do the Dremel ones do that too? I used one YEARS ago, so can't remember. I think my Dad's still got it, I might have to find out if it's still servicable as my car restoration is gonna start soon :)
     
  17. willwebby Member

    Messages:
    6
    diss
    really good to see another mk1 gettin sorted. im about to start :welder: this up in the next couple of months. keep the pics coming.

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  18. i like them steel wheel's you shuld get them banded, powder coated black and get some wide tyers on them :cool:
     
  19. Marky

    Marky Member

    Messages:
    179
    Scotland
    I hope after all this restoration and time and skill your gonna make it perfect and take that horrible aftermarket sunroof off the car !!!! please lol


    looking good keep the pics and progress coming ;-]
     
  20. littlenewt2067

    littlenewt2067 Member

    Messages:
    27
    Southend Essex
    This thread is exactly the reason I joined the forum! I have several resto's lined up and want to do pretty much what you are doing. I love the pics of making the templates, transferring to metal and then welding. Absolutley superb, please keep the updates coming!!:clapping:
     
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