Mk2 Golf GTI - Full restoration

[GolferGraeme]

@jo1010 I don’t get on here much these days and have not had the pleasure of your input on one of my threads but, man, you have no filter!
You every thought of retraining as say a crisis negotiator or something. I reckon building jumper deaths would increase tenfold

I've thrown the towel in twice already, once after I failed to get it spinning on the spit in the garage and again (briefly) after removing the underseal with the grinder gave me tinnitus. But the forum has been a big help in keeping me going and even when people are sticking the boot in I get the sense it's well meaning so I'm fine with it

 

[Exuptoy]

Good. Stick with it pal. Your car deserves it. Can’t wait to see the outcome.

 

[Keithmac]

@Keithmac Just read your build - outside in all weathers - that would be one of those heroic efforts I was referring to! Must feel great to have saved it though and I bet your kids absolutely love it. I really felt like I'd let the side down parting with mine in such a state, determined to make amends.

I'd love to go the 16v G60 route at some point; more than enough power for a <1 ton car, no lag, a proper tune out of the exhaust and (pretty much) a factory spec too! How's it running atm?

Hello, ours is going great thanks.

Had a bit of bother with a random fuel pressure fault a while back but managed to find the cause and fix it (I run a 340lph fuel pump in the Mk2 Tank).

I have a fuel pressure gauge to fit, hopefully this Sunday.

It's running the stock G60 pulley at the moment (78mm?) which gives around 9psi boost. Decided to start off gently.

Planning to strip and rebuild the Glader this Autumn and go back to the 64mm pulley (1 bar boost at 1800 rpm), that's where it was most fun!.

It's a JabbaSport Stage 4 Supercharger, don't really want to blow it up as I doubt I'd find another now.

Great to see you are cracking on with your Mk2 and saving it from the scrapper.

Yours looks very tidy underneath, definitely worth saving.

The bitumen on the inside of the floors is a nightmare to remove, I use hot air gun, plastic scrapers and loads of gun wash (paint thinner) to do ours.

Did find some issues starting underneath the bitumen so worth doing.

These Poly disks for the angle grinder worked well taking the OEM underseal off but looks like you've already got that sorted.

Keep the updates coming!. Nice to see the job progressing.

 

[Olderisbetter]

@GolferGraeme just keep going at it you know it will be worth it in the end, we have one stored to do later on that has a V6 R32 in it but I just fancy an old school engine or Tdi, I will keep.looking in

 

[GolferGraeme]

@GolferGraeme just keep going at it you know it will be worth it in the end, we have one stored to do later on that has a V6 R32 in it but I just fancy an old school engine or Tdi, I will keep.looking in View attachment 500332

That's a rare colour, Miami Blue??

 

[Olderisbetter]

That's a rare colour, Miami Blue??

It's a block colour blue but not the original colour, it was a metallic greeny blue

 

[Bluemotion]

Ey Up Graeme, it’s Eric! Didn’t know you were on here as it’s a surprise! Just make the sections for now and leave a 1mm gap all way round things and tack corners for me to sort. Then go onto the next ‘sub assembly’ and do same. That lot will save you pennies if you keep doing it.
You might want to tack tab loops on to hold the things that you can’t get grips nr when you align the repairs. Cheers E oh and keeeeeeep smiling!

 

[GolferGraeme]

Ey Up Graeme, it’s Eric! Didn’t know you were on here as it’s a surprise! Just make the sections for now and leave a 1mm gap all way round things and tack corners for me to sort. Then go onto the next ‘sub assembly’ and do same. That lot will save you pennies if you keep doing it.
You might want to tack tab loops on to hold the things that you can’t get grips nr when you align the repairs. Cheers E oh and keeeeeeep smiling!

Well I did wonder about that. Just cut the shapes, do the bending, tack it all together and let you weld it up. But I would like to get better at welding.

And the more I can get done the more time we get to spend on the paint job which right now feels like it might be epoxy and brush and that will definitely upset people including you. Not that I mind so long as the shell is solid and vaguely black.

I will be very happy when you appear though, not least for the company

 

[dobbslc]

epoxy and brush

That made me laugh
Nice job on the welding so far.

 

[eddie49]

Had another play with the welder today using some 0.8mm cut from the door that got mangled in the attempted break in. Found that with the voltage on 1max - which was working a treat on the 1mm sheet - I was blowing holes for fun. Playing with the wire speed and ditching the root gap helped a bit but not much so dropped the voltage down to 1min and problem solved.

Have you considered the advantage of having infinitely-adjustable voltage, rather than discrete steps, by the simple step of buying an inverter MIG ?
The downside, of course, is questionable quality and reliability, but they really are cheap now, and possibly worth a punt?
E.G.here's one for £90 :

Pardon our interruption...

 

[Melvyn Best]

I have to say that one thing made a vast improvement with my Clark Mig welder , I sold it ! The RTech that replaced it is so much better

 

[Bluemotion]

I have to say that one thing made a vast improvement with my Clark Mig welder , I sold it ! The RTech that replaced it is so much better

That’s the correct way!!

 

[Keithmac]

I've used this cheap igbt welder to do all sorts now (bought it for our Golf resto mainly).

This with Lincoln Innershield NR211 gasless wire worked a treat.

Very fine line not to blow holes in panels.

Had an SIP Mig before, was bloomin terrible!.

 

[GolferGraeme]

Have you considered the advantage of having infinitely-adjustable voltage, rather than discrete steps, by the simple step of buying an inverter MIG ?
E.G.here's one for £90 :

Pardon our interruption...

Damn, missed it and can't see any other 2nd options on eBay atm. It was local too.

I have considered it and Eric (@Bluemotion) suggested the same. The one @Keithmac got is £260 which is doable. I'll have to have a read up on em tonight.

 

[eddie49]

A recent topic referred to the Ukrainian-made Paton inverter MIG welder:

https://www.mig-welding.co.uk/forum/threads/refurbished-paton-160-migs.143675/

There are two of those refurbished machines left, at £240 or "Offer" :

Pardon our interruption...

They are very well-respected machines - but not sure that I would like Up/Down push-buttons rather than twisty potentiometers....

There is plenty of info about the pros and cons of inverters ( and the sub-topic of synergic vs. manual ) in the "Buying a Welder" section.
E.G.

L

Thread 'I am looking to buy mig for v.w. caddy body repairs'

Apr 20, 2025

I am looking to buy a mig for v.w. caddy body repairs diy. have stick weld.

• learner
• Replies: 150
• forum: Buying a Welder

The product names and brands for inverters that are most well-known here include R-Tech, Paton, BlackLine, Uptime, StaticArc, Rohr, and Stahlwerk. There are some reviews, which can be found using the Search box at the top right.

 

[GolferGraeme]

A recent topic referred to the Ukrainian-made Paton inverter MIG welder:

https://www.mig-welding.co.uk/forum/threads/refurbished-paton-160-migs.143675/

There are two of those refurbished machines left, at £240 or "Offer" :

Pardon our interruption...

That looks just the job so snapped it up - woooooo new toy - cheers fella

 

[jo1010]

You'll get better results with that - and get maybe £100 back from reselling the Clarke on FB

 

[GolferGraeme]

You'll get better results with that - and get maybe £100 back from reselling the Clarke on FB

Yep, and when you add in all the money that would have gone in the swear jar I should be quids in!