shitbox edition JYD's 1990 Mk2 Golf Gti.

[junkyarddog]

26 minutes ago, Tickman said:

Get well soon

Thanks,I'm annoyed that I've lost a fairly decent week of weather because of it,it's broken my momentum. 

[junkyarddog]

Covid has thankfully left the building, but I've lost two weeks welding on this heap.

Paneled up the front end,used the bonnet from the doner car as it's pretty decent, the old one was a repainted red that my nephew and his pals had used as a trampoline sometime in the past.

The wings are off my other golf,not sure if I'll use these ones yet,but for now they will suffice in lining things up.

Then it was onto fixing the windscreen surround. 

That took me three days,was knackered after the first day,but gradually felt better.

Floorpans next.

[junkyarddog]

Work has restarted on this heap.

Today's endeavour was to fit a windscreen to make sure the repaired surround was the correct shape.

I didn't have a spare screen,so had to buy a new one.

Thankfully they are still readily available,went for one with a top tint.

It fits!

[junkyarddog]

Floor pan repair is next.

Started on the passenger side front first.

Bit scruffy,but not too bad.

Some wire brush action revealed more holes.

Welded up and welds dressed.

 

[junkyarddog]

Rear passenger side Floor pan next.

Wasn't too bad.

Long strip needed under the seat rail.

Then gave it all a squirt of red oxide primer. 

One side done.

[junkyarddog]

Driver side rear.

Seat rail has rotted through,luckily had a good one on the doner vehicle. 

Just have to weld it in the correct position!

Overview of the whole floor pan. 

Welded in the seat rail first.

Then patch the rest up.

 

 

[junkyarddog]

Drivers floorpan next.

This one needed the most work.

Managed to get quite a chunk from the doner car.

Chassis rail needed a minor repair too.

That done,time to tackle the rest.

Next was the front corner.

Underneath this is a jacking point.

So I chopped out a bigger section to see the condition of what lay beneath. 

I had thought I'd have to repair this from underneath,but the rust was very localised,so it could be repaired from the top,result!

Ground the rot out then fashioned a repair patch and welded it in.

Then welded the floor section back in.

Then make up another patch.

Then weld it in(was a bit of Vauxhall Viva once upon a time)

Time to make up a few more repairs then clean up the welds.

Done.

[junkyarddog]

Next was this cheeky little rust hole in the front wheel arch.

Doner car came to the rescue again.

Welded in.

Cleaned up the driver side floors ready for a squirt of red oxide primer. 

Floors in the cabin are finished. 

[junkyarddog]

Spare wheel well.

Rotted around the retaining bolt to hold the spare,and also the fuel tank strap that is on the underneath. 

Mmmmmm,rusty.

Fortunately the Mk3 I bought recently had a reasonably decent spare wheel well,unfortunately the tank strap bracket has rusted and been plated up before.

Time to chop out the grot.

I was going to make several smaller patches,but decided to chop out as much as I could in one go.

Doner cut lined up.

Welded.

Still got to do the tank strap bracket. 

I left the old one on to maintain its position for the time being. 

 

[junkyarddog]

Next was to finish the fuel tank strap bracket.

First make up a patch for the top of the bracket.

Then  drilled a hole in the panel and threaded a bolt all the way through the bracket and floor to preserve the location point,the original had this too,it doubled up as a drain hole.

Next I could remove the tank bracket. 

Hmmm,needs a tickle of the welder.

The doner mk3 bracket was in worse shape.

But there was enough material between the two to make a useable one.

So it was time to refit the fuel tank and double check everything still lined up.

Time to weld it all in and clean back the welds.

Done.

Boot floor where it joins the rear panel next.

 

[Matty]

Weirdly looks like the outline of an alterboy.

(As an aside, I served on the alter till I was 16. In that time no priest ever laid a finger on me. As a result I grew feeling somehow unattractive 😆)

[junkyarddog]

54 minutes ago, Matty said:

Weirdly looks like the outline of an alterboy.

Well I guess it is a bit Holy(holey)

[junkyarddog]

Next was the rear edge of the boot floor where it meets the rear panel.

The seam between them traps moisture with the inevitable result. 

Rot.

Great.....

I needed a folded edge for the boot floor my metal folder isn't big enough to do the the fold in one go.

A rummage in my shed turned up this sill,for a mk1/2 Fiesta,but of surface rust but otherwise perfect!

Chop chop, weld weld.

Despite it looking straight, there is a curve to the rear panel, so I had to slit the patch in a few places to suit.

Time to make up the rear panel repair.

Bashed a groove into it with a bit of square section steel bar.

Trial fit. 

Weld.

Removed rotten section. 

Time to clean up the welds. 

That's pretty much it for the main structural repairs.

Still a few more spots of rot that need attention,so I'm not done with the welder just yet,wonderful🙄.

 

[stuboy]

keep up the good work!!

[junkyarddog]

Another common rot spot.

Under the rear tail lights.

Some rust appearing under the seam sealant too.

Cleaned off.

Grot chopped out.

minor repair in the lower flange.

Ground down.

Patch made.

Patch welded in.

Welds cleaned up. 

Taillight still fits,time to do the other side.

 

[shampooefficient]

Oh, I'm having flashbacks. I bought a slightly rough one theee years ago. Just under three years ago it started misfiring and then as we started to investigate, discovered there was rather less metal in it than VW had originally specified. 

I'm still convinced it was Mot'd by phone.

I've still got a few days work left to do on it... Having given up trying to make it realy nice, I've gone for solid, mechanically sound, and satin black paint...

[Tickman]

Glad you are back on this. Excellent work again.

[juular]

How did I miss this great work going on?

Great work going on.

[junkyarddog]

Time to do the other side. 

Was much worse.

Chopped out.

Lower mounting edge had rusted through too.

Never mind,it can be fixed.

First repair welded in and being cleaned back.

Ready for the top repair now.

Made from the same old sill panel I had used to repair the boot floor edge.

Welded in.

Check the taillight fitment. 

Squirt of red oxide primer. 

Done.

 

 

[grogee]

This is some elite level sparkler action here. I can see the donor car has saved you some time but there doesn't seem to be any section that you can't fabricate from some other old bit of car.

Do you do commissions? Puma floor is just starting to 'go' and will need doing one day, it's very much like the front floor bit on your Golf with the box section running underneath.

[grogee]

Also, here's what yours could look like. My semi-employer's one that he picked up at auction recently for £14k...

[junkyarddog]

9 hours ago, grogee said:

Do you do commissions?

Frayed knot,besides I don't live in the UK😉

[junkyarddog]

Next was the fuel filler surround.

Surprisingly good on this,it's a common grot spot,my 5 door was really rotted here,both inside and out.

The inner on this is mint,no work required at all.

The outer has a few pin holes though.

Ground out the worst of the rot and let in a small patch.

Ground down the welds and test fitted the flap.

Done.

[junkyarddog]

More rot,this time the top of the offside rear 1/4.

Underneath too,never seen one rust here before.

FML.

Chopped out the top,donor car helped here once again.

Same underneath. 

Welding upside down is such fun*

Some surface rust was ground out around the wiring grommet hole too.

Squirt of red oxide primer and we're done.

Such fun.

 

[JMotor]

Impressed with the metalwork you've done. Looks neat 👍.

Quite surprised at the places it's rotted too. 

[junkyarddog]

Moar weldage. 

Surprisingly good on the rear window seal channels,I've often seen 3 door Golfs totally rusted through here.

This is the only grot in this aera on this shell. 

Cleaned up.

Chopped out.

Flattened out.

Scribed around it on a leftover piece of metal.

Much twatting and bashing later,This slightly misshapen patch.

Welded the flange on with the spot welder then seam welded in the rest.

Ground down,had to add some weld to the curve to get a good smooth match.

Its a miracle,the glass still fits😂

Squirt of red oxide primer and we're done. 

The body line under the repaired aera still needs a bit of work as the body was dented,will sort it when doing the paint prep,that is a while off yet.

[Dick Cheeseburger]

On 3/14/2023 at 8:25 PM, junkyarddog said:

 

Is that factory lateral bracing within the chassis rail? 

Kudos to the sheer determination you've clearly got in the bucket loads for this mk2. Is it a car you've got a sentimental attachment to or just a case of you wanted to resurrect it regardless of grot? 

Seeing your mk2s makes me want to track down my old 1991 mk2 which ran a 2.8 VR6 lump from a mk3. The rot side of things concerns me though!

[junkyarddog]

8 minutes ago, Dick Longbridge said:

Is that factory lateral bracing within the chassis rail? 

It's the channel that the fuel pipes run though.

9 minutes ago, Dick Longbridge said:

Is it a car you've got a sentimental attachment to

Not really.

10 minutes ago, Dick Longbridge said:

or just a case of you wanted to resurrect it regardless of grot?

Pretty much,I've got a shit load of parts and Mk2 Golf Gti's are going up in value,and I fancied a 3 door.

[Skizzer]

Just been catching up on this - hats off, lots of cracking work going on here. Great stuff.

[junkyarddog]

Roof skin repairs next.

This had a 'Bee Sting' aerial fitted at sometime,and had let water through into the sound proofing material below with the inevitable result.

I did toy with the idea of reinstating it,but decided not to. 

Grot!!

Decided to drill out the rust rather than use a grinder to cut out square patches. 

Sprayed some paint to get an idea of size.

Whacked a dimple into the metal using a socket.

Nice fit!

Start welding.

Some tapping required to get everything flush.

Next patch.

Ground flush,happy enough with the result. 

Squirt of primer and that section is done.

More of the same around the aerial hole.

Start by cleaning up the aera.

More of the same...

Welds dressed back with a flap wheel. 

Primed.

Can't say I'm best pleased with this repair as the roof skin has warped,not hugely but enough,I'm guessing it being jumped on previously hasn't done it any favours,the strengthening ribs are detached from the skin as they are bent out of shape.

I'll get to this problem in time.

There was two small areas of welding on the bulkhead where the clutch cable passes through,but they were small quick jobs,so I didn't bother to photograph them.

That's about it for the shell welding,bar a few pinholes here and there!

Closing panels next.