MK1 project No. 2

[ross_m]

New outer cut and offered up. This took ages to trim to the right size but got there in the end!


And how I left it tonight.. Tacked in position











Tomorrow I will have to sort the axle mount and finish the sill/inner wing infront of the rear wheel. I hoped to have one side done today and the other done tomorrow but as usual it didnt go to plan!

Oh and I also got the paint etc through the post the other day. Im not sure if its going to be done in time :| My mk1 polos coming off the road on the 1st of september although I could just get it MOT'd and use it for another month or so

[ross_m]

More progress

Pics of the axle mount repairs etc

Crushed and gone into holes








The arch is now almost finished. Some more up to date pics







Ready for a skim of filler



Filled




Started the o/s arch today but ran out of gas!

And thats that for now

[Dub Toffee]

MAAATE thats tremendous, can't believe how much effort your gone to cut all that out.
Looks so much better now hope you don't get any warps from the welds i found it hard to keep patient
and go slow but its worth it hey. Anyway awesome to see the amount of effort here!
keep up the good work!

[Jarred]

Thanks for sharing Ross!

glad to see you havn't forgotten about us!

[ross_m]

Ofcourse not I come on here quite a lot to see whats happening.

Another update from yesterday. Made a start on the drivers door



Take one spare GTI door and cut out the bits needed



Cut to size


Welded in






Skim of filler today since I ran out of gas half way through welding the n/s arch so I cant get that finished until next weekend :redfaced:

[Preen59]

Nice work, Ross.

Loving the DIY panel work, mate.

[madglf3]

Good work mate, looks like you've got some skills there and the interior is pretty cool too.

Can I ask, are you using a MIG welder, and if so what type is it? Also, what gauge metal are you using for the repair panels? I've got to do some slighly similar repairs to mine and it'd be good to see what you're using.

[ross_m]

Thanks again for the comments

Yep mig welding. Its a clarke 160TM. Highly reccomended by everyone it seems for hobby/restoration and isnt expensive. This is the second restoration its been used for and its still going strong. The metal is 1.6mm thick sheet. Any more questions just ask

[madglf3]

Thanks for that Ross, keep up the good work mate.

[ross_m]

Some more updates

Treated the surface rust on the back panel. Just needs filled and painted. Theres a small dent I'll need to beat out too actually under the o/s light.



Finished prepping the door.









And jarred - you may or may not like the next update....

New shoes. Stance achieved with quality street lid and other random stuff :p







I'll be refurbing them and they'll do for the winter. Colour coded possibly

Sorry to copy but it just happened haha Good wheels, good price.

[Jarred]

not like it, I love it!!

Super cool wheels, and pretty rare! tough looking wheels!

Keep up to good work! Makes me miss working on my mk 1!

[ross_m]

Yep, not sure how Im refurbing them yet. Where is your mk1 now?

[ross_m]

Loads more done last weekend.

The n/s arch/axle mount area was worse than the o/s. I'll skip the 'during' pics since its basically the same as the other side.

Axle mount repaired


Inner and outer arches done


Sill repaired




Front of sill/a-pillar rot.




The rust had spread to the floor


Rot cut out




Floor repaired




I made this inner sill repair panel

[ross_m]

Welded in


Painted in anti rust paint and then waxoyl


Repair from inside


Unlike on the other side i have used a section of a sill repair panel. It would take too long to shape it all right and Im running out of time! Its amazing how much quicker it is.


Ground down


Found some rot along the sill where water has got in the sill trim clip holes so I cut it all out and again used parts of the sill repair panel







Didnt get a pic of it ground down

And thats pretty much how I left it on sunday

[ross_m]

Tried a wing on and stuck one of the zenders on. I cant decide what to do with them