Mk1 16v Project

[Jarred]

Hahaha I lol'd.

[Preen59]

FYI, found a site that specialises in Weber stuff, in Aus..

LP3000 - DCOE Single Cable Linkage kit - Bottom Mount Weber Performance Carburettors

[Preen59]

Well, I started unpicking the rain tray today. I've ummed and ahhed about it, but it had to go. It has been modified previously (and not that neatly) and didn't seal on the bonnet anyway, so i figured "what the hell".. They look much cleaner without them anyways.. Plus it will allow me to get into the plenum chamber and clean it out properly..

Here's some pics..





What i've done there is identified where the spot welds are and done my best to centre pop them with a centre punch as close to the centre of the weld as possible. Then i got a centre drill and centre drilled them (a fairly small one. tip diameter of about 2mm). I did my best not to break through, but it's not really a big deal. A quick zap with the MIG and it's filled. The reason for centre drilling, apart from the fact that it stops the drill from wandering is that it removes the material from the centre point when you drill the weld out with a sheet metal drill. It cuts much, much easier and you don't blunt the drill anywhere near as quickly.

Once you centre drill the spots, grab the sheet metal drill and press pretty hard. Then pulse the drill, a second or so at a time so you can watch to see when you break through the first layer. Now that you've broken through the first layer, what I did was use a good, solid scraper and hammer to drive it between the two panels to separate them and get any last little burr etc broken away. Repeat on as many of the spot welds as you can.

When you get to the welds behind the strut tower, it's a different story, you can't get a drill in there (well you probably could get a 90degree drill with a stubby drill bit, but I don't have one). All I did was bash the scraper between the panels and do my best to break the welds.. Unfortunately in the corner I accidentally cut the firewall and made a bit of a mess, so i've created work for myself.. But ahh well..

More pics..

Here's where the firewall had been repaired after the infamous pulled through clutch cable. It was a bit of an ugly job, tek screwed in and bogged over. So I removed it and will make a repair panel. I plan on making a template when I get it right and i'll make and sell some if you guys are interested..







....... Ahh crap.



I also dropped the angle grinder, fitted with a 1mm elastic wheel down between the rain tray and the wing on either side to cut off the little tab that goes under the guard.. I wasn't going to pull the guards off just for that..

Should have the tray off tomorrow.

[Jace]

I love your work. (no homo)

[ScottyMK1]

This is mint. I was looking for info on removing this literally days a go.. Maybe you can read my mind haha.

[Preen59]

Haha cheers dudes. If you need info on how to grind up a sheet metal drill, let me know.

I think you can buy them off the shelf, but i'm not 100% sure.

[Peter Jones]

You can get spot weld cutting drill bits from panel shops.

There's a couple of kinds, these work well



and these ones suck



Well done getting that rain tray off, VW must have put more than a hundred spots welds into holding those things on!

I have factory reinforcement plates for the clutch cable repair if you want one to copy.

Pete

[Preen59]

You can get spot weld cutting drill bits from panel shops.

There's a couple of kinds, these work well



Well done getting that rain tray off, VW must have put more than a hundred spots welds into holding those things on!

I have factory reinforcement plates for the clutch cable repair if you want one to copy.

Pete

Ahh yes. I tried to get an online pic but couldn't find one (not that i tried very hard). That's basically what mine looks like, except I have more clearance between the centre and the tips. So it breaks through on it edges first.

If you could scan one of the plates for me, that would be fantasic, Pete. I wasn't aware you could buy an off-the-shelf item, but it does make sense.

I'm about 75% of the way through it, it took me about an hour to do, so not too bad really. Not a job for people without patience though. haha.


I've also been given access to a bag blaster (a sand blaster you use out in the open), which i'll be able to use in a couple of weeks. Need to get these few things done first, then pressure wash, blast, weld up, grind/fill/sand etc and prime. Then I can put the engine and gearbox in to go to Tim's.

[Peter Jones]

If you could scan one of the plates for me, that would be fantasic, Pete. I wasn't aware you could buy an off-the-shelf item, but it does make sense.

VW used to make them - VW part number 171-898-152

Sometimes they'd come with the clutch cables.

GSF usually stock them too, I think it's part number 715VG0420

UK E-Bay usually has a couple too.

Like this one

MK1 Golf GTi Cabriolet Bulkhead Clutch Repair Panel on eBay (end time 31-Dec-10 20:36:37 GMT)

[Preen59]

Ah righto. It's not a simple flat sheet item.

I'll see how I go with it, as to whether I buy one of them or make one..

Thanks for the link!

[GoLfMan]

ive been twiddling my thumbs and wondering if I should take out my rain tray, really want to do it (means my weber will get some more air! Plus it looks better). But how will it go with Roadworthy?

[mikinoz]

ive been twiddling my thumbs and wondering if I should take out my rain tray, really want to do it (means my weber will get some more air! Plus it looks better). But how will it go with Roadworthy?

If the clown looking at a MK1 can pick if the tray should or should not be there, all the best to you. Doubt they would even notice.

[GoLfMan]

If the clown looking at a MK1 can pick if the tray should or should not be there, all the best to you. Doubt they would even notice.

too true!!!!!

[Preen59]

Road worthy.. Meh. I'll be ok with that I think. It's not structural..

Now, onto what i got up to today..

Firstly, i worked on that pesky rain tray. Drilling, wedging, hammering and prying my way along. It took some doing, but I got it out..






Then it was onto the bracket on the LHS. Not sure what it was for originally, but there was no reason to keep it! Took a bit, but I got it out..

Houston, we have rust!



Looks like i'll be cutting a repair piece and welding it in.. No biggie, I hope. I've done bugger all panel work! haha.

After that, it was onto removing the tar sheet sound deadening. Grab the hot air gun and a scraper, and start peeling... Following with a thinners soaked rag to remove all the glue when i was done. Came up well.

[mikinoz]

So give you a headache or get you high?