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Erik & Rupert: The Tale Of Two MK1s

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  • #76
    Time to get up to date! It's been a while as things got more complicated and slowed down, so there was less to show for each night spent in the shed. I kinda stopped taking photos and updating. Despite the lack of updates I have been getting into it and making progress.



    The green car is finished. Yesterday I took it on a proper drive from my place in the Hills to Fairfield Showground for the VW Nationals. Surprisingly the drive was much less scary than I thought. It has a gearbox problem, but I've managed to find a way to make driving it at least semi-predictable.



    Getting this car back together has been the main focus for the last couple of weeks.



    I took a shot in the dark tonight of the finished engine bay all back together. Gearbox troubles aside, this 1.9L 8V goes really well. It's a really nice and pokey little engine.



    Inside it's pretty shabby and in need of a vacuum, but it's together. The colours don't look this bad in real life. Haha. It's all working as it should after some initial electrical gremlins.



    So with that now done and dusted, attention is fully turned to the yellow car.



    Here's where the engine bay is at currently.



    This wiring is the next challenge. Nothing needs to be changed exactly, just neatened up. I'll be tackling that next.



    The Golf Diesel tank from the green car is fitted and the rear beam bolted up again. You can see the fuel pump perched in its new home as well. I have to hook up the fuel return line and run the fuel feed up through the front arch to the filter, but that's straightforward.



    Inside it's about where we left it last time. I've plugged the dash loom into the switches and cluster.



    These damn switches were the cause of a lot of grief. It meant changing the whole steering column assembly which then meant changing all of the key barrels in the doors and hatch between the cars so that the same key works for everything.



    Changing the steering columns also meant changing the pedals as it's welded together as one unit. I think these ones are just waiting for some skateboard grip tape offcuts! Haha.



    On the other side you can see the heater box which has had holes drilled for it and is now properly mounted and not resting on a tub of grease and a screwdriver. While the wiring looks messy it's actually sorted out and just waiting for the engine loom to come through before a final tidy up.



    As soon as the car is fired up and the electrics are checked and sorted, this roof lining will be the first to go. I have a complete replacement kit sitting on the bench.



    The MK2 dash will be fitted once the roof lining is done, and then the rest of the interior will follow.



    Here's the bench of parts which has been refined a bit since last time. It's all pretty well ordered and I know where things belong (hopefully).



    Picked up a pair of replacement taillights at the VW Nationals yesterday which I was happy about. These will get rid of the mismatched and cracked ones currently on the car.

    And that's really where we're up to! Still a bunch of steps left to conquer but there is a plan. I've got a few nights to work on it so I'm ambitiously setting Thursday night as the first fire up night. Expect video if it all goes well.

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    • #77
      Just organised a mobile motor trimmer to come out and fit my new roof lining kit on Friday. I'd love to do it myself but I don't have the right tool to get in under the windscreen or rear quarter window seals.

      I did the roof lining in my KE70 and it was one of the most frustrating things I've ever tackled. I'll pay the $250 to get a pro in this time.

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      • #78
        hi ryan.

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        • #79
          HAI M8! Pub?

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          • #80
            le's doo et!!!

            i have a craving for mk1 action. can't have you rolling in a yellow 2 door on your own

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            • #81
              Can't wait. I will drive green car to work on Friday. It smells like a Mk1. Slowly I will entice you to get Clunker back in action.

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              • #82
                Engine bay as of ~1:30am last night.



                Got home from work yesterday and:

                - removed old fuel lines
                - ran new fuel line
                - cleaned and fitted the intake
                - fitted throttle cable
                - ran speedo cable
                - sorted wiring and ECUs
                - washer bottle
                - mounted coil
                - fixed alternator mount
                - mounted oil cooler
                - plumbed heater tap

                Tonight I have to shove the engine loom through the firewall, wire up the fuel pump, fit the radiator and catch can, and fill up the tank with fuel. Then we'll turn the key and see what happens!

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                • #83
                  fingers crossed for the key turn mate! looks like you have been busy from your list lol

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                  • #84
                    Mate if we all worked as fast you there would be a lot more cars on the road. Well done!

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                    • #85
                      Originally posted by EwenHayton View Post
                      fingers crossed for the key turn mate! looks like you have been busy from your list lol
                      Originally posted by Water Boy View Post
                      Mate if we all worked as fast you there would be a lot more cars on the road. Well done!
                      Thanks a lot, mates. I've been pretty damn motivated to get this thing on the road ASAP. I miss driving this motor!

                      Sadly it didn't go last night. Pretty bummed.

                      I'd like to think that if I'd had the energy to stay up until 3am it might've worked, but I called it quits at 1:30am. Everything is finished and assembled, all the electrics are working properly except for the fuel relay. I cannot for the life of me work out why.

                      The relay connects to:

                      - constant power
                      - ignition switch
                      - ignition coil
                      - ground
                      - fuel pump power

                      All leads are connected correctly and I've tested everything with a multimeter and it's all as it should be. But, for some reason when you turn the key to reds, the pump doesn't prime, and it doesn't spring to life when you crank it over either. When you connect the fuel pump to constant 12V you can hear it doing its thing, and when you turn the key the multimeter gets the correct reading at the relay, but it's just not working.

                      Could the relay have died in the process of moving things over? It seems so unlikely. The fuse on it isn't blown.

                      Quite a blow to morale after half killing myself with late nights this week. It was all set it to go but wasn't to be. Crossing everything that fresh eyes tonight will help me solve it quickly.

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                      • #86
                        Update from this morning.



                        Trimmer turned up super early so we could do a few things before I left for work.



                        Windscreen and rear quarter windows had to come out to do the job properly.



                        You can try and do it with the windows still in, but you can't get a result that will last.



                        Chad doing his thing. Nice bloke if anyone needs a mobile trimmer. They're not easy to come by. http://totaltrimming.com.au/

                        I saw it going up as I left for work. The result is going to look like a million bucks. Can't wait to see it.

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                        • #87
                          wanna swap mk1s? mine's yellow and 2 door too

                          let me know if you need a hand getting the glass back in. like i said at the pub, the string method worked a treat for me. i'll be a local soon, moving in 2 weeks.

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                          • #88
                            All good, man. Got it done myself last night using whipper snipper line. Worked perfectly! Need a hand moving in?

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                            • #89
                              Originally posted by HuH View Post
                              Thanks a lot, mates. I've been pretty damn motivated to get this thing on the road ASAP. I miss driving this motor!

                              Sadly it didn't go last night. Pretty bummed.

                              I'd like to think that if I'd had the energy to stay up until 3am it might've worked, but I called it quits at 1:30am. Everything is finished and assembled, all the electrics are working properly except for the fuel relay. I cannot for the life of me work out why.

                              The relay connects to:

                              - constant power
                              - ignition switch
                              - ignition coil
                              - ground
                              - fuel pump power

                              All leads are connected correctly and I've tested everything with a multimeter and it's all as it should be. But, for some reason when you turn the key to reds, the pump doesn't prime, and it doesn't spring to life when you crank it over either. When you connect the fuel pump to constant 12V you can hear it doing its thing, and when you turn the key the multimeter gets the correct reading at the relay, but it's just not working.

                              Could the relay have died in the process of moving things over? It seems so unlikely. The fuse on it isn't blown.

                              Quite a blow to morale after half killing myself with late nights this week. It was all set it to go but wasn't to be. Crossing everything that fresh eyes tonight will help me solve it quickly.
                              K just studying the pic,

                              Have you got the static timing set ?
                              Is the coil an electronic ign type
                              Cant see an ISV so assuming your using the early electronic idle control
                              Knockbox , vacuum line and knock sensor ?

                              How you got the cold start wired up ??

                              Looks to be Kjet basic Not CIS - E ?

                              Looks like your using the early relay plate, ( fuse on top of fuel pump relay)

                              Check that the relay is getting a pulse from the coil, as no pulse = no pump running.

                              I cant remember the terminal numbers . If you need the wiring diagrams PM me your email , your so close that this will drive you nuts !!

                              I would ditch the hose clamp on your fuel line, this system runs at up to 80 PSI, a fuel line coming of in the position you have it will certainly end up with an engine fire. The factory uses banjo bolts for a reason.
                              Lots of MK 1 Scirocco's...

                              If it aint a MK 1 then it must be a donor car ??

                              Cheers,
                              Grant...

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                              • #90
                                Thanks for your reply. I've send you a PM.

                                I've been slaving away on the interior. It's been slow because I want it to be as perfect as possible. The fit of the Mk2 dash in particular has been a trial.



                                The dash is in now and I'm happy with the fit. It went in and out over and over again as I trimmed more off the underside in various spots to get it as snug as possible. In the green car the steering column had been hacked up a bit to accommodate the dash which I wasn't happy with and did not want to replicate in this car.



                                The new headlining looks mint. I'm very pleased with it. It makes such a huge difference to how everything feels.



                                I was quoted a stupid amount to refit the windows by a windscreen bloke so I just did it myself with a length of whipper snipper line and another pair of hands to put some pressure on from the outside. All three windows went back in no dramas. Cleaned up the sun visors and the interior light which now works properly.



                                Got out some black vinyl dye to tidy up the kick panels, rear door cards and the rear parcel shelf supports which were brown. They're the later model ones which have rear speakers in them. I wanted them for that reason and also because I have a late model parcel shelf. They don't fit directly with my rear seat latches and arch covers but I trimmed off the unnecessary bits which fouled and they're now perfect.



                                These are the pads for the tops of the doors above the door cards. I thought mine were in better nick than they are. One is great but the other is unusable. Sadly my doors weren't painted in that spot so I needed another solution.



                                That pile of rubbish on the floor is the remains of the old one which was on the passenger door. I scraped it all off and I'm going to use black vinyl to cover the same area.



                                You can't really tell from this photo but the vinyl I've got is a kind of satin finish rather than gloss. It should blend in fine.

                                It should come along pretty quickly after the long weekend. I'm off to Coffs Harbour so sadly no time for the Golf.

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