76 Blue 2 Door

[Peter Jones]

A brake place can make the entire line which runs from the master cylinder to just under the back seat or just make a repair section to replace the rusty bit.

For some unknown reason, when a brake line rusts through it will always create a hole pointed directly at the car's occupants.

[brasstinman]

Walked into the garage yesterday morning and there was radiator fluid on the garage floor. It was leaking out from the water pump. Tightened it up, wiped it down and threw a tray under it and had to run out for the day and had friends coming around in the afternoon so couldn't look at it until today.
Drained the radiator out and took off the pump and checked the seal and checked there wasn't anything on the pump and the elbow and refitted and filled with some water to test it. Again it was leaking.
Looks like I'll put on some gasket glue and test it again otherwise it's a new seal and problem solved.
I won't get to the brake line this side of the trip to Vietnam.

[hiho]

Leaky quarter vents + brake lines + carpet = rusty floor + no brakes

Internally running the brake lines was not VWs greatest idea

[GRN_VAGN]

Leaky quarter vents + brake lines + carpet = rusty floor + no brakes

Internally running the brake lines was not VWs greatest idea

1980 changed that, they changed it to under the car. ive had a look at both floor pans from a 78 and 80 and i see no way to run them under the car on a early model which sucks. Ive had to replace 2 broken lines, current car has a repair section done near the passenger seat.

[brasstinman]

Hmmmm that's a shame coz I was going to look at moving them underneath the car

[brasstinman]

OK so I'm back from Vietnam (awesome trip) and I've been flat stick since I got back so I haven't looked at the golf. Not to mention I spent all my coin over there.

I need to get the metal brake line replaced as it has a hole in it right where it runs across the drivers floor beneath the peddles. Does anyone know the best way to get it out as it runs from the master cylinder through the firewall and down the side of the car to the rear. That's one long metal pipe!!!

The 2nd thing on my list is replacing the water pump seal. Anyone know the best place around Sydney or a web site to pick this up from?
Put a small amount of water in to test it after I cleaned it and reseated the water pump and it started leaking immediately.

[Peter Jones]

There's no easy way, You'll need to pull the seats out and take the carpet out to get at it all.

If there's only a small section that is damaged a brake place can put in a repair piece by using joiners.

Tooleys will have a gasket for that water pump.

[brasstinman]

Thanks for getting back to me. Been crazy at work this week and haven't even checked the site....

It's just one section, a small pin hole. I think I'll line up a local brake place and just run it down and get it fixed.

[AUC-05L]

Thanks for getting back to me. Been crazy at work this week and haven't even checked the site....

It's just one section, a small pin hole. I think I'll line up a local brake place and just run it down and get it fixed.

B&R brakes on sunnyholt Rd. they do everything brakes, and are top blokes to deal with!

[brasstinman]

Been a while since I've posted, since mY last post I've replaced the water pump seal and I had to bleed the brakes as the leak was pissing brake fluid out all over the drivers floor and I couldn't start rust repairs with brake fluid everywhere....
I started rust repairs on the drivers floor during the week and spent all day today finishing up 3 sections on drivers side (grinding still to do) and cut out and tacked in 2 sections on the passenger side. Few hours left on that side before I start grinding.
I'll post pics shortly.

Once I've got the rust sorted I'll trailer it down to Klaacks Motors and gets Hans to give it a once over to get it ready for a blue slip, get the brake line repaired and a carbie filter put on and hopefully the little blue 2 door passes blue slip first go.

[mikinoz]

Any progress is good progress! I bet your itching to get out and about in it.

[brasstinman]

Bloody oath!
I was sitting up on the deck this afternoon overlooking the back yard and staring at the golf and sipping my coffee and I said to my wife how much I'm looking foward to driving it around. With a good spit n polish it'll come a real treat.

[brasstinman]

Spent a little time grinding down some welds (pics taken part way through when I stopped for a breather), don't want to make them all pretty as I'm more interested in just taking out the cancer and treating the surface rust and getting back on the road. Besides it'll be under sound deadening and carpet and she's not going to be a show pony.
I still have another small patch to tackle this week and the rust work is done.

[brasstinman]

So I got the front floors finished off and coated in blue rust guard. Carpets and seats back in but left the centre console out so I can get the heater radiator tested and then put it all back together. I like it without the heater box and centre console but a heater would be nice on those cold winter mornings, it's why I'd drive instead of cycling to work.

Much to my wife's horror the Golf is under the carport as the two Triumph TT600 motorcycles I picked up on Sat are in the garage with the Norton. One is a parts bike for the other. Couldn't let a bargain pass me by.
The Golf doesn't have the heater unit back in the rain will go straight down the gutter rain guard on the bonnet and into the front floor. Carport it stays until it's all back together plus it makes it so much easier to work on when I don't have to roll it in and out of the garage.

Vacuumed the interior and filled the vacuum twice.
The spare wheel section is so clean, not a spec of rust. I was a very happy camper.

Moved onto the outside of the Golf, took off the rear bumper and straightened and panel beat the dent out of the rear panel just next to the back left tail light. Still want to give this another go so no close up pic yet

Gave her a bath and started putting paint cleaner on to see how well the blue comes up.
Came up pretty well on the boot lid and back right panel.


Spent Sunday working on the front. Took off the bumper (bolts for the front side bumper are a pain to get to because of the radiator ) Straightened two dents on the bumper and panel beat sections behind the bumper even though you can't see them when the bumper is put on.

Before pic


Took the front right guard off, and beat out the horrible dent on the corner. Couldn't get a good picture of the finished result because the marks on the paint made it look like it wasn't shaped properly but to feel it it's pretty close to original. Small skim of miki and a sand and it would feel and look great.
Cleaned the paint and put the front back together.

[brasstinman]

Battery charged, fuel topped up and..... [birds chirping].... After checking a few leads and electrical cables I pulled out the How to Keep the Volkswagen Rabbit Alive book and trouble shooted and found out what I suspected already was a dead fuel pump.
Looks like it'll be pushed onto the car trailer on Friday to be taken the mechanics for a once over for blue slip, of and add replacement fuel pump to the bill.