mk1 fixer

[regularjohn]

Hey

Thought it was about time I start a thread on my mk1 resto.

Months back (maybe longer!) I bought a 76' 4 door LS. It was (and still is) pretty beat up. Rust in all the usual spots ie. floor pan, front inner arches, etc. and a few spots i didn't know got rust like the hatch! It was sporting the original 1.6, some rather "modern" ROH 6 spoke alloy things with super fat tyres and an extremely trashed interior. Oh, it has an after market sunroof too, hahahahahaha.

(please excuse the phone photos and the lack of them, I some how lost my real camera in the last few weeks, along with all shots of car progress (if one would call it progress)

So here it is, untouched, earlier in the year.

Approximately 4x months, 1x 4.6m^3 tank of argon, 2x bandsaw blades, a pile of sheet metal offcuts and a lot of lying around on the garage floor and the golf (wolfie) is rust free. Again, apologies for the lack of pictures.

Having learnt to TIG weld cromoly tubing and other bits of thin wall metal, I really did think tig welding car bodies would be a total walk in the park. I was wrong. I found myself lying on my back, in all sorts of tight spaces and using my left hand (im RH) on many occasions. It really made me want to pick up a cheap mig just for this project, as the "hot glue gun" of metal would have saved me a bit of time!

More to come soon!

[MeeM]

Excellent effort mate. You and the welder have become best buddies looking forward to more pics.

[sports racer]

Isn't a welder an optional extra when you buy a MK1?

[GeorgeMK1]

Great start mate! Some good craftsman ship by the looks of it.

[regularjohn]

Thanks for the feedback everyone.

Degreased the new (old) engine and box yesterday. Its a 1.8 ADZ and 5spd from a 98' mk3.

Other than deleting the AC and PS pumps (waiting on the new belt), the current water pump feels super rough, like the bearings gone. Will order a fresh one tomorrow. Then it should be about ready to drop in.

I did notice that I might be missing vital parts from the water hook up on the head. What I can only guess are sensors that go in the top two parts of the fitting. (see picture)

Anyone have any experience with this? I imagine I need to get the sensors (not that they will hook up to anything) in order to block up the holes.

j

[sports racer]

The sensors are a tight fit with a thick O ring under them and a circlip holding them in. Probably easiest to go to a wrecker and get a couple. Like you say, they don't need to work, just plug the holes.

Cheers

Paul

[Peter Jones]

There's a factory block off plug to seal those ports. Only a few dollars and comes with the clip and o ring.

[regularjohn]

Awesome, thank you for the advice!

Pete, you wouldn't happen to know the part name/number for the block off plug? So far Ive struggled to find it on the internet.

In other news, can anyone see any issues with using this manifold with a carby? (once I have machined an adapter plate)

I have a 32/36 weber carby. I was planning on tig'n an adaptor plate to the original mk1 manifold, but after I milled it flat and opened up the inlet size there wasnt a huge amount of material left to weld to. See milling exercise below.....And its cast aluminium. ha. So I thought Id machine those pins on the mk3 one flat and mill up another adapter plate. Anyone have any words of wisdom on this topic? I know should find a passat manifold, but they really do seem hard to find and I have access to fabrication gear.


Cheers

[GeorgeMK1]

Best to find a passat manifold mate, as they came with the 32/36 webers and are an 8v too

[Peter Jones]

It's called "plug, sensor port" I've got one at home I'll see if I can get the numbers off it.

Here it is listed on GAP. GermanAutoParts.com : Volkswagen Golf Cooling

[dubstar]

357121140

[regularjohn]

Thanks Pete and Dubstar!

George, Ill keep a look out! In the mean time Ill dial up some g-code for an adapter plate!

Cheers

Johnny

[regularjohn]

Well its been a while!

There is a bit to update!

I stripped the engine bay and decided on a fresh colour. The paint on this golf is all over the place. Originally was baby blue, then had a 2k mars red recoat. The red is peeling and super faded. However the engine bay was left the original blue, guess they didnt want to pull the engine for a respray?


While I was at it I sprayed the wishbone linkage things (technical terms much?) and driveshafts. Repacked the MK1 outers and the 100mm MK3 inners while the shafts were being painted.

Completed a few minor duties on the engine while it was. This included the PS and AC delete (Pete Jones method), fresh water pump, new timing belt, dizzy swap etc. Silly me ordered the outer part of the water pump without even opening it up. When I did it looked like this!

Im no expert, but it rather worn out to me. Actually does anyone know if I can just use the MK1 housing till I get a fresh one? The MK1 casting has less structural ribs, possibly this is an issue, maybe not in the short term just to get it running.

Anyway, dropped it in last week. Used an engine crane I knocked up at work. Was great in theory, however I was about 150mm out in calculations and getting the engine over into the bay became a struggle! (will have to get a picture of the crane up, its part dragster/space frame/mad max. What else does one do with excess thin wall hi tensile tubing?)


Now comes the task of wiring and plumbing it! Will update again soon.