Author Topic: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto  (Read 14992 times)

Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #75 on: March 30, 2018, 04:40:25 PM »
Got some replacement wishbone fitting bolts to freshen everything up:



Due to impending house move, I've had to put the car back together without getting some of the work I'd of liked done first like powercoating the subframe and roll bar but never mind. It'll all come back off again when I'm set up at my new place. Spent today giving the subframe and roll bar a quick once over to clean off the worst of the rust:




New G60 engine mounts and roll bar bushes on:



Also fitted the Powerflex black series power steering rack bush:



Likely I'll get more Powerflex bushes sorted at some stage but considering only the rear beam and suspension mounts are now the only older parts, it's not a priority. Also got the old tie rods off after much fighting, subframe fully fitted and engine mounts bolted onto the brackets to the engine, steering rack secured and the flanges for the drive shaft cleaned up ready for fresh grease. Stopped there as needed tea and biscuits.

Over this Easter bank holiday I'm hoping to get the entire front end built ready to go minus tyres on the Sebring wheels. Also need to get hold of a 22.2mm master cylinder and a bottle for the fluid as I can't find my one and then it's pretty much fit and finish the other jobs off before booking an MOT and getting her back on the road.

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Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #76 on: April 08, 2018, 10:56:33 AM »
Fitted the new driveshafts, front wishbones and roll bar bushes:



Stumbling block, I didn't get every part I need, got to order caliper carrier bolts, steering arm gaiters, the master cylinder and reservoir bottle. Also want to strip down and clean the front suspension as it'd be a shame to leave it looking like this:



Hopefully order the parts this coming week and get new tyres fitted to the Sebring alloys so I can take it for a first test drive in nearly a year.

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Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #77 on: April 17, 2018, 05:54:38 PM »
Cleaned up the original brake bottle which came up alright:



I did order a new 22.2mm master cylinder and brake bottle but neither will work, and for a simple reason. I bought a Corrado 16V brake servo which has the studs for the master cylinder offset from horizontal like a Golf, so a Golf master cylinder sits at an angle. Luckily I didn't get rid of the Corrado 16V master cylinder so I still am able to put the car back together. Had to bend one of my new brake lines round to fit the cylinder but not fussed about it as the master cylinder has a bleed nipple which is actually a nice touch. Being an ABS setup as well means I could, in theory, upgrade to that one day if needs be. Just nice to know it's there...

Went to fit the front hubs and realised I'd made a bit of a mistake. I ordered the drive shafts for a mk3 Golf GTI, which is a 5-stud and, as I've now learned the hard way, has a different size spline on the outer part of the outer CV joint. So those had to come off, bagged them up as I can use them on Harriet as she's going 5-stud (full VR6 front and rear setup in all honesty) so all is not lost. Also fitted up the G60 brake lines ready to put into the calipers, so currently looking like this:



Anyone spot a bit of a theme with recent work..? Ordered the right CV joints now, as well as new wheel bolts, spacers for the rear and camber bolts for the front as well to help correct for the wide track and eventual lowering. Need to have this car running and road worthy within the next month as I'm moving house and also want to take the 6R off the road to upgrade to the TTE420 setup.

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Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #78 on: May 05, 2018, 06:30:04 PM »
Got myself some 13mm spacers and longer wheel bolts for the rear as well as some new bolts for the front:



Got the passenger side hub built back up:



Looks like a good fit all in all:


Another issue cropped up, the immobiliser in my car fell apart, so had to break out the soldering iron:


More on that shortly. First, got myself some extra goodies to fit, a boss kit, a new knock sensor as my old one fell apart, a 16v brake light switch and some new washer jets for the bonnet:



Now back to the immobiliser issue. Refitted the part I repaired but sadly it was not going to play ball. I decided I’d have a go at removing it myself, my logic was that any wires that had been tapped into would match so it was a case of just matching them all back up. Warning, view advised as the next few scenes contain sensitive content:



Definitely need to spend some time sorting the interior out, it’s a right mess! Stripped down all the wiring and sure enough:


One power wire and one earth had been completely cut and another power cable was tapped into, so stripped it all out and re-soldered everything back together and while I was there I untangled all the wiring loom and tidied things up:


Seeing as I was half way there, decided to fit the new steering wheel:


All that’s left now is to replace the rear brake hardlines, discs, bearings and pads then fit the wheels and book an MOT. May of take about 11 months longer than I planned, but she should finally be back on the road. For now, it’s a fond farewell to the immobiliser:

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Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #79 on: May 12, 2018, 07:01:27 PM »
Got round to fitting the rear brake lines:


Fitted all but one of the hard lines as I ran out of securing clips, decided that it wasn't too bad and seeing I plan to later replace the middle section brake lines that connect the front to the rear, thought I'd just leave it. Naturally, being the type of project this is, that particular hard decided to p*** fluid when pressurised so needed replacing! Decided to get all new flexi lines for the rear too so that only the regulator and the mid-sections as mentioned are left to be replaced for new items. Also finished off fitting the new rear discs, pads and bearings:



With that all done and sorted, I broke out the auto-bleeder. Love this tool, such a good investment if you want to run your own servicing:



During the bleeding process I couldn't get the system to pressurise, meaning air was trapped somewhere. I went round 3 times before I remembered the master cylinder I used has a bleed valve on it, so bled that and then immediately had perfect brakes. Also got all new rubbers for the pedals, including the accelorator, which I haven't taken a picture of but really help to refresh the feel of the car. Also had tyres fitted to the Sebrings, went for my now favourites of Avon ZV-3 in a 195 50 R15 flavour. Was worried that when fitted to the car with this choice they'd foul the arches:



Needant of worried. Even with a 20mm and 24mm wider front and rear track respectively, they sit beautifully. And so, ladies and gentleman...



After one year being on axle stands and collecting (a now thick layer) of dust and dirt, she lives and drives! Got to see the garage floor for the first time:




Need to sort those slicks out as we're moving out next week and we rent, so can't leave them like that! But grabbed another shot before taking her for a quick spin:



Comparing this to the first picture I took of here, seems like little has changed but under the shabby looking bodywork is a world of hurt, emotional turmoil but ultimate pride and joy. Cliché as f*** but I really did smile like a kid with a free ice cream the whole time I was driving her up and down the road to check I had gears and no major failures.

I didn't have a horn at first, realised after taking the boss back off that the little copper spring strip on the column wasn't making connection with the boss itself, so sorted that pretty quickly. One area left to work on now:



Got no wipers front or rear, washer or heater blower in the cabin, it the two relays numbered 72 and 19 that I need to replace. I also have an issue where the coolant level light keeps flashing despite more than enough coolant in the system, suspect it's another relay as I've seen one for sale on Heritage Parts that is for the level monitoring system, but I can't see it on my fuse board. For anyone else who is having issues with relays, this topic over on Club GTI is a god send for identifying relays by the number stamped on them:

https://www.clubgti.com/forums/index.php?threads/relay-numbers.166865/

Just got to sort these issues out, a damn good clean up and then it's off to the MOT centre to get it back on the road fully. I intend to sell off my currently little daily run about and use the funds to get new bumpers and other bits for Hayley now, start tidying her up and making her look a lot better.

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Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #80 on: June 30, 2018, 09:50:47 AM »
I've been busy with moving house recently so things like the cars have taken a slight backseat while I'm sorting everything else out. That being said, I did put Hayley through for an MOT to try and at least baseline what else needed to be done and hoped that she would pass so I could get using her. Sadly it wasn't meant to be, which I will come onto shortly. One thing that's been bothering me is the grill (of all things) as I miss the signature GTI red stripe, so bought myself another one off eBay which wasn't exactly the best condition:





It's also missing the two top clips but these really aren't that necessary as it screws into the slam panel anyway and secures nicely. I broke out the glue gun and got to seal it back together:




So onto the results of the MOT. Well, when I was called up by the receptionist for the garage, the term "failed miserably" was used, which was a bit unfair but the list goes like this:

Do not drive until repaired (dangerous defects):
Offside Macpherson strut mounting fractured (5.3.3 (b) (ii))
Nearside Track rod end ball joint worn to the extent there is a serious risk of detachment lock nut lose (2.1.3 (b) (ii))
Offside Track rod end ball joint worn to the extent there is a serious risk of detachment lock nut lose (2.1.3 (b) (ii))
Brake load sensing valve inoperative and ABS not fitted or inoperative (1.1.17 (c) (ii))

Repair immediately (major defects):
Bonnet primary retaining device ineffective (3.1 (c))
Offside Front Suspension component mounting prescribed area excessively corroded significantly reducing structural strength jacking point area (5.3.6 (a) (i))

Repair as soon as possible (minor defects):
Offside Windscreen damaged but not adversely affecting driver's view (3.2 (a) (i))

Monitor and repair if necessary (advisories):
Steering wheel very close to column switches
Brake pipe corroded, covered in grease or other material front to rear (1.1.11 (c))
Nearside Rear Wheel bearing has slight play (5.1.3 (a) (i))
Offside Rear Wheel bearing has slight play (5.1.3 (a) (i))
Nearside Rear Road wheel slightly distorted (5.2.2 (c) (i))
Offside Rear Road wheel slightly distorted (5.2.2 (c) (i))
Park brake effort on minimum percentage to pass
Rear service brake effort low

So starting from the top of the list, the tie rods and rear bearings were simply where I'd not tightened the locking nuts properly and instead of the garage just tightening them (literally a few minutes work) they just failed it. The top mount being broken is a bit off as I had the suspension off the front as you can see but when I inspected it I didn't see a split but I haven't yet removed it again to look. The more pressing issues are the brake regulator for the rear brakes and the front jacking point. I did have trouble bleeding the rear brakes so that one makes sense and I knew about the jacking point but didn't think it would fail but lesson learned.

The wheels are another issue that I've already addressed:



Bought them off eBay, the story goes that they were removed from the car by the dealer at purchase and been stored ever since. They're genuine G60 steels in a 15x6J size with an ET45 which is 10mm more than the Sebring wheels I currently run which is nice. Plus the tyres will swap straight over so it's a cost-effective way to carry on the G60-theme that seems to be running through the car now. The MOT guy did say to me the wheels were probably OK but the fact the tyre shop advised fitting them to the rear and now they've been picked up under the safety inspection they have to go.


The windscreen needed replacing when I bought the car so that's no surprise and the brake lines were also needed to be done. Just a lesson that skipping jobs to speed things up doesn't work...


And now the elephant in the room. The jacking point. It's not something I can resolve myself, especially when it looks like this:




Luckily for me, there are some body shops/painters just 10 minutes drive down the road so I popped into them for a chat, turns out there an awesome bunch of guys:

https://en-gb.facebook.com/leadfoot.racing.lfr/

Check out the crazy TDI Corrado they've just finished, the thing is insanely awesome in the metal. Keep an eye out for it when touring around at shows. We discussed options and came to a plan to cut away the jacking points, plate them with fresh metal and use box steel from the sill to the chassis leg to create a much strong, reinforced jacking point. This will allow me to safely get the car up in the air without worrying about damaging the floor which is essential as this project will require a lot more work yet. There will definitely be much more work from these guys being done, just right now time and money (as always) don't allow for the full-scale crazy plans.


To end this update, here's how she currently stands with a new grill:



Oh, wait, one more thing...



Yes, that's Harriet, the other car that appears to have dropped off the radar. Well, the old 1.6 engine is out and sat waiting to be scrapped (unless someone wants to come to grab it for free) and I've fitted the Corrado VR6 front cross member. Got to source a VR6 subframe and gearbox, going to opt for a 5 speed for the short term just to get the car driving and functional. It means parts are easily available off the shelf and cheap enough I can get it together sooner than trying to get the 6 speed working. I'm trying to get back to her once a month at least now to get things moving again.
« Last Edit: June 30, 2018, 09:54:31 AM by th3_f15t »

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Offline Dave J

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #81 on: June 30, 2018, 03:06:19 PM »
Awesome work - found myself looking at a lovely mk2 the other night, just don't have the space. Great to see the progress on yours - hope you're well  :drinking:


Edition 30 - no. 1387

Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #82 on: June 30, 2018, 05:32:58 PM »
Cheers man. I'd find space for a decent mk2 Golf if you can as they're only creeping up in value, even the GTI 8v's are increasing like the 16v's did a few years back. Mostly original and well looked after models are fetching thousands now, I paid a fraction of what I've seen some GTI's going for in recent times. Even the "barn finds" (a.k.a I've left it parked up for years and done nothing to it) are fetching more than they should. Some of the "projects" that have sold, which don't run or drive in most cases, sold for more than I bought this GTI for.

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Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #83 on: July 08, 2018, 01:05:38 PM »
Bagged myself a G60 rocker cover to brighten up the engine bay:



And a genuine Momo steering boss to move the wheel away from the stalks to clear the MOT advisory off:



Got a selection of tools to help finish off the remaining MOT jobs, got a Sealey suspension nut tool:



Had to file it down as the lugs were too big for the nuts, but it does make the job a lot easier none the less. Also got all my brake pipe tools:



Had Friday afternoon off work so decided to get out in the sun and crack on.



Driver's side suspension. Looked alright, top mounts have in fact been replaced within recent years as they were Febi items which didn't show any real signs of wear. However, the dampers are definitely worn as the second picture shows:




No rebound left in it! No leaks from the gas/oil in the main body so they'll do for now until I can afford a complete overhaul of the system. Got the other side off and the top mount was also fine, the MOT garage had failed me on this:



Wasn't sure a dust cover is a pass/fail item, but apparently so:

https://assets.publishing.service.gov.uk/government/uploads/system/uploads/attachment_data/file/671818/mot-inspection-manual-for-classes-3-4-5-and-7-from-20-may-2018-draft.pdf

A handy one to have so you can check out what your codes really mean as the description on my sheet would lead you to believe the top mount itself has failed, so double check first before rushing out to buy replacement parts. Next step now really is to get the brake lines and rear compensator sorted, into the body shop for repairs and then back in for an MOT.

Planning to completely overhaul the suspension now with new dampers, springs and hardware which includes bolts. Freshen everything up then get it fully aligned and the caber corrected as much as possible before putting her into daily service so I can crack on with the 6R.
« Last Edit: July 08, 2018, 01:11:05 PM by th3_f15t »

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Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #84 on: July 15, 2018, 11:11:27 AM »
Decided to get the new boss kit installed, you can see the difference in height:




Feels a lot better behind the wheel now. Got to sorting the brake lines out and fitting the new regulator for the rear brakes as well:







Haven't seen flares that good since my dad showed me a picture from his teens. Would have bled the brakes through but I've not got any tube to do it so I'm off to Halfords to get some supplies.

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Offline Jakey

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #85 on: August 03, 2018, 08:21:54 PM »
Wicked project and great work! Have always loved a mk2.

Offline th3_f15t

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Re: Mk2 Golf 3.2 VR6 Kamei Edition + GTI 8v Mini Resto
« Reply #86 on: December 31, 2018, 01:07:58 PM »
I've not been updating this project lately for which I apologise but things have been moving forward, although not all in the direction I originally intended. To fill in the gap between the last post and up to about a week ago, I bought replacement panels from VW Heritage to replace all the floors and sills, but after chatting with the body shop we decided it wasn't cost effective to continue as it's all a bit too far gone everywhere. To seal the deal, a branch fell onto the roof at some point and has damaged it there as well so there was no longer any desire to save the shell so decided the only thing left to do was to strip it down:




The mk2 Scirocco is also mine, I picked it up cheap as I needed a new run around and wanted something older (still was sulking with the R at this point) but now it's sat awaiting a new MOT and some work to get it road worthy again before selling it on. Has been an awesome car but I want to get back to Harriet, which was another influence on breaking Hayley. Gutted the wiring loom out the bay:




Currently working on repairing a few connectors, separating it out into 2 distinct looms (engine management and others) as I have a plan for it:




The plan now is to take the wide track gear off of Hayley and transplant it onto Harriet which changed from the original plan of a full VR6 wide track/5-stud conversion. The reason is I have the parts and they're tried and tested so going to re-use them for time's sake. Will use my VR6 rear beam and fuel tank in Harriet as well and keep the GTI rear beam and fuel system separate, along with the re-built engine I have planned, to transplant into another decent body shell. Ideally, I'll find a rolling shell with interior and drop the GTI parts into that and once I transport Harriet to my home in Wiltshire (from my workshop in Essex) I can get her up and running much sooner.

Another change from the original plan is to use a VR6 5-speed gearbox from a Corrado instead. This is simply for ease of conversion right now, allows me to re-use parts I already have and means any part to replace something is off the shelf available. Still working on which flywheel and clutch to use right now, I'm not aiming for forced induction, big power or likewise, just a comfortable, awesome sounding cruise machine.

Hoping that I'll get Harriet down to Wilshire by end of February and at least firing up by the summer, but there's a ton of work that needs doing so don't hold me to that...

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