Well i for one like the tartan rug! Its different and it breaks up an otherwise very black area.
The underside work is quite fascinating as you don't often see this work done well in isolation. Normally there is also other extensive bodywork going on or the underside is just getting re-protected.
Thanks, appreciate that I'm probably doing it all completely in the wrong order but breaking it down into stages is the only way I can realistically do it with the snippets of time I get to work on it and without a roll-over jig or my own working space. It's going to be a long job!
Another messy day under the Golf yesterday. God the beige sealer stuff VW lay on at the factory is the work of the devil! In a way, I guess it's good because it's probably the reason these cars have stood the test of time. Now after 30 odd years it's failing though and boy is it a pig to remove!
The main issue is it seems to be a lot thicker on the rear arches and boot underside than it was on the sills - must be nearly an inch thick in places. Getting in the nooks and crannies is proving time-consuming as well as challenging. Many people have done the tried tested heat gun and scraper route which does work but is super slow going. I'm opting for a variety of knot wheel brushes, an angle grinder and a belt sander. When the sealer is cold it's rock solid, when hot it melts and spreads about meaning at least 4 passes of the grinder to get back to bare metal. Most of it dripping on you like hot lava
My decision to take it all back rather than just suspect areas is paying off though as I'm finding spots of rust otherwise completely hidden by a good looking sealer.
Anyway, two days of solid work have gotten the drivers' wheel arch and most of the rear boot floor stripped:
Boot floor and chassis rails:
Anything suspect got treated with BH hydrate 80.
Check out the aftermath! (and yes I looked like I'd been down a coal mine 10 years haha):
Into the booth (largely to avoid any accidental overspray on other cars)
Back up on stands:
Cleaned with Xylene and hit with some BH Electrox:
So that's pretty much where we're at currently. Can't thank my mate enough for the use of the workshop (considering I don't even have my own garage this was a proper treat). There's still cleaning up to do around the lower rear chassis rails and valance but a lot of that is going to be cut out. Over to him now for the welding along with the rear arch and this rotter:
There's also the possibility the rear quarter may need painting due to the repair needed in the filler area being so close to the outer skin. We shall see.
Once it's all solid it'll be getting the same BH zinc treatment. Then it's onto epoxy mastic, seam sealed and followed by a coating of body coloured Raptor. If I can get anywhere remotely near this I'll be dead happy!
Progress has been sloooow as of late. I can’t go any further until my mate/glutton for rusty punishment finishes welding so have been trying to gather parts and supplies ready to put it all back together.
And...things have escalated...don’t they always? If you like rust and welding read on
As you can see the entire rear valance is now off allowing better access to the drivers chassis leg. A little scary to see your pride and joy with the hanging off!
Stripping this down further and peeling back the skins has revealed some quite extensive rot in the ends of the chassis rails so all of this needs cutting out and replacing. Not sure how this is going to be achieved yet as parts from the shelf are limited. Full-on mentality of ‘if in doubt cut it out’ with the car at the mo!
The passenger side is better but is starting to go so that’s being chopped out and replaced for a new genuine panel too.
2x these ordered up (only need the ends but had to purchase the whole section).
Both of the ‘mounts’ spoken about above weren’t in great shape so as they don’t seem to serve a purpose I’m going to leave them off.
I bought an entire rear quarter a few weeks ago which on first inspection looked solid. On strip down the fuel cap area is just as fubbard as the one on my car.
So no use there then! Something from scratch will need to be fabricated.
It did donate part of its turret though so all wasn’t lost.
Huge hole chopped out and the replacement tacked in:
Much better. Just the new filler bracket to weld on to that now.
The outer and inner arch has been chopped out:
Look how thick the damn Veedub underseal is!
A big box of Raptor and Epoxy has arrived so with any luck the welding will be sorted over the next couple of weeks and I can crack on with sealing it up.
Really sucks that the car has spent most of the summer in bits, draining my wallet but hey ho, do the job properly right?
I missed the weekender. Can I get it to the Gathering?! Time will tell!
Love this project. I'm busy gathering/stealing ideas!
Thanks mate. Haha, maybe a lesson in what not to do? Glad the thread can be of some assistance to others
Small update. More metal is disappearing from the car gulp...
Scrabbling about for bits I can do at home so treated the door cards to some protection. Yup clutching at straws. They are essentially moulded cardboard which is subject to moisture damage. Mine aren't too bad but are starting to go in places, especially the front drivers where the plastic membrane behind split years ago. I read a tip about coating them in yacht varnish to weatherproof them. Worked a treat.
So to make up for a sh1t update have a few pics of what I spent last weekend drooling over at the Silverstone Classic:
So I missed the gathering too. Pretty gutted about that. Things are taking longer at the bodyshop than I’d like (don’t they always? 4 months so far haha) but it’s a mate doing the welding and he’s doing a good job - just need to be patient.
Any shows, trackdays or hope of seeing this on the road this summer are pretty damn slim but hey ho, keep plodding on! Really hoping to get the epoxy and raptor done by mid September latest before the weather turns.
Some of the good stuff - latest round from the weldathon: