Erm, yep, that is a bit rusty isn't it. Just started working for Calor so deliver to framlingham most weeks. So many little villages out there!! Well I've still got some panels if you need anything so let me know?
It's plodding along on daily duties, not really done anything to it due to being skint, but it's running generally pretty nicely. I hadn't even opened the engine lid for months until I made the mistake of deciding to flush the coolant and put some antifreeze in it the other day. First thing I did was snap the thread insert for the bleed screw out of the top of the radiator
Once I start the new job and earn a bit of dollar I'm thinking of taking it off the road, Redoing the sill my mate welded on last year put a few other bits more steel in here and there and work towards getting a coat of paint on it. But I might just smoke around in it for a while longer.
Thanks Koen. Well, been a while, but I had a side project to practice my welding, turning this
There's a thread in readers other mods if anyone's interested
I'm pretty happy with it, but enough mucking about, I need to get on with the van!
Quick bite to eat and I'll finish dropping the engine out to sort the rust. It also means that I can strip out underneath and sort the remaining rust and throw on some paint. I'll keep you all posted on progress.
I'd forgotten how easy it is to get a VW flat 4 engine out!! Bit fiddly on your own, but really not difficult at all
Slightly unorthodox way of raising the van up high enough to get the engine out
Doesn't look too bad, but there is some rust that needs sorting. Not to mention the fact that there's another engine to go in there ;D
And the 2.1. Anyone want it? 12000kms since new, slight running problem......... Be a good base for a rebuild though! (Pretty sure it's a 2.1, but I looked at the paperwork a little while ago and it said it was a 1.9! I really have no idea why I would have replaced the 2.1 with a 1.9 though? I'll have to do a bit more investigation.)
Tidy up and make a start on cleaning up the engine bay next, but think that'll do for today!
Well, another day in the garage (there are perks to unemployment ) and after getting distracted cleaning up (all this grinding makes an awful lot of dust ) I started looking at the rust in the engine bay. I needed to remove various bolts that had been used to hold on the coil and electrics boxes.
Inevitably, I found more rust
So, choppy choppy!
Ballcocks!! More welding then. That's all been ground down now but no pics. Then I dropped the gearbox.
Makes it sound easy doesn't it. It wasn't, it was a ballache, but it's done now and on the floor. I've spent a bit of time underneath cutting cable ties, dodging coolant (trying to move the pipes underneath, a, because the heater pipes were crushed and b, because I am a bit OCD and want it to be tidy under there after I've thrown some chassis paint on) I really wish I'd been able to jet wash it underneath before I'd started, it is minging
So, a bit more time spent on the van this week. First off though I had to have a tidy up There was dust everywhere (Denise pointed out that garages are supposed to be like that!) but it was doing my head in. After that, I wanted to make a bit of effort to keep the dust off the shelves so up went some cloths.
Then it was time to get cracking. Out came the grit blaster to start tackling this;
And after a few passes
Different sides obviously I didn't want to strip off all of the paint back to bare metal, just the horrible black stuff, which has clearly done nothing to stop the rust taking hold It's all pretty much surface rust though so I'll treat it before I put some paint on (I've got chassis stuff, or I'll use some gloss black rustoleum that I used on the bumpers.
Next up, I decided that to do the job properly I'd drop the driveshafts (easy) and the rear suspension (You all know where this is going don't you......?) So, bolt for the shock came out a treat, then the one form the inner side was the same. Brilliants thinks I, whoever did this before coated it with copperslip so no rusted in bolts for me. Nope! Typically, it was seized solid! On both sides
I've drilled out the bolt head on this side, thinking that I may be able to give it a good whack to get it moving. Erm, that'll be no then So, I've packed up for the night and am having some tea. Mainly because I have no idea how to chop off the other end of the bolt
Bloody van! Oh, I put the alloys back on the Golf (Insurance came up for renewal and I mentioned that it had larger alloys on and they wouldn't cover me ) Thought it prudent to take them off until my renewal came through One just happened to fall against the van ;D
Back on it when I've figured out how to fit a grinder/saw/drill etc into a gap that a saw blade will only just fit into let alone anything else
Those lower wishbone bolts are a right pain in the aren't they! My rear camber and toe are completely cocked all over the place, but I can't (be arsed to) shift the bolts to adjust it because I know I'll end up having to cut them off and it'll turn into a much bigger job.
I'm not usually phased by even the most stubborn fasteners, but it took me about an hour to get the rear wishbones off the T25 I broke, I ended up just grinding the mounts off the shell!
Erm, yep. And that's the advice I'm getting off the brickyard! New mounts aren't exactly expensive, but my fear of welding these pieces is pretty much why it went off to get welded in the first place I'll see how I get on with it, but this will probably be the easiest option!! Camber etc will just get sorted when it's all done........ Whenever that might be!
Well, I finally dragged my out to the garage and tackled the seized bolts. With much grinding and mucking about they finally were free!
They were headed outside to the garden to get jetwashed, but my power washer is broken so might scoot down to Morrisons tomorrow and use theirs So, now we're looking at this;
Tomorrow I'll get the grit blaster out again and finish off the stripping underneath, and then I'll throw some rust inhibitor and paint on. Probably gloss black, although I do have chassis stuff. Undecided, but I do want it to last (forever....... I'm not curse word doing this again!)
Bit more done. (although I'm not exactly sure why it took me all day ) SO, paintstripping? Why? Well, I don't really know to be honest, but I do want this to look good so I set too with wire brushes in the engine bay to get it looking clean. There are a lot of holes everywhere, mainly drilled for attaching things like the coil, electrical junction boxes etc, but most use self tappers and are hence a bit rusty. I want rid of all of these as most will no longer be needed and nor will the fixing for the air filter. Off that came
Oh, ffs, more crispiness. Choppy choppy.
Here's another area full of holes, and most of them surplus to requirements when the Scooby lump goes in, so after finding more rust around the seams that came out as well.
This will be remade so that the airfilter for the Scooby lump fits properly and can be routed around the engine and put somewhere cold (although up and above the axle may work as well)
Then I spent some time sanding down the dash again Just not happy with it and wanted all of the sanding marks gone! Knifing putty? plop! So had to scrape that off and start again
I also dug out the engine mounts for the Scooby lump to have a fiddle and see how they fit up. A couple needed derusting ready for paint and that will go on a bit later. All seems fairly straightforward, I need to get some new bolts and stuff, and drop the sump to fit one of the mounts, but looks OK.
Then after choking on dust for an hour and basically getting nowhere on the paint stripping I went off and bought a proper grit blaster so will set to the van with that next week. Thanks for checking in
Thanks Martin, not sure that inspirational is quite the right term! Instead of being in the garage, I'm sat here on my laptop The 'beautiful' 18's look better on the Golf I do want some new rims though, but something a bit more retro. Fuchs, BRM's or a set of Torque Thrusts! Wheels are a way off yet though, but the current Borbet's are too wide at the front so I'm looking at arch extension options at the moment. Mind you, 17 x 8.5 A's are like poor quality wobbly children's play pony doo doo so might be worth a few quid anyway
Evening! Well, I've managed to motivate myself a bit and after getting a proper grit blaster I set too on the engine bay. The stuff gets everywhere, but after masking up a bit and making a grit catcher out of a very large cardboard box we got to here
Why I didn't just bite the bullet and buy one months ago, I will never know Suffice to say, it will be getting a lot more use! Today I had a clean up and hoovered up the used grit before tackling the dried waxoyl that had been spread liberally around the back end, and which wasn't doing a lot apart from collecting dirt. After an hour with a wire brush we got to what you see above ^^ I had noticed a couple of flaky areas though so had a tentative scrape with a small chisel
Erm, that doesn't seem to be right! It basically looks like someone has painted chassis black everywhere without any prep! More scraping....
I'll be attacking it with the grinder tomorrow. More work, but there is surface rust under there and I don't want to have to go back and do any of this again so I'd rather give it the best chance possible!
Well, another day, another......... (Load of rust with this bloody van!!!)
So, I took to it with the grinder and a new wire cup brush courtesy of Aldi (or Lidl!) In fact I went a bit mad with grinder attachments!! Sure I'll get the use out of them though. After a bit of grinding we get to here,
But I can't get to some areas so out comes the spot weld drill and.....
They were in a right old state to be honest.
But as i had foreseen their demise I had (for once) thought ahead
6 metres of 40mm x 20mm box section. Sadly the other stuff with it was an exercise in man measurements All too small
I spent another hour with the grit blaster, but it doesn't really look too different! Next job is to start treating some rust, otherwise I'll be getting a bit carried away! The box section will be reinstated to form a better base for the new bed as well as making up an area for an engine lid.
On another note I caught sight of the side of the van At this rate I'm going to need some more grit
Thanks Jim. I have a dirty great gas heater.... I'm just lazy really! Warm once you get going anyway. Quick update for today. I did a bit more blasting. Taped up the outside of the vents to make the grit collection a bit easier (sheets, plastic, cardboard etc. Garage looks like it has a couple of kids in it making a makeshift camp!) soit can be reused. I wanted to clean up the vents as best as I can as they will be impossible to replace (the van's originally aircooled, when was the last time you saw an aircooled DoKa?) They came out quite well.
They'll get some etch primer over the weekend to give them maximum protection and then a coat of gloss black. I also had a blast around the offside battery tray area.
Oh dear I'll need to have a clean up underneath so I can see what's what, but it looks like it's double skinned behind the rear valance so I'll tackle that next week.