Meet my red-headed stepchild!

[echassin]

i hate finding rust in hidden areas

Me too, but I was bracing myself for worse because it's a Midwest car.

I do need some sheetmetal though:

Hood
Cowl patch (no rot, but a hood latch failure bent the driver corner badly)
Lower driver fender
Both rear arches
Both rear inner arches?

All of these parts could be patched, but I would prefer stamped stuff.

Now, this is the part where I have to eat Crow (I can hear the snickering already...):

I see people obtaining new metal, and I see people cutting off parts of shells for each other, but I didn't pay any attention to sources, because I'm a cocky Bastard and figured a rusty car would never find its way here (*infer apology* that's the best I can do ).

Help!

[DUBSfightinRUST]

[nickbukowy]

Yeah, I got to fix the little rust spots on the inside on the fender well on the back driver side, but I can't get any wire wheels back there, so I'm going to use this stuff that you put on rust and it stops it dead in it's tracks, a good friend of mine used it on a couple of his muscle cars years back and hasn't had any problems since

[echassin]

Sounds like you're luckier than me, I need new metal.

Hopefully someone will chime in with the source.

[echassin]

Big day tomorrow as I start to remove the mechanicals.

Today I organized the spaces into which I'll store everything. I'm trying to do this in a way that doesn't disrupt the flow of daily life around here, and doing the whole car at once (as opposed to rolling restorations) sure takes a lot of space!

I also did a little work on the car, the steering column and relay panel are out, and I organized and tagged all the harnesses:



So now the interior is almost done being stripped. The electricals are so tangled that I won't be able to pull them out until the engine bay is also cleared. My hope (fantasy?) is the do the electrical sytem a bit neater than VW did it, I mean sheesh, what a mess!



I started a bit in the engine bay too. The fan shroud appears to be from an 8V car, it's quite a bit narrower than the radiator and it was only anchored on one side Oh well, I guess a PO did what it took to keep the car running, kudos for that



The battery tray is perfect, meaning that unless the underside of the car surprises me, the rear arches and the one fender are the only bad spot on the car:



Well those and the hood and this damaged area of the cowl, from an apparent latch failure:



More to come

[scirocco*joe]

Eric, this is the source I see most frequently for sheet metal:

http://www.klokkerholmusa.com/servlet/StoreFront

A brief look around showed me no Scirocco-specific parts, but I suppose that depends on what stampings were used amongst the Mk1s. Either that or my poor reading and website navigation skills failed me.

[echassin]

Woo boy...

That's the site I've seen mentioned, but a search for "Scirocco" yielded no results. Zero. Nada. None

I'm beginning to get concerned...

Any of my problem areas could be reconstructed, but even a great metal worker (which I'm not), would end up using some filler, which y'all may have surmised by now, I don't like...

Hopefully there's a good skin donor out there somewhere.

[fredybender]

I know its a pain, but if you can brush up on your German, (or use babelfish)
You can get some nice parts out of Germany...
Shipping might be a bit costly, but these are the Shizz, for body repair sheetmetal...

Browse through that store, or use e-bay.de with babelfish translator

http://www.ebay.de/itm/NEU-Kotflugel...item256ddb61ac

[Chris16vRocco]

I have a good used drivers side quarter panel if you need it. The problem is getting it from here to there.

[PoorHouse]

New Project! Happy day for us spectators!

[echassin]

@ Fred: My wife's a Kraut so maybe she can help me. Unfortunately her car vocabulary is limited even in english (anything drivetrain is "engine", all glass is "window" )...

@ Chris: Cincy maybe?

@ Jake: I see you lurk here as well, hope to make this one entertaining for all

Today I'm keeping it short, it's beautiful out and I wanna goof off with the boys. I did get the suspension and exhaust off, and the tank out:





The bottom looks pretty good:



The only rot was where part of the fuel system rubbe the trunk floor for 25 years, it's not near any edges so another piece of red Duct Tape and it should be good as new :



Adios

[Chris16vRocco]

I intend to be there, and I can bring it along if it'll fit in the back of a Mk1. We shall see.

[California 16v]

I like your approach to restoring this S2 16v, by dismantling it entirely

looking forward to seeing the reassembly process of this Scirocco

[Falcor]

The always too far away to be usefull Swede stands up and waves his hand.....

Klokkerholm is a Danish company that also has a facility here in Sweden. I'll see what I can dig up in part numbers and information for you.

/ Mats

[Falcor]

Mk2 Rear corners:
http://www.klokkerholm.com/xProductC...&Group=1612346

Sadly that seems to be it for the mk2, for the mk1 they list heaps of stuff:

http://www.klokkerholm.com/xProductC...?Group=1612276

Shouldn't be undoable to find a shell to cut the wanted parts from tho.

[echassin]

I like your approach to restoring this S2 16v, by dismantling it entirely

Thank you sir I'm not sure where I'm going with this thing, but start with a shiny clean shell seems like a decent short term goal.

As for the sheetmetal, we'll just have to see how it all pans out. Worst case scenario I know a good metal worker, but if I use him I'll consider that a sign a weakness .

Today I continued stripping the car, but I had to cut short for a school fundraiser.

The tank has a leak from some rust at the pinch weld, I don't know if I'll split the halves and restore them or buy a new tank:



I drained all the fluids and was pleased at the appearance of the coolant:



Overall the engine is very dry , only the final drive seals are leaking. I haven't cleaned anything at this point:



The metering plate looked like this, no wiping:



The throttle body had a little oil in it, not too bad:



Here's where I'm at now, hopefully get the rest out tomorrow:





Edit: at first I assumed the engine was spent and I'd have to rebuild it, but it looks good and I'm wondering if at 181000 miles, maybe somebody got to it already? I can tell from incorrect fasteners and such that it has been out of the car before. I'll run a compression test and then decide what to do. The gear oil also looks good, so maybe I'll just replace all the seals without splitting the case open, I haven't decided yet.

Happy Friday

[PoorHouse]

Took a walk around the junk yard today.

They had a MKII Scirocco there last fall with a clean body, though I would see if it was still around.

It's still there but in sad shape, a few to many moves with the fork lift I think. Body is now pretty beat up
, to the point that the roof is buckled.

I'll keep my eyes open for others, you carry on with the OCD restoration.

[Mtl-Marc]

The only rot was where part of the fuel system rubbe the trunk floor for 25 years.



Adios

Der auto ist rot.

[echassin]

[QUOTE=PoorHouse;76439622I'll keep my eyes open for others[/QUOTE]

Thank you sir

Today I got a bunch more stuff off the car, engine out:



I had to cut one of the bolts :



Compression test results, no oil in the pan: 155, 140 (150 with a suirt of oil in the cylinder), 155, 155. A mechanic friend said "clean it, paint it, and put it back in". Obviously I will put new seals, clutch, water pump, timing belt, etc... but I agree with him unless y'all have overwhelming evidence that this is a bad idea:



I got the front end cleared of everything:



I got the firewall mostly cleared, what mess! I started organizing and labelling the engine bay harnesses so they'll come through the firewall holes:



Pedals and various cables and hoses out:



All that remains on the car is are the harnesses, the exhaust heat shield, the brake and fuel lines, and the sunroof. I'll do the harnesses, heat shield and the sunroof with the car as is, and the hard lines with the car on its side.

Adios

[fredybender]

Eric, I remember this quote from you:
You, my friend are at that point too

Quote, originally posted by fredybender »

This type of pic is always my favorite. Getting a car stripped to this point, it's staggering to even think about it all, for those of us who have never done it.

[Michael Bee]

Factory roof in this hog?

[Mtl-Marc]

Compression test results, no oil in the pan: 155, 140 (150 with a suirt of oil in the cylinder), 155, 155. A mechanic friend said "clean it, paint it, and put it back in". Obviously I will put new seals, clutch, water pump, timing belt, etc... but I agree with him unless y'all have overwhelming evidence that this is a bad idea:

If you are going this far with this car, taking the motor apart and having new bearings, rings and oil pump is not that much more money. You can have the block hot tanked, and painted. Lap the valves and making sure everything is good and within specs.

[echassin]

Factory roof in this hog?

Yessir.

@Marc: your point is the logical counterpoint to my current preference. I'm leaving both as options depending on how things go.

[ziggirocco]

Yessir.

@Marc: your point is the logical counterpoint to my current preference. I'm leaving both as options depending on how things go.

In my experience, with a project of this level, usually the one thing you try and skip doing will bite you in the but.

I would say stuff like bushings, seals etc all need to go new and it is much better to refresh the motor inside and out while it is out.

It would suck to put it all in and then need to rip it apart shortly after.


Misspelled by my iPhone using Slaptalk!

[echassin]

The boys had some friends here for a sleep over and I made a nice big breakfast for them, plus I'm having company over for a BBQ, but I was able to get more stuff off the car. Now the only thing that remains is the sunroof, which is fairly clean work that I'll do during the week after work.

Speaking of work, some people wonder how I get grubby at home, but then get clean to do surgery. The trick is Kevlar gloves that I use in the O.R. to keep from cutting myself. When I'm working on the cars, I wear a layer of latex, and the Kevlar keeps the latex from ripping. Here's my hands at the end of the day yesterday, before washing them. You can see how dirty the Kevlar gets:



Anyhoo, here's the wiring out and organized:



The shell is pretty empty by now:



Heat shield is off and I was able to snake off the hard lines too:





Fuel pump bracket; I'll just throw some black paint on it and call it good :



Anyone know what this is? It was sitting up by the firewall in the engine bay . at first I thought it was a golf tee, but it's hollow:



Next is the sunroof, and then it's time to rig up a tiptissory

[PoorHouse]

Speaking of work, some people wonder how I get grubby at home, but then get clean to do surgery. The trick is Kevlar gloves that I use in the O.R. to keep from cutting myself. When I'm working on the cars, I wear a layer of latex, and the Kevlar keeps the latex from ripping. Here's my hands at the end of the day yesterday, before washing them. You can see how dirty the Kevlar gets:

We are going to need a group buy on the kevlar gloves.


Do you have a blast cabinet for the little pieces?

[echassin]

Do you have a blast cabinet for the little pieces?

Yes, but if I blast that fuel pump bracket, it will vanish

Hey, if y'all have ever wondered: a bare mk2 shell weighs 500 lbs We weighed it using a bathroom scale under the corners and added it up.

[DT1]

Anyone know what this is? It was sitting up by the firewall in the engine bay . at first I thought it was a golf tee, but it's hollow:

Looks like part of the bonnet release.

See post #8

http://forums.kilometermagazine.com/...etails-diagram

[fredybender]

Yes, but if I blast that fuel pump bracket, it will vanish

Hey, if y'all have ever wondered: a bare mk2 shell weighs 500 lbs We weighed it using a bathroom scale under the corners and added it up.

Hehehe...
Did you know a Mk1 weighted 360lbs
Thats 38% lighter...

Hats off to you Eric, for taking this on, I really hope you're having as much fun doing it, as I am watching you, doing it

[Mtl-Marc]

Hehehe...
Did you know a Mk1 weighted 360lbs
Thats 38% lighter...

A kitted MK2 has less drag than a mk1, so it can get a higher top speed!

[TheTimob]

Looks like part of the bonnet release.

See post #8

http://forums.kilometermagazine.com/...etails-diagram

Yep. Here's the pic from the post:

[echassin]

Yep. Here's the pic from the post:

Yep, it was indeed missing off the cable, thanks

Fred, yours and a few others on Vortex are the inspiration for me trying this. It's been fun so far because for decades I've fixed A1 VWs, even rebuilt a few gearboxes. But I've never started with a bare shell and added each bit back to it one by one, I'm looking forward to that

[fredybender]

Eric: I just might end up at your house just for sh!its & giggles to help you wrench out!
I also hope, and wish you "pace" to help you, and your family, get through this.
Never loose the "pace" : have up & down swings, to take care of the real stuff, not the "German stuff", although I am a vivid fan, of "get it done"

I am looking forward of seeing you again at Cincy!

PS: this thread is Epic !

[echassin]

Don't worry, for years I was a super-busy surgeon but I got burned out, and now I only accept about 1/4 of the work I used to, it's the best choice I've ever made.

I sleep 8 hours every night, do all my chores, and have plenty of free time while the boys are at school, and when my wife is sick of having me underfoot and grabbing her a$$ .

I don't work long hours on my various projects, nor do I rush, nothing magic, but a few hours every single day adds up fast.

I will be at Cincy, but with the GTI, er Kia .

Anyone is welcome to come visit. Jim and Timbo have stopped by

[Mean 'n Green86]