Meet my red-headed stepchild!

[al@absolute]

looking great - is this your first full paintjob that you've sprayed yourself?

[echassin]

is this your first full paintjob that you've sprayed yourself?

No. Why, does it look like it ?

I worked in a body shop 30 years ago, but things were very different then. We sprayed lacquer color with lacquer clear over it, all in open air and with siphon feed guns. Very little skill required because everything got wet sanded and polished, and it dried fast so it was easy to fix mistakes, remove a fleck of dirt, etc...

HVLP, hardened enamel, having to be careful of dirt, booths, etc... are all all new to me.

I put on a lot of paint so hopefully there's plenty to wetsand with impunity

Today I took it easy but still got a few things done. The Cosmoline worked great. I made a little fixture so I could aim the tip and slide the tip in or out depending on the need:





The result was gratifying. I filled the beams and got Cosmoline to drip from all the little holes in the beam, even the little one way back behind the hard lines (There's a drip where my finger is pointing):



I also did the arches where I welded the inner skin to the outer skin:









Then, to add a little levity to the day, I made a tag to replace the code tag on the rad support that disintegrated when I removed it. I decided to put the color code on it:



I also painted the rivet underneath to avoid a rust source:



The tag is Lexan with vinyl characters, all painted after rivetting so it looks factory "plausible"

I like it, so that's that.

I think I'll sand and buff over the weekend and I'll check in after that IF I don't need to respray it all

[echassin]

I got a box of 1200 DA paper and tried the dry sanding trick, and it works for sure. Much less messy than wet sanding. I didn't take the paint all the way smooth, just enough to look as good as a Kia on a dealer lot :





I'll sand and polish more after the paint is good and hard, in a few weeks maybe, but for now the shell is done enough to start bolting stuff to it.

Unfortunately, I don't have anything yet that's ready to bolt on It's all broken, worn, crusty, or just filthy.

[vwdaun]

I this thread. You do amazing work, and make it look SO easy.

[fredybender]

Eric, you have my upmost respect;
If I can hold a tad of your passion in my post, my job is done.
Been there, done that

[SciroccoPowered]

Hot damn! Subscribed.

[echassin]

Kind words of encouragement are always appreciated, thank you!

Today I got some of the first parts ready to put on the car, namely the heatshield and the tank.

The heatshield got just enough love to look decent in pictures, mostly cleaning, straightening, and a mist of engine silver to even the tones, but not so much it could easily peel:



Installed:



I didn't use the stock steel speednuts, but rather firm plastic donuts I made with the holes slightly undersized, so that the plastic deforms when hitting them home and holds tight without damaging the paint/seamsealer on the mounting posts

I spent quite a bit of time on the tank even though I'd already sealed the pinch weld and covered the tank with two coats of undercoating. I'll install the thing tomorrow to let everything dry well.

The sender and transfer pump are serviceable, the new gasket came with the tank :



New foam strips in the same areas as the old tank, sender and transfer pump installed, and also header tank and associated hoses, all covered with Cosmoline where paint got gouged pushing various clips into position:



Bottom of the tank with heatshield, along with all the bits needed to complete the job:



The heatshield took time because I had to strip it of rust, dirt, and undercoating, plus it needed new mounting feet fabbed and welded on. I painted it with rust converter and this BBQ paint I used on our stove grills and which holds up great. Any metal to metal contact is touched up with paint and covered with Cosmoline.

Finally, I got the gravity valve worked out so no fasteners will penetrate the wheelwell steel and cause rust again:



The valve sits snug in the foam and the foam is glued to the wheelwell for a total seal. I'll glue the plastic hose cover to the bottom of the foam, again for a total seal, except the bottom edge so any water that manages to snake in can drain out easily.

Not sure what's next, gotta rummage around for a part that catches my interest, maybe the rack?

[al@absolute]

No. Why, does it look like it ?

not at all, i'm actually very impressed, but the fact that the car was in your garage i assumed either you or a buddy sprayed it in your garage. Nice job.

I've sprayed a few cars in my time and i can tell you, its no easy thing to do, its an art - one i haven't quite mastered yet

[echassin]

Thanks, I wouldn't say I'm "impressed" with my paintjob, certainly I'm satisfied. Even with minimal preliminary sanding and buffing, it looks as good as what comes off many dealer lots.

More hours should only improve things assuming I don't sand or burn through anywhere. But even if I do, it'll just get touched up, no respraying. I'm building this one to drive, even on salted roads, so Beauty Queen is not the objective.

Last night I got the tank and associated plumbing installed, as well as the plastic cover that covers everything in the wheelwell. No pics yet because I glued the cover into position and held it there overnight with a floorjack and pieces of wood.

I'll post some pics of it after work today, and I think I'll start making a "new and improved" fuel pump bracket.

[echassin]

OK, as promised, here are pics of the tank and associated plumbing:







I also got some niggly things done under the car, first up that hanger that holds the exhaust in front of the shifter:



Then I spent some time making a new fuel pump bracket, the old one was only flakes of rust in the vague shape of a bracket:



The new one is made of narrow strips to avoid trapping water (the original is a "tub" ):



The soft mounts are left over from an old RC plane I had a while ago.

Test fit looks good:



Fuel system parts all primed and painted:



I'd love it if someone can locate a $10 knockoff of this hose that goes from the accumulator to the main fuel hard line, I'd like to avoid $55 for the real thing if possible:



If y'all don't know where I can get a cheaper one, I may just JB weld the old one

JK. Bye

[SciroccoPowered]

Any shop that works with hydraulic equipment parts should be able to make a new one for you for fairly cheap, way less than $55 at least

[cholland_]

I've used a lot of mk1autohaus' fuel line stuff in my mk2. It's top notch stuff.

http://www.ebay.ca/itm/VW-Scirocco-I...item53e731332c

[echassin]

I've used a lot of mk1autohaus' fuel line stuff in my mk2.

That's the $55 version, I don't need top notch for this car...

cuz it's a Mk2

I don't know of any hydraulic shops off hand, but I will ask around.

I'd still prefer a "Chinese $10" version from a megastore or megawarehouse, if anyone knows of one.

[TBerk]

Sir!, I salute You!

[TheTimob]

That's the $55 version, I don't need top notch for this car...

cuz it's a Mk2

I don't know of any hydraulic shops off hand, but I will ask around.

BURN!!

My local NAPA with machine shop does this sort of stuff. You might check them out... The meaner the NAPA, the more they'll know!

[echassin]

Meh. For the trouble of having one made and hoping it fits right, I guess I'll splurge. I was just hoping I'd missed an alternative.

I got done at work early so I was able to hang the pump and accumulator from the bottom of the car:



There's a lot going on in a small space, but I was able to tweak everything so the pump swings comfortably from its soft mounts without hitting anything . I might make a pigtail so the pump leads stay on the pump and feed into an extra plug that's easier to reach. We'll see.

Although all the brackets and fasteners are painted, I covered them with Cosmoline to protect any nicks. Neat stuff, I think it's wax with a surfactant and a foaming agent, so it covers intricate parts thoroughly even without aiming in all directions. It foams up and penetrates like WD40 but leaves the waxy coating we're all familiar with.

Hmm, what's next?

[scirocco*joe]

Meh. For the trouble of having one made and hoping it fits right, I guess I'll splurge. I was just hoping I'd missed an alternative.

I got done at work early so I was able to hang the pump and accumulator from the bottom of the car:



There's a lot going on in a small space, but I was able to tweak everything so the pump swings comfortably from its soft mounts without hitting anything . I might make a pigtail so the pump leads stay on the pump and feed into an extra plug that's easier to reach. We'll see.

Although all the brackets and fasteners are painted, I covered them with Cosmoline to protect any nicks. Neat stuff, I think it's wax with a surfactant and a foaming agent, so it covers intricate parts thoroughly even without aiming in all directions. It foams up and penetrates like WD40 but leaves the waxy coating we're all familiar with.

Hmm, what's next?

This fuel pump bracket reengineering is TOP NOTCH. I believe one corner of my old 16V bracket was held in place with a zip tie. And that was after I replaced the pump.

[Mtl-Marc]

Awesome thread is awesome.

[echassin]

Merci Monsieur

Today I got the steering rack decluttered, degreased. decrusted, modified to run manual, painted, and installed on the car:



One of the tie rod assemblies and its boot are good aftermarket pieces so I just cleaned them, painted as needed, and installed them:



The other tie rod assembly and its boot only vaguely resemble car parts, are completely spent, and will need to be replaced.

I think I'll work on the pedals tomorrow, but for now, I hafta cut the grass.

Aloha.

[868valver]

I'm building this one to drive, even on salted roads, so Beauty Queen is not the objective.

I'm having a very hard time believing this^^^That S2 is going to be cherry!

[echassin]

It'll be cherry enough as one gets a quick glance at it going by

Everything's getting refinished to hopefully make the thing last through the winters here, but it does make things look good too

Progress is a bit slower because every part that goes on the car starts out crusty and filthy, and generally in disrepair...

...like the shifter:



Anyway, I got a bunch of stuff done, first the steering column U-joints and the boot:



The boot isn't minty but it's serviceable and since it doesn't move at all during use, I thing it'll last quite a bit longer.

Then the happy pedal with new cable retainer:



Then the pedal assembly, the clutch tube is crack-free :







Lastly, the shifter:







I modded the undercar shifter boot, the one that always rips, costs a fortune to replace, and rips again . I cut the torn accordian from the old boot, enlarged the resulting hole, and stuffed in an extra tie rod boot. I'm the man :



I realize some may question this, but I elected to make the shift rod hole big enough that the accordian does not follow the rod except for sideways motion. I hope there's minimal resulting strain on the boot and that it will last. Some dirt will work its way into the boot, but I hope minimal.

Now I'm sorry to say that the electrical system is next (or soon, at least), and I'm not looking forward to that tedium...

...so y'all should anticipate stall tactics on my part .

Edit: tomorrow I'm putting in the first big parts orders, so I thought now would be a good time to add up where I'm at. Some people find money discussions distasteful, if that applies, avert your ears .

Anyhoo, here goes:

Car $500, gas to go get it $200, tiptissery $50, gas tank $150, rattlecans $25, faceshield $15, paint tools $150, paint supplies $100, Cosmoline $30, Paint and supplies $500, undercoating $20, Buffer and supplies $150.

Subtotal $1890, and I have a still largely bare shell . Results will vary depending on what you do or don't already have for spare parts and tools, but it's a good ballpark figure. It is DEFINITELY more cost-effective to buy a creampuff, but we all already knew that

[ziggirocco]

Looking good! No matter what, make sure you put all new bushings in the shifter assembly!

[echassin]

Yeah, I had a set already.

The little task for the day was installing the sunroof drain pipes.

The big task was readying the harnesses for installation,

Engine harness:



"The rest of it":



If it looks a little thin, it is. Here's what's going on the "delete" pile:



Speaking of the delete pile, here how big it is so far:



The car will have what it takes to go, stop, be fully street legal, and make heat in winter. That's it. Therefore, it'll have stuff like license plate lights, but nothing like glovebox lights.

I spent quite some time unwrapping the harnesses to remove any un-needed wires, then rewrapping. Tomorrow I'll stuff it all into the shell.

[fredybender]

"Still lurks in silence" in awe, looks at the work, and says, oh yes, I recall...
Eric, many stand in silence, but we all want to cheer!

Fred

[Blaines_Rocco]

Nice job on the wiring! I hope to some day do much the same.

[echassin]

Thank you, gentlemen.

Freddy, did you get my PM? I need one of them steering column collars for this thing, if you could bring one more to Cincy, perty pleeze, $$$.

Got good time on the car today,

Electrical system is in:



You can see how little is left. The one harness that goes to the back runs the pumps, the tailights, the license lights, and the defogger. That's it.

The ground strap:



SciroccoJim taught me the trick of vinegar and baking soda, makes the strap like new .

Got the pumps buttoned up, the external pump is wired too, with good rubber boots to keep the contacts dry:





For some reason putting the cover over the sending unit felt REALLY good, like closure

The engine bay all wired:



I didn't want to chase down a one-piece speedo cable, but it turns out it's easy to "make" one. Take the box apart, cut out the cable mounts and discard the rest:



Take a bit of steel tube out of your "I might need that someday" drawer, trim it, jam the cable mounts into it, JB Weld it all together, paint it up, and here's whachoo get:





It's all the way on the right in the pic, along with the clutch cable in the middle and the throttle cable on the left.

Finally the electronics:



...and it's time to go out for Chinese food, yum.

Next big task is to get the gearbox rehabbed as needed, assemble and install the engine/gearbox, and see if the thing'll start after everything I did to it...

[8716vrocco]

Looks sick, I love the simplicity

[scirocco*joe]

This might end up being the most efficient 16V build evAR. A massive amount of preparation to make it 4-season drivable, but not a single wire more than it needs to run.

This continues to be an incredibly satisfying build thread. Bravo, Dr. E. :thumb up:

[echassin]

Thanks, except for the A/C and the radio, which even I admit are things I'll occasionally miss, most of what I deleted are things we don't need at all:

Hand brake and seat belt warning lights, interior lighting (there's enough ambient light around here that I don't recall ever using the dome light, and certainly I don't need the trunk, the glovebox, the HVAC functions, and the lighter to each have their own bulb and wiring.

As far as oil temp or gauges like that, we'll see. None for now.

The car will basically be simple and lightweight like an early Rabbit was, but with all the performance upgrades we craved in the day: power, suspension and wheels, disc brakes, nice seats, etc..

[Mean 'n Green86]

this build is great and very motivating. i'm still amazed that you can pull so many wires and still have a running motor

[echassin]

i'm still amazed that you can pull so many wires and still have a running motor

Well, that remains to be seen...

Today we're gonna go goof off with the boys' uncle, but I did get the vacuum booster refinished and installed, along with the MC and the front brake lines:



I think next I'll clean and paint the gearbox. Final drive seals, input shaft seal and clutch disc should be here any day, then I can get the engine off the floor and out of the way, and put it where it belongs.

[California 16v]

Awesome progress on the project

... at this rate this 16v will on road before Cincy this year

[Michael Bee]

[Lord_Verminaard]

Love this thread. So much great information. Thank you!!!

Brendan

[vw_Dru]