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    Thread: 1988 scirocco project (shortened bumpers too)

    1. Member JonnyPhenomenon's Avatar
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      04-30-2007 09:15 AM #1
      bought myself a good condition 88 rocco last year and promptly put it away in the garage for the winter. it had never seen snow and I wanted to keep it that way.
      now that spring is here, I decided to roll it out and get to work on it.
      I dont really mind the north american headlights, but I really needed to get rid of the ridiculous "clown shoes" bumpers I had on it.

      interior was ok for the most part, but the drivers seat bolters were shot and the dashboard was totally destroyed by sun.

      I hand stitched in some new vinyl for the drivers seat bolsters and located a great condition dashboard from a junk yard in my area. [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      you cant even tell the seats been repaired. it looks mint

      Previous Owner had it resprayed with what looks to be a maco paint job since it is peeling off in sheets. Therefore, I have devoted some funds to getting it painted again by my father who is a very skilled body man.
      of course, something had to be done about the damned Clown Shoes, so we went to work on trimming those down. since I cant afford 500$ for a set of euro bumps, I decided to modify my own.
      we took 2.25 inches off the front, and 2.5 off the back. this required cutting the tow hitches all off, flipping the bumper brackets in the front, and flipping the brackets and rebar in the back, busting the clips off the rear, sawzalling and plastic welding etc etc.
      here are some pics of that process:
      hack the brackets:

      weld on the rebar to .75" from body

      using painters tape to measure how much to remove from front clown shoe

      snip

      much better.

      now we had to plastic weld them back together.
      tip when plastic welding: use a very powerful iron or hot knife. add tons of extra plastic that you can chop up from the bits of plastic you cut off the bumper. try not to introduce air bubbles and take your time. ventilation helps here too. heh.
      to reinforce the joint, I used part of the inner bumper skin and welded it in place. the resul is a very strong bond that will not crack and should bne undetectable when the car is finished.

      is this any better?

      before they were plastic welded on, we had to do a bit of shaping to them to get them to fit right in there new location. the ends of the bumpers were intended to be held in place by brackets and they pushed n the body when they were in there new home. we ground them down and shaped them to fit without rubbing on the body, and that cured the "saggy bumper" issue some people with pulled bumpers have complained about.

      so thats all for now. expect more pics as we get the car all sanded down and start the painting proccess.
      p.s. I will also have pics of the patching proccess for the body kit parts that need filling in now that the tow hitches are gone. check back tomorrow night


      Modified by JonnyPhenomenon at 7:40 AM 5-4-2007

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    3. Member BluDemon's Avatar
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      04-30-2007 09:23 AM #2
      that's excellent. [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      You make me what to chop my bumpers as well.

    4. Member tcfootball's Avatar
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      04-30-2007 09:29 AM #3
      Very nice! Looks like you have a very clean car too!

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    6. Member JonnyPhenomenon's Avatar
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      04-30-2007 12:27 PM #4
      very clean indeed. it was brought up here (Maine) from alabama and I rescued it before it saw snow. (and salt) its got zero rust on it, but the paint was faded from all that desert sun, and the dash was toast.
      now I got a new dash and should be painting by this weekend.

    7. 04-30-2007 01:29 PM #5
      It looks like your luck this weekend was a bit better than it was Wednesday night at the shop. What's next on the list now that you have the bumpers pretty much squared away?
      I still can't believe how well your hand-stitched seat repair came out. Should I ever get a bike that needs the seat shaved down I know who to call to recover it!

    8. Member JonnyPhenomenon's Avatar
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      04-30-2007 03:29 PM #6
      Quote, originally posted by Madchen »
      It looks like your luck this weekend was a bit better than it was Wednesday night at the shop. What's next on the list now that you have the bumpers pretty much squared away?
      I still can't believe how well your hand-stitched seat repair came out. Should I ever get a bike that needs the seat shaved down I know who to call to recover it!

      next on the list is to smooth out a couple dings and get down to sanding.
      as for the vinyl, it wasnt very hard really. just time consuming to do it all by hand. when I replace all the velour with suede, Ill have to use a machine. also, my headliner is wrecked and will need replacing too, so thats on my list...

    9. Senior Member Iroczgirl's Avatar
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      04-30-2007 09:00 PM #7
      Still trying to save money for some euro bumpers this looks like a really great alternative! [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      Lots of VW stuff|Rare Scirocco parts!
      The family: 1955 Customline 351C | 1970 TR6 262Olds | 1977 Capri Cologne | 1980 Rabbit AAZ | 1984 C30 350 | 1988 Scirocco 9A | 1988 Scirocco LP7Y | 1992 Pickup 22RE | 1997 D21 KA24E | 2000 Grand Marquis Modular
      Quote Originally Posted by Crimping Is Easy View Post
      You're always better off with a Citroën.™

    10. Member JonnyPhenomenon's Avatar
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      05-01-2007 12:28 AM #8
      Quote, originally posted by Iroczgirl »
      Still trying to save money for some euro bumpers this looks like a really great alternative! [IMG]http://*****************.com/smile/emthup.gif[/IMG]

      its proved to be kind of a pain in the ass, but money is money and I havent got a lot of it.
      -----------------------
      another day and a lot of progress. my father DA'd the entire car today while I was at work. by the time I got here at 5:30 he had thrown in the towel for the day and I went to work on filling holes and fabricating stuff.
      since we hacked the bumpers so short we had to cut off the tow hooks, and that left a gaping hole in the body panels.
      everything below the black line would show beneath the bumper:

      and since the bumpers would be pulled in and raised up, these holes would be a lot more visible from behind.

      I couldnt plastic weld the body panels because the plastic was not the "melting" kind. bumpers were TEO, but the body bits are all some other kind. thankfully, this is the kind that the plastic repair stuff sticks to best. [IMG]http://*****************.com/smile/emthup.gif[/IMG]

      a little bit of that stuff and the hole was patched right up.

      I used up all my plastic repair so tomorrow I have to get some more so I can finish filling in the cavity left in the side skirts now that my bumpers are so much higher. whos effing idea was it to put that there anyway? it never looks right...

      at least I got the left side done

      anyway. tomorrow I get up at 5am and get to work on the car till about noon. then I have to drive home and get ready for work till 9.
      why am I still up?

    11. Member Loshambo's Avatar
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      05-01-2007 01:08 AM #9
      Great work on this car. It really seems like a labor of love. I'll be tracking your progress. [IMG]http://*****************.com/smile/emthup.gif[/IMG]

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      05-01-2007 08:16 AM #10
      Very nice thread, it gives me idea on how to fix one crack I have on my kit as well. [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      Quote Originally Posted by Mk1Madness
      Back when making your car faster and better handling was the big thing.
      Quote Originally Posted by Tavarish
      The car's best safety feature includes ejecting you in the moment of impact and wishing you the best of luck.

    13. Member JonnyPhenomenon's Avatar
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      05-01-2007 02:32 PM #11
      turns out bondo works pretty good on the body kit parts too as long as they arent going to be moved around. the rear corner "bumper cavity" was easily filled with bondo. the bumpers themselves require a bit more finesse.
      I spent a few hours this morning scraping the black vinyl decal stuff off the hatch. this is hard to do with the window in place
      we got most of it sanded now. We should be ready to paint on saturday. but I have to work this weekend so I am going to try to work around it.
      that reminds me, I have to order a ton of parts...
      no pics of todays work yet. left the camera in the shop 45 minutes from here.




      Modified by JonnyPhenomenon at 11:20 AM 1-31-2009

    14. 05-01-2007 07:48 PM #12
      nice Work Bro!!

    15. Member JonnyPhenomenon's Avatar
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      05-01-2007 08:28 PM #13
      just placed this order from worldimpex.com.
      ORDER SUMMARY
      -------------
      QTY: 2
      SKU: 4732
      ITEM: DOOR HANDLE GASKET small
      COST: $3.31 ea
      SUBTOTAL: $6.62
      QTY: 2
      SKU: 4741
      ITEM: DOOR HANDLE GASKET large
      COST: $3.13 ea
      SUBTOTAL: $6.26
      QTY: 10
      SKU: 124482
      ITEM: CLIP (for rain gutter rubbers)
      COST: $0.49 ea
      SUBTOTAL: $4.90
      QTY: 1
      SKU: 92153
      ITEM: GASKET for hatch popper button.
      COST: $5.20 ea
      SUBTOTAL: $5.20
      QTY: 10
      SKU: 95492
      ITEM: CLIP (for rocker panel sils)
      COST: $0.49 ea
      SUBTOTAL: $4.90
      QTY: 1
      SKU: 137784
      ITEM: PACKING (left side view mirror trim)
      COST: $10.26 ea
      SUBTOTAL: $10.26
      QTY: 1
      SKU: 137780
      ITEM: PACKING (right side view mirror trim)
      COST: $10.26 ea
      SUBTOTAL: $10.26
      QTY: 2
      SKU: 171866
      ITEM: BRACKET (sun visor retaining hooks)
      COST: $3.73 ea
      SUBTOTAL: $7.46
      QTY: 1
      SKU: 136403
      ITEM: ESCUTCHEON (platic trim that covers the screws that hole the mirrors on)
      COST: $3.59 ea
      SUBTOTAL: $3.59
      QTY: 1
      SKU: 136404
      ITEM: ESCUTCHEON (platic trim that covers the screws that hole the mirrors on)
      COST: $3.59 ea
      SUBTOTAL: $3.59
      QTY: 1
      SKU: 53321
      ITEM: GRILL EMBLEM (Chrome. because I like it better than black)
      COST: $17.86 ea
      SUBTOTAL: $17.86
      QTY: 6
      SKU: 49937
      ITEM: GROMMET (rubber bits that hold the hatch emblems on.)
      COST: $0.64 ea
      SUBTOTAL: $3.84
      QTY: 1
      SKU: 49923
      ITEM: LOCK KNOB (the button that makes the back seat lay forward)
      COST: $3.68 ea
      SUBTOTAL: $3.68
      QTY: 1
      SKU: 109335
      ITEM: ESCUTCHEON (actually part of the sunroof.)
      COST: $9.47 ea
      SUBTOTAL: $9.47

      ORDER TOTALS
      ------------
      SALES TAX: $0.00
      SHIPPING: $11.50 (UPS Ground)
      GRAND TOTAL: $109.39

      then I ordered a new roofmount antenna kit from http://www.germanautoparts.com for 65$. now I am broke.

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      05-01-2007 11:18 PM #14
      nice d.i.y

    17. Member JonnyPhenomenon's Avatar
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      05-02-2007 12:05 AM #15
      Quote, originally posted by vdubkid06 »
      nice d.i.y

      thanks
      I was scanning through the pics, and I realised that I was going to have to cut my muffler shorter now that it sticks out farther than my bumpers..
      You have no idea how good it feels to have THAT as my problem. I never thoguht I would see the day that my muffler was "too long" compared to those stupid bumpers. lol.

      anyway, sleep now. will post updates tomorrow.

    18. Member JonnyPhenomenon's Avatar
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      05-03-2007 06:37 AM #16
      drove out to the shop yesterday after work, and found that my father had primered the car. Man he works fast!

      check out these bumpers!


      and heres Me.

    19. Member ginster86roc's Avatar
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      05-03-2007 08:31 AM #17
      Quote, originally posted by JonnyPhenomenon »
      Man he works fast!


      boy howdy!
      it's taken me 2mos (working a couple hours a night after work when possible) to reach this point:

      go pops, go! [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      i good vibes... and sciroccos.
      Quote Originally Posted by sciroccojim
      Yes. Follow the adjustment procedure in the Bentley. Works like "magic."

      Quote Originally Posted by punchbug
      That's just how we roll.

    20. Member DutchVDub's Avatar
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      05-03-2007 11:13 AM #18
      [IMG]http://*****************.com/smile/emthup.gif[/IMG]

    21. 05-03-2007 12:18 PM #19
      That's a great job on those bumpers, can't wait to see the whole thing.

    22. 05-03-2007 12:27 PM #20
      Quote, originally posted by Throttlepimp »
      That's a great job on those bumpers, can't wait to see the whole thing.

      I agree.
      Are you going to paint Red again?

    23. Geriatric Member JUS_GT_EYEZ's Avatar
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      05-03-2007 01:28 PM #21
      Im not sure how I ended up here . but glad I did.. Nice work...
      [IMG]http://*****************.com/smile/emthup.gif[/IMG]
      "Its cool to spool, but I'd rather be blown.." - JUS_GT_EYEZ

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    24. Member al@absolute's Avatar
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      05-03-2007 03:41 PM #22
      very good job on the bumpers!
      14 Mustang GT | 87 Buick Grand National | 37 Plymouth Coupe | 13 Focus 5door | 13 F250 XLT 6.7

    25. Member JonnyPhenomenon's Avatar
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      05-03-2007 03:55 PM #23
      Hey Ginster, trust me man, your project was an inspiration to kick me in the behind and get me going. (Mr Lees too!)
      I was determined to see my car painted in time for the summer, and wouldnt you know it, its gonna happen
      My father had primed the car yesterday and it needed to set up overnight to be sanded today. he uses a high build primer and layed it on really thick in a few areas where it needed it.
      I showed up at 5pm and took the late shift. I stayed up till 1am sanding out all the door jams, pulling out the dash and other interior bits so I could run a new antenna wire. and effectively destroying my headliner in the proccess
      (anyone know where I can get a new liner? I might just make one.)
      we made mad progress today I tell ya. Got up at 5:30am, had a cup of coffeee and went straight to work.
      I sanded all the bumpers , side skirts, mirrors and other loose bits. my father did all the delicate sanding on the rest of the car.
      by noon we had the car completely sanded and ready for paint. My father said this was the fastest hes done a car in years. LOL.
      unfortunately, I wont be able to be there for the painting proccess. I have to work from 8am to midnight tomorrow and I will miss it. on the bright side tho, I will also miss all the masking, wet sanding, masking, wet sanding, masking, wet sanding and buffing that will happen between layers of paint and clear [IMG]http://*****************.com/smile/emthup.gif[/IMG]

      sanding rrrreaaly friggin sucks.
      I have to work all weekend too, so by monday the car should be read for me to get up there and put it all back together. hopefully by then worldimpex will have delivered all my parts. they can be really slow.
      if the car is painted by tomorrow, he is going to send me a picture. rest assured, I will be posting it

    26. Member ginster86roc's Avatar
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      05-03-2007 04:00 PM #24
      go go goooo johnnie go!
      +1 on the sanding sucks comment....and lucky you, gettin' to miss out on all that.
      bet you feel real bad 'bout that too.
      i good vibes... and sciroccos.
      Quote Originally Posted by sciroccojim
      Yes. Follow the adjustment procedure in the Bentley. Works like "magic."

      Quote Originally Posted by punchbug
      That's just how we roll.

    27. Member JonnyPhenomenon's Avatar
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      05-03-2007 04:02 PM #25
      Quote, originally posted by 53BGTX &raquo;
      I agree.
      Are you going to paint Red again?

      hell yes.
      700$ worth of tornado red, clear, sealer, primer and reducer.

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