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vw cabriolet fixer upper

27K views 156 replies 21 participants last post by  MK1_74 
#1 ·
Hi Everyone,

Brought my self a 85 cabriolet locally in Washington, brought from family from new and only had 2 family members drive it. low miles, LHD, runs and drives, has AC and power steering but needs some love and few things are not working, but who wants to buy a perfect mk1 anyhow! :laugh:

Plan is to get it running and working 100% and then I will focus on body work, interior and suspension, wheels and other areas I am thinking about upgrading.

Biggest issue to focus on straight away is a good clean inside and out, its seen better days!

Will do some research on best places to buy parts for this cab, but where do most people buy their parts for general servicing of engine parts - oil filters, air filters, spark plugs, leads, timing belt, other belts? Local auto parts or online companies?

Here is car!





Hopefully should be fun project and I hope to share my experience, what I learn, how I fix things and overall get to meet some like minded people who enjoy mk1s as I hope I do!

Thanks Si
 
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#38 ·
Finally with some dry weather I reinstalled ground units again and cleaned up the ground cables and plugged all back in. Also added the one fixed relay and new relay.



Relays


and all installed :)


I did a few things to the cluster. I add electrical tape on both sides of the plastic parts where the cluster electrical plugs go, this makes sure the connectors actually have a firm connection. I found that when I moved the cables connected to the cluster the cluster functions would stop and start.

Cluster in and now the lights in cluster are actually working. This I think was two fold. Ground issues and the cables connectors not having firm connections. Happy now.


also all the other dash lights are now working too :) all except one center console dial :( will need to order new light for that one.





On the wheel front, had to make sure I had the right bolt setup to order my adapters - confirmed 5 x 112. Ordered 4x100 to 5x112. Due to wheels are ET35 been thinking I might do conversion to 5x112 would give me more options for future too.


and could not stop myself to see roughly what they looked like. I think once the car is lowered on coilovers and adapters installed the wheels are going to fill that wheel arch nicely.


Happy Friday everyone!
 
#39 ·
ok checking brakes and suspension setup today in preparing for coilover installation. Need to order new front rotors and pads and full brake flush and fuilds, lower arms going to replace too, overall what I thought.

Starting to clean wheel arch areas to see what it would look like under all the that crap and looks to be nice clean paint so good news.

Then I noticed something I've not seen on any of my previous mk1's - the wheels bolts are not bolts but nuts with threads. Is this normal for US spec Cabs? Asking to see if I need to change this, I might just as well look at 5x112 setup instead all around as adapters for threads from 4x100 to 5x112 is going to be 1" min and that will push wheels too far out :(

Appreciate other cab owners insight.

 
#40 ·
well after further investigation looks like someone added threads to front and rear (bolts on the rear drums :( but both front rotor, pads and rear drums and pads are shot so I am replacing them all and will take out the front threads, this will allow me to go OEM setup but get the adapters for the wheels I want.

I also had the lovely job of getting the ash tray out of the lower dash as the light and unit was not functioning. The actual light unit itself was a pain to get apart to separate from ash tray unit itself without braking ash tray unit. Ordered a new light unit that can be used as power adapter as well from later VW model. :) near perfect in spec and cheap. Still needed to take apart the light bulb so can replace that too with LED version.



Also took apart light bulb unit for one of the center dials to replace it and the other two with LEDs.

 
#41 · (Edited)
Finally the day when I get to see all the interior lights working and with upgraded LEDs too!

Got new lighter unit in which now will allow me to charge my mobile and other stuff - this is from a later VW model - near perfect match. Just have to adjust the connector on the loom


Install into the unit






Testing out the light


Moved onto the start of replacing all dash bulbs to LEDs - I will show few of them below, most are the same way I did them. Got this down to less than 4 minutes a unit to complete.

Each unit at the top of the pins where meets the bulb, there is little piece of metal push down - this hold the pins inside the bulb unit. you push these up, with tiny flat screwdriver from the ends and same time push pin upwards - this will allow you to remove bulb and pins from unit. Do this part slowly


Give you idea of bad bulb, new OEM bulb and LED bulb


some other units doing at the same time


I usually do all my soldering using my multiple clamps but for the life of me I cannot find them :( so had to revert back to old ways of taping bulb down and using pliers to hold pins while using soldering unit. Worked out very well actually.

Then moved on to preparing LED light and then soldered first pin on (I will always get soldered on and then afterwards clean up weld to make flat)


Both pins soldered welded on


Key to now test bulb (I always test each new bulb before trying to install as well)


Now time to install into unit. Key you do this part gently to start, you need to make sure each pin goes down into the bulb unit slows of each side and then using small screw driver you can push down on top of pins to get it down 30% into unit as you can see below.


To get bulb and pins to sit completely in unit as below, I use two ways. 1. Keep pushing top of pins down with screwdriver until the bulb gets in the way, this then allows the pins to show on each side of unit and I then use a pointed screws driver to put into the pin hole and pull pins down - works really well.


Time to test again to make sure LED is ok and working


Now I just repeat this process again to all the interior lights...

This is the unit I used with some electrical wires to test out the bulbs


I tested out one or two of the LEDs in the car.

Compare OEM to LED


LED is on the left the other two are OEM - but both will be replaced to LED.


Then replaced the light switch bulb to LED and can also see much better now the dashboard with LEDs


What dash looks like at night...


Well I for one am happy now I have all the wiring working and lights as I want it, just got to finish up 2 more units to LEDs and then we can put the dashboard all back together.

Another set of jobs done today.

Hope you all are getting your VW fix of fixing or installing new parts.
 
#50 ·
Then moved on to preparing LED light and then soldered first pin on (I will always get soldered on and then afterwards clean up weld to make flat)


Both pins soldered welded on


Key to now test bulb (I always test each new bulb before trying to install as well)
Looks good. Nice work on the LED upgrade. Where did you purchase yours from?
I did the same, and the LEDs were of terrible quality (I used superbrightleds)...now I am having to redo them.
 
#43 ·
Been working on my other mk1 white cab the last month getting it ready to sell... this one is automatic.

Just finished up full service and clean, fixed battery cables, new water pump, alternator, in-tank fuel pump, painted the wheel arches and now just waiting on side trim to turn up and this cab is complete and will be sold. Really is a great car but I just cannot keep two cabs.



I took off the wheel arches and was amazed to find not a single bit of rust underneath anywhere = result :) I was very happy to discover this - I hate rust and its always a concern us Mk1 owners worry about.


Updates on the other cab will be coming soon - waiting on few new parts to arrive and then a lot of work will be happening.
 
#45 ·
Well I have been collecting loads of parts for the car, in short over next month I will be taking out suspension and all four corners setup and replacing everything. This will then leave me with focus on improvements to the engine, then interior and last paint job. Actually thinking more about it I really need to do that in the other direction..

In short I want to get the car completely repainted, short out interior and then all running gear.

The most exciting part turned up - big thank you to KW suspension. Will be working with them more for my other build soon too. Quality of this suspension is very high.



Also 4-1 downpipe/header turned up, I have some work to do to this so it has a flexi part. More to come on that later.



Did two pieces of work recently

1. Upgraded stereo and put in a aerial booster





2. Fixed the drivers door top trim

Lucky I save stuff over the years so pulled out of my own stock





I then used 3M heavy duty weatherstrip - boy this stuff works great and gives you about 5 minutes before starts to go off.

You apply 3M to the back of the trim, make sure you have good amount at bottom ends (not too much that it goes everywhere) and using clamps hold it in place and let try for few hours.



Working on clearing out my garage at weekend, need to do some work on my MGA and then I can get some more photos of all the parts I have (currently in loads of boxes)
 
#46 ·
Well I know this is way overdue, but sometimes family stuff just gets in the way of projects :lol:

So in short, I have the interior fully out and working myself on new covers for the front and rear seats. I have everything now to completely take apart front and rear wheel areas and add new parts.

I also have most parts for engine refresh and service, but need to this winter really get the car stripped down more to fix some areas and get it repainted while I have interior out and all the old parts still on it.

Will get some photos up in coming weeks.

I am interested in hearing from any of our VW racing car owners on some questions I have relating to racing in Europe in mk1. Feel free to PM me, I will properly start up thread on this area too.

thanks Si
 
#51 ·
No I helped on them, but had someone else do sewing as I'm just not good enough at it, trust me I've tried a few times but I want them perfect.

Looks good. Nice work on the LED upgrade. Where did you purchase yours from?
I did the same, and the LEDs were of terrible quality (I used superbrightleds)...now I am having to redo them.
Actually I got mine from them too, but some of mine are few years old and some new. I didn't have any issues with mine. What ones did you order?
 
#52 ·
added the BBS wheels to cab to figure out how much I can lower the cab and figure out metal required to be notched out. Really like these wheels. my originals will go up for sale, if interested PM or look on C-list.

Before


during


after!


Nice part is the wheels fit nice inside the arches so the drop can be really good. Some work to do on inside arches and front notch for the drive shaft clear metal ;)

All covered up again!




Original ones, will clean them tomorrow and then up for sale....
 
#53 ·
last month I have been working on the interior. Took out the complete front and rear seats, door cards for complete overall.

Taking everything out was easy, don't think anything has ever been taken out before, everything is solid, just covers of seats worn out and cards need refresh.

Door damp covers still working and foam at bottom still there!


Rear speakers still work... will be upgraded later


Trying out the mk2 recaro seat base, make sure it works (had to do some slight welding on them)


with everything out, time to strip down seats - so can use material for pattern to make new interior.


All part (forgot to take pics of front seats)


Well after copying the current cloth and many many hours of helping someone managed to have complete front and rear seats redone in leather with red


and little insight to front recaro seats


Next up is work on redoing the four cards and then I will install everything and show end results. lots to do, but having fun doing it :)
 
#59 ·
more goodies turned up - European mk1 bumpers


4 screws soaked for few days with WD-40 and out comes the metal structure of bumpers. I don't think these screws have been undone since production line 30 years ago.




Both metal parts of bumpers is now off to be powder coated. Areas in white on metal part of bumpers is rust treatment as I wanted to see how bad surface rust was.

the plastic part of the bumpers are in outstanding condition, just need a good clean and restore to bring black plastic back to its former glory.

waiting on few parts to arrive to complete my interior.
 
#61 ·



I just was looking through your thread and noticed that the coils have the smaller spring section on the top. The ones I ordered (different brand) has the smaller section on the bottom.

Do you think that matters? (hoping not)

Seats look great.

I'm getting to the point on my cabby where carpet and seats will probably be the next thing to do as I am running out of things to fix (finally)



Mine is an auto. My last cabby was a 5spd with the close ratio.. As much as it was fun to shift this little auto is pretty nice. I have been reading that a manual valve body can be purchased for it too and that the autos can take up to 250hp+ it starting to make me think a little about future engine mods or swap options
 
#62 ·
Have a look at this photo of when I did a suspension upgrade on a mk1 cabby I did years ago - its shows the standard setup and upgraded coils to show individual parts, this is the same as you see in photo of my suspension. Various models due to spring size might have bigger or smaller sections. Remember each suspension is designed for those springs sizes and might be for your make.

Yeah Auto gearbox can take 250BHP as max, been done many times by many people. The only down size is the gearing is crap.

 
#63 · (Edited)
Actually finished up my European bumpers refurb.

Taking mk1 bumpers apart is easy and painful.

1. Painful - front bumper
2. Easy - rear bumper.

Here is why;
Each bumper front and rear have a outer and inside part, primary outer is plastic part you see and inside is metal structure.

Painful: The front bumpers are plastic pressure welded from factory to hold the plastic outer to metal structure inside which is used to bolt to your VW.
There is no easy way of getting the plastic and metal apart for the front bumper other than drilling plastic out and then its a pain to try and reproduce the OEM method. So of course when I tried it I tried the lets see if I can pry out the plastic, it worked for 1 of 4 areas of plastic weld. The other 3 broke and so now I had to come up with another solution. My idea was to use plastic weld make up mold, but I don't think I could get the pressure to hold the bumper in place, so I went with the bolt, washer and nut solution and I have to say it worked very well. I used a high pressure plastic weld to hold them into the existing holds and let set for 48 hours. Bumpers have been on the car week now and I've tested them out and solution for front bumper is working. I will keep on eye on this and report on this in 6 months and year to see how it holds up over time.

Easy - The rear bumpers are great and easy as there is only 4 screws you undo and the outer and inside parts come apart lovely!

I ended up having metal parts restored properly and powder coated and then got all new bolts, washers and screws.

If you want to see more in-depth video of process view here:

Before
https://flic.kr/p/2iTDCanhttps://www.flickr.com/photos/187933084@N08/

https://flic.kr/p/2iTzgGxhttps://www.flickr.com/photos/187933084@N08/

After
https://flic.kr/p/2iTDBr8https://www.flickr.com/photos/187933084@N08/

https://flic.kr/p/2iTzgeihttps://www.flickr.com/photos/187933084@N08/

Next update is on Part 2 of interior and some additional exterior changes. You might notice one change already in the after photos.... hint hint arches...

Fun facts of doing this job: Best tool I used during this time was my hammer :lol: can you guess what for?
 
#64 ·
More progress on interior refurb

Completed the front door cards.

Before:


Cleaned up and painted them using vinyl paint - 4 thin coats is perfect finish


Installed. Just one screw plastic cover waiting on arrive.


Really like the finish with few items with chrome.


Moved onto Recaro seat rebuilds - these are taking far too long, but I want them perfect. I am recording every step to put into a video for others usage.


only one area that requires repair


The side bolsters are being replaced with new and base and back foam will have a layer of 1/2" added to them to bring the shape back to what OEM is. Foam over time will always flatten down.

The key on doing seats is getting the right foam and this doesn't seem to be documented well online, so I will add this into my video.



and why I am using new bolsters :eek:


and back base rust repaired and painted ready for usage. I am working on base unit as that is really rusty. I basically treat rust, metal prepare, prime and P15 it, so it never rusts again!



I also stripped my original seats down for parts as Recaro seats and cabriolet seat parts are nearly the same. I was planning to use part of foam to fix my Recaro seat, but they are in near perfect condition I will be selling foam from original seats as they are perfect. Look out for those in sell sections or Flebay




Hope everyone is enjoying your VW projects?
 
#69 · (Edited)
So I figured out how to remove the lovely plastic lever handles on Recaro seats. I know this works for mk1 and mk2 VW seats as well (tested it out) might work for mk3 and mk4 but would need to test that to validate.

Part: Seat Slider Handle part:171 881 253 (Plastic end piece)

If this part is warn out (most are) you can still get these online at various VW specialists or on fle---bay.

The challenge is how do you get the plastic lever off the metal rod without damaging both.

The part in question!


Solution:
The original knob is held on with a little metal clip inside. The clip helps it grip to the rod. It may take some pulling, but it should just pull off.

What I did was tape up the plastic lever and put foam around it, put it in a vise and pulled back and forth on the metal rod part and bingo, with few twists it comes off.

New part: you just push on the new part and you now have handle that looks new.
 
#71 ·
So managed to find time to focus on first Recaro seat;

Goal: 1. Check and fix foam. 2. Check and fix metal structure of seat. 3. install new seat covers

Overall Foam on Recaro seat was good except for few areas.
1. One upright back bolsters shot - require fixing with new foam
2. Base seat foam had split - required gluing
3. Base seat bolsters shot - bought new ones.
4. Head rest foam was perfect.

Overall I spent 2-3 hours working on below seat, mainly so I could take loads of photos for full write up I am doing and for video. Here is summary;

Before starting on fixing...


Cut bad foam out


I ordered high density foam, cut foam and glues three layers together. I use 3M 74 Foam glue.
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Start shaping the foam.. I use Carving knife - works perfect to cut foam.


Then moved onto using my air tool sander 1.5" diameter end.


Then using cheese greater for final shaping (this one is not taken from my kitchen... not sure cheese and foam go well?!)


To get to final shaping i made a template to check from one side to another.. for perfect finish - you go alone surface from back to front checking and take off foam where not needed. Also both sides are level in height too :thumbup:




Then moved onto cleaning up the Metal frame back, didn't take photos of this, but it had very little rust but I sanded and painted it anyhow.

Then installed the foam back to metal frame and added the backing on using 3M 74 Glue


Then installed the back new seat cover.


Then worked on back and base - I got into the zone for these and only did video for them, so here is the end result. No major repairs on foam, just install covers, put metal roads in and secure to foam and staple on the back


All the new covers, had a 1/2" foam on the inside, so the seats all have now a nice smooth extra feel to them.

I need to leave these out in the sun for few hours and then they are finished.

Next up new base bolsters and seat cover install and then add to main base and install in the car :D
 
#74 · (Edited)
more progress on the front seats. Second seat back section complete, even got my base metal back from being powder coated.
One area I am not happy with is the head rests, can see in photo below the new covers just don't fit well, so going to redo them.



So with new bolsters, you have to cut these to make it perfectly. Notice extra form on new ones at bottom, so cut these and so there is extra foam at the rear on the underneath, so cut this out too.



parts cut out of new bolster to make them perfect match to originals.


pulled the base foam together to make sure all fitted properly - very happy with results


Then install the new leather onto the new side bolsters and for about hour I am fighting to get them to fit nice and tight with zero luck, then I went and measure the new to original covers and bingo the new ones are 1" longer so I need to correct that and then retry installation again.



Well I have some work to do on head rests and side bolster covers and then I can complete the seats. Next update will be once I have these done and installed in the vw.


I also did some outside work on vw, I painted the side indicators to match the vw color. Interesting to note i found each corner was not even wired up!!
I also removed the arches and have new ones coming.
I also removed my front grill to change the color of chrome to Vw GTI red.
My european small ducklip turned up too, will install that this weekend and update once have grill done as well.

OEM side indicators;




Paint!


and painted...


and the end result on the car
]


and the front grill off! thinking should I upgrade my lights or not?


I did remove one other part from outside of the car to paint black, can you see what that is?

Here is my new european lip and compared to the GTI one. I prefer the European version - mainly due to when I put coilovers on I won't loss it!!



The GTI one will now become Art in my office!


and the car is all covered up again..
 
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