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    Thread: TinyGiant 1985 Cabriolet Build Thread

    1. Member
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      1985 Cabriolet
      02-24-2020 01:49 PM #1
      I was able to grab another cabby last july and start the process all over again... (I had a 1989 that I ran for 5-6 years and eventually sold)


      I have been keeping track of everything in notes on my phone.. time to dump the data here and let you all in enjoy. I will try to get the photos uploaded and placed in the text.


      1985 cabriolet expenditures



      Car $500.00

      Oil pan gasket $6.15

      Valve cover gasket $14.95

      Fuel pump relay $free

      Accessory belt $6.32

      Windshield seal $50.00

      Seat guides $3.68

      Heat paint vcd $6.99

      Paint & Supplies $50

      Trim clips $15

      Borbet type E wheels $150

      Rotor $6

      Distributor cap $14

      Fuel filter $14

      Rear reflector $28

      Heater switch $6

      New top $270

      Headliner $170

      Windshield $50

      Fabric for pad $17.00

      Alternator $89

      Vac tubing $4

      Oil filter $0

      Oil $0

      Air filter $32.99

      Steering belt $8

      Dipstick funnel $7

      Top bracket $35

      Duckbill $40

      Top strut $38

      Top seal supplies $19

      Top tensioner $63

      Battery $140

      Tape deck $0

      Hot pulse relay $12

      Clamp collar $2

      Cutting compound $25

      Reman starter $75

      Bumper end caps $65

      Ignition switch $11

      Lower ball joint $27

      Labor (for ball joint/exhaust)$110

      Power steering parts $40

      Ps line/fluid $35

      Ps install parts $10

      Battery hold down $6

      Trans to chassi ground cable $7

      Hazard switch $10

      Bumper hardware $50

      Install parts for Bumper $25

      Valve stem caps $9

      Bulbs for vdo $11

      Usb/ power port $12

      Install parts $19

      Rokkor Coilovers $260

      Exhaust Connector and Clamps $17

      New tires $244

      Junk yard finds $60

      Passenger hub $30

      Passenger wheel bearing, install and alignment $292

      Ball joint $22

      Door strikers $9

      Center caps $25

      Stereo $65

      Speakers/wire $60









      Purchase date: july 6th 2019






      Cleaned interior: July 6th








      Discovered a friends name written in the manual



      Valve cover gasket: 7/24/19
      Also Painted valve cover




      Removed windshield 7/26/19
      -discovered small rust hole on lower passenger channel.
      Fixed with “lab metal”






      Broke windshield trying seat new seal
      Painted : 7-28-19
      Rustoleum gloss black dtm




      8/1/19
      Three days of 1.5-2.5hrs of wet sanding. Up to 600 grit
      Fresh washing after last wet sand




      8/6/19 1000g and 2000g and an impatient scratch remover and polish on a spot to see how shiny it would be



      8/8/19 Purchased Borbet type E wheels
      [img]https://i.ibb.co/kJSGP8b/77-C9-BDCA-7-FD9-4-A54-801-A-C12524514000.jpg

      8/10
      Seat bolsters. Found free office chair with close enough colored fabric




      8/13/19
      Removed carpet to degrease and clean it.


      Discovered small hole in floor. Will patch with lab metal.




      While waiting for lab metal to return from lending it out i decided to paint the floor with rustoleum
      Before:


      After:


      8/14/19
      Filled spot with lab metal top and bottom, sprayed some of bottom with rubber coating.

      Installed clean carpet



      Patched passenger seat to cover weird melted plastic stain from who knows what...


      8/17/18
      Repaired and replaced grounds





      8/18/19
      Replaced cap, rotor and fuel filter




      Also did more wet sanding

      8/20/19
      Windshield installed. Also noticed wiper arm on driver side was stripped. Added a washer under the nut to give it more clamping force. Seemed to work.


      8/29/19
      Off with the old top. replacing headliner and fixing top pad. Bought burlap and underlining matierial to cover top pad.
      Also replaced heater switch... still no fan, will try relay or new blower




      8/30/19 Headliner finished.





      8/31
      Put on oil pan gasket. Omg worst time getting things lined up. Eventually used a floor jack to hold pan in place. Removed alternator, bought new mounting bolts. New power steering belt, installed alternator belt. Replaced vac line connection tubes, replaced air filter and did an oil change.




      When reinstalling the power steering pump i noticed half the bracket was missing and the power steering line will need to be replaced very soon.


      8/3/19
      Installed new alternator.


      Installed 3d printed charm from cuz bruce


      9/6/19 installed new dipstick funnel


      9/7/19 top installed, rear window put back in place. Waiting to finish right rear of top for lift support to arrive from ebay seller.


      9/10/19
      Installed lift struts for top


      9/12/19
      Tightened top near rear seals, tightened front of top to lay flat.
      Another two coats of paint. Painted until dark.



      9/13/19
      Another wet sanding



      9/15/19
      Repaired switch on heater fan. I think it was just plugged in in an
      incorrect orientation.


      Also installed chin spoiler


      9/15/19
      Registered ordered antique plates “mk1”



      9/16/19
      New battery installed. Car starts


      9/17
      Put strips back on with new clips.



      Also on 9/17
      Tape deck installed. Free from “Dover Bill” brand new in box saved since 1992 in his garage



      9/24/19
      Installed clamp collar to retin steering wheel bearing



      9/29
      Starter died.
      New plates arrived



      Worked on wet sanding and buffing hood.



      10/3/19
      Test fit custom bumpers. Had customer weld aluminum half strut to 1-1/2 aluminum tube stock removed oem bumpers. Drill and installed brackets and trim










      Rear bumper is perfect. I need to figure out how to get the front bumper tighter to the car

      10/6
      More wet sanding, tried hand waxing





      10/11/19
      Installed bumper endcaps, painted bumber and installed retainers and screws to hold everything together. Still want to bring the front bumper in a bit.







      10/24/19
      Car came back from shop. Installed a new ground from battery to transmission. They removed ground from chassis to battery. Need to add that. Starter was installed. Starts right up now.

      Powersteering has been squealing. Looked to see bracket is broken and missing all tensioner parts.





      Updated shots




      11/4 bought power steering line and fluid. New pump and tensioner parts arrived a couple days ago. Hopefully will get everything transfered over this week.

      11/05
      Added ground wire from tranny to chassis. Also added battery hold down kit

      11/7/19
      Friend helped me out with lift at his work to install the pump and he nh-oiled the whole underside.

      Pump has all new bolts, hoses and fluid.


      Notes-
      -spare tire well has a small rust spot.
      -Heat shield had been screwed directly into the fuel tank.
      -small fuel spot on fuel tank wet. Maybe replace fuel tank next season


      12/24 dropped off cabby at granite state glass because the windshield was leaking at both lower corners. They seemed to have fixed the issue by sealing the corners with a black sealant of some sort. Hopefully it does the trick. Not looking to ruin any more relays with water dripping on the fuse box.

      1/26 weekend
      Car stalled out the other day 1/4 mile from the house. Brought battery and alternator to advance auto to have it checked. After a couple trips it was discovered the alternator wasnt giving out a charge. Went to autozone to order a warranty replacement

      2/23/20
      Took the dash apart and installed t new voltage regulator on the cluster. Seemed to be working fine... then as the car sat it dropped out again. Restarted the car and it was working. Hopefully it stays working.


      2-23-20
      Finally replaced bulbs in vdo gauges. Also installed a usb/cig lighter jack with a lighted switch I didn’t want to add anything too modern, but I do want to be able to charge my phone if I am going on a longer trip in case I have to call for a tow.



      Also new problem...oil buzzer keeps going off. Need to make sure i didnt forget to plug something in. Going to try flipping the voltage stabilzer as it seems maybe i didnt need to flip it.

      2/25/20 flipped stabilzer. Problem solved. Noticed bar gauge light wasnt working need to check wiring or bulb

      2/26/20 found an old socket for the peanut bulb when installing my usb port and wired another light to plug into my heater faceplate. Also fixed the bar gauge bulb too. (It just unplugged)
      Last edited by tinygiant; 08-10-2020 at 10:39 PM.

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    3. Member
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      02-24-2020 01:59 PM #2
      Sadly, there are no pictures to enjoy.

    4. Member
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      02-24-2020 02:45 PM #3
      Quote Originally Posted by Butcher View Post
      Sadly, there are no pictures to enjoy.
      Pictures are coming.. had to upload 82 of them.. now the hassle of inserting them properly since the hosting site uploaded them in improper order...

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    6. Member
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      02-24-2020 03:12 PM #4
      pictures updated... gosh.. too much cutting and pasting in ibb to notepad to forum.. but its done!

    7. Member
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      02-25-2020 06:00 PM #5
      2/25/20 flipped stabilzer. Problem solved. Noticed bar gauge light wasnt working need to check wiring or bulb


    8. Member
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      02-26-2020 11:12 AM #6
      That is a lot of work.

      I'm always amazed on how much rust you guys get in the east.

    9. Member
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      02-26-2020 11:53 AM #7
      Quote Originally Posted by Butcher View Post
      That is a lot of work.

      I'm always amazed on how much rust you guys get in the east.


      Its getting worse too. Some towns have started using a brine truck instead of a standard salt spreader before storms. They drive around and spray salt water on the roads to combat early freezing. The downside is the water evaporates and creates a salt dust that sticks to everything... I had to have my wheels on my tiguan resealed a couple times last year because the salt would get into the bead and create pockets.. very annoying problem.

    10. Member
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      02-26-2020 05:56 PM #8
      2/26/20 found an old socket for the peanut bulb when installing my usb port and wired another light to plug into my heater faceplate. Also fixed the bar gauge bulb too. (It just unplugged)

    11. Member vwrabbit's Avatar
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      02-26-2020 10:40 PM #9
      Nice work and great documenting! I'm in the process of fixing up an 84.

      Sent from my VS996 using Tapatalk

    12. Member
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      02-27-2020 07:25 AM #10
      Anyone know How to tell if the cluster is original? My car is an automatic, but has a tach cluster. I also noticed that the screw mounting points were busted on one side.

    13. Senior Member briano1234's Avatar
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      02-27-2020 09:49 AM #11
      Automatics have a tach as well. So that is about normal.
      Busticated screw mounts is normal for one that has been worked on a time or two.
      You can use Automotive trim screws with the fancy washer to hold it in, or epoxy metal tab over it.

    14. Member
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      02-28-2020 05:47 PM #12
      Quote Originally Posted by briano1234 View Post
      Automatics have a tach as well. So that is about normal.
      Busticated screw mounts is normal for one that has been worked on a time or two.
      You can use Automotive trim screws with the fancy washer to hold it in, or epoxy metal tab over it.
      Thanks for the info. Screw with a washer help up enough 🙂

    15. Member
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      03-06-2020 10:25 AM #13
      I'm having some cold starting issues..

      starting is labored and slow. like rrrr pause rrr pause rrrr and it

      If I hold pedal down sometimes it will start easier.


      This morning was in the 30s and it wouldnt start.



      If its warmer out it will start easier.

      I've replaced the starter, grounds/cables, ignition switch, ignition module. battery and alternator, rotor and cap, and cables were done recently too



      how badly would timing effect the starting of the car? I haven't checked the timing yet.

    16. Member
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      03-06-2020 10:39 AM #14
      Yes, ignition timing certainly could cause starting issues.

      I certainly would recommend starting on a firm foundation before you start just throwing parts at it. I understand it's an older car and most of those parts are on their way out. You certainly want to have enough money when you finally find the root cause of your problem.

    17. Member
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      03-06-2020 10:47 AM #15
      Ill time it tonight and see what happens 🙂

    18. Member
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      03-07-2020 09:33 AM #16
      Quote Originally Posted by tinygiant View Post
      Ill time it tonight and see what happens 🙂

      Well didnt make time for that nor did i realize aligning the flywheel would be different on the automatic. On my last 5spd i would just put the car in gear and keep nudging the car until the flywheel got where i wanted it.


      I did have another thought. All of my starting woes have been in the cold. When i did my oil change in the summer i used 20w50.

      Do you think in the 20-30F weather the oil may be too thick and giving the starter too much physical resistance when trying to start?

    19. Member
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      03-07-2020 11:18 AM #17
      Quote Originally Posted by tinygiant View Post
      Do you think in the 20-30F weather the oil may be too thick and giving the starter too much physical resistance when trying to start?
      No.

      How's the starter bushing in the bell housing? It may be too late, but you should have purchased the Mk4 diesel starter.

    20. Member
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      03-07-2020 11:55 AM #18
      Quote Originally Posted by Butcher View Post
      Quote Originally Posted by tinygiant View Post
      Do you think in the 20-30F weather the oil may be too thick and giving the starter too much physical resistance when trying to start?
      No.

      How's the starter bushing in the bell housing? It may be too late, but you should have purchased the Mk4 diesel starter.

      The bushing was fine and the starter is new. It was this morning (near 40F) and the car started right up...

      And maybe if this starter cooks ill look into getting a beefier starter

    21. Senior Member briano1234's Avatar
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      03-07-2020 11:59 AM #19
      Quote Originally Posted by tinygiant View Post
      Well didnt make time for that nor did i realize aligning the flywheel would be different on the automatic. On my last 5spd i would just put the car in gear and keep nudging the car until the flywheel got where i wanted it.


      I did have another thought. All of my starting woes have been in the cold. When i did my oil change in the summer i used 20w50.

      Do you think in the 20-30F weather the oil may be too thick and giving the starter too much physical resistance when trying to start?
      I have been using the 20-50w for years and it won't effect the starting of the beastie.

      To set an automatic you rotate the engine to move the timing plate on the transmission to the 0TDC slash.


      Both types of flex plates and the 0tdc marks, align with the finger on the big hole.
      When the mark is at 0, your dot on the back side of the Cam gear will be even to the top of the Valve cover tin, not the rebar.
      Remove the diz cap, rotor, and shield and then replace the rotor, it should be in the middle of the hash mark, if not loosen the diz and move the diz so that you are in the middle of the has.

      Remove the rotor, replace the shield, rotor, and cap. Your car should start. When the Car is warmed up and the Fan Cycles on the radiator, Using a tiing light set the timing to about 6BTDC and your RPM should be @ 800-950.

      http://www.cabby-info.com/ignition.htm . no pictures of the Auto tranny....

    22. Member
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      03-07-2020 12:03 PM #20
      When it warms up and i decide to tackle to timing i will take some picture and post them. You are more than welcome to use whatever i post on cabby info 🙂

    23. Member
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      03-08-2020 01:19 PM #21
      Warmer today. Painted calipers and drums. (Dont hate on painting drums lol)

      Ordered rokkor coils the other day. Had them on my last cabby and had no complaints. They should be here mid week






      Discovered i was missing a center cap too 😞


      Last edited by tinygiant; 03-08-2020 at 01:22 PM.

    24. Member vwrabbit's Avatar
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      03-09-2020 06:10 PM #22
      I found VW center caps that fit Borbet wheels. Makes them look sightly factory. Looks good so far!

      Sent from my VS996 using Tapatalk

    25. Member
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      03-10-2020 07:14 PM #23
      Well a few things.

      My tach/fuel/water temp all dropped out. On the way home they all came back. I have a feeling mk1 electronics are more faith based than any thing....

      Secondly on the way to work today i got a hard wobble on a couple wheels. Guess i forgot to re-torque my lugs after driving a few miles. No harm done.

      Thirdly in the on and off of my wonky cluster behavior i had a blinking water temp light related to nothing. It would just blink on engine start and keep going. It caused me to check the bay just to look arpund and i noticed my water pump belt could have used a little snugging up. So thats nice and back to where it should be.

      Lastly powering up a hill on the way to work my exhaust decided to let go between what should be a flex pipe, flange and mid pipe and i discovered was really just a pipe clamped into another pipe clamped and welded into more pipes that eventually stopped at the end of the car. So saving for a new exhaust. For now i was able to zip in a self drilling screw at work to hold the two pipes together to get home.

      Suggestions on exhaust options? Should i completely replace everything from headers to tail or just go from the down pipe to tail?

      Are there real advantages to a 4-2-1 header?

      https://rover.ebay.com/rover/0/0/0?m...2F272845618265


      Thanks for any input. Ive done plenty of bolt on exhaust stuff but have never done a header. Is it terrible on the 8v?

    26. Member
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      03-11-2020 07:56 PM #24
      What is that metal bushing called inside the strut tower bushing between the strut shaft and the top hat?

      My pass side is missing. Anyone have one?


      Got my front coils in. Going to have to redo the pass side when i get that little bushing thing



    27. Senior Member briano1234's Avatar
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      03-11-2020 09:01 PM #25
      Spacer sleeve, 133412365

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