MK1 Golf - Project

[Drysponge]

Ok, It’s been I while but I’ve managed to get a bit done on the Golf with what limited time I have now that I have 2 children.

Thanks to Roccodingo – Grant, for the Scuttle panel and rear window sections . I’ve now completed the scuttle replacement and RHS rear window section, only the LHS remaining.

Here’s a couple of photos of the progress.

The rust has gone through the outer and into the inner panel



Scuttle panel off



All rust removed from inner section ready for replacement from donor panel, painted in POR 15



Donor section ready to be welded in



Donor sections welded in





Area under the scuttle requires repair, managed to purchase a repair panel from the UK and locally cut out whats needed







Sealed up and painted in Epoxy and weld through primer where the scuttle will be re-attached/welded





Now onto the scuttle

[Drysponge]

All done, I kept the hood on as a good datum check for flushness and gap.







Now onto the rear window repair

Donor panel marked up for trimming



All rust cut out, any surface rust remaining was cleaned up as much as possible and treated before epoxy paint







New section tacked in









I had to fabricate this small section, turned out ok.





Before



After

[Drysponge]

Next challenge was to replace the roof to a tin top.

Thanks to Ben for chopping off the upper portion off his 5dr Golf and shipping from Sydney to Melbourne. His car was advertised on here for parts prior to scrapping. This was his car prior to becoming a convertible.



The roof arrived and I thought this was as good as any place to store it safe away from little feet.



Next job was to unpick the outer skin off the internal sections. This was a painstaking task. When I was taking this photo my 4 year old son asked if he can stand on it! You’ve never seen move so fast



Roof skin is back in a safe place



I braced the just in case there is any movement when the old roof skin comes off. I don’t think this is really necessary though and there’s plenty of support within the inner roof structure



Old roof off



The whole area was then cleaned, any surface rust was removed as much as possible. Any remain surface corrosion was treated prior to epoxy

[Drysponge]

Whoever butchered a hole in the old sunroof had also damaged the area that houses the interior lamp, luckily I was able to replace this section from the donor car. The pictures show before and after. It’s now fully welded with welds ground smooth.









Now the new roof skin can go on



New roof skin in place, I made a simple tool to ensure the mating flanges are flat to each other prior to tacking in place, seemed to work quite well.



I put the tailgate back on to ensure all the gaps – flushness were ok before welding in place.



The roofs on, just need to weld the outer return flange back on and clean up.



I was hoping to have made a neater job of welding this flange back on but I’m sure a little filler will finish it off.