Project Poppy - 1987 MkII GT ... ***REWIND***

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Cpt Custom
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Posts: 117
Joined: Sat Apr 30, 2011 9:14 pm
I drive a: Mk2 1.6 Carb
Location: Northallerton

Project Poppy - 1987 MkII GT ... ***REWIND***

Post by Cpt Custom » Mon Apr 22, 2013 6:18 pm

Those of you who know me, will be well aware that Lily was not the first Scirocco I’ve owned. :arrow:

That was another GT - a red one, which we called Poppy and one which was intended a couple of years back to be the subject of a major restoration.

Back then I started a project thread on it elsewhere, but for some reason unlike many of you out there I never got around to copying it across to SUK.
Then last week while sorting through some old files on my computer I came across a copy of the entire thread from start to finish and thought I’d post it up, minus the comments people made along the way.

Why after all this time? Well, first and foremost, I thought it would be useful to have a copy of it on SUK. However, I also thought that some of the work undertaken and the problems we encountered along the way might be of interest to anyone who has been bitten by the Scirocco bug since Project Poppy.

So, if you’ve not seen the thread before then sit back, put your feet up and read on … but be warned it doesn’t have a happy ending. :cry:
Last edited by Cpt Custom on Mon Apr 22, 2013 8:42 pm, edited 6 times in total.
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1987 D reg Mk2 Scirocco Tornado Red GT 1.6 8v
1987 E reg Mk2 Scirocco Alpine White GT 1.6 8v

Cpt Custom
Scirocco UK Regular
Scirocco UK Regular
Posts: 117
Joined: Sat Apr 30, 2011 9:14 pm
I drive a: Mk2 1.6 Carb
Location: Northallerton

POST 1 - Wed Jul 28, 2010

Post by Cpt Custom » Mon Apr 22, 2013 6:19 pm

So, let me introduce you all to 'Poppy'. :arrow:

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Poppy is a much-loved 1987 D Reg 1.6 Volkswagen Scirocco GT who sadly has seen better days. We bought her way back in 1992 when she had less than 50,000 miles on the clock. We have now owned her for nearly 18 years and only put her into storage in 2004 when we could no longer afford to run two cars.

At that time she was taxed and had a valid MOT, but now she has a SORN in place. Our intention was always to have her restored, but I'm afraid that having had her assessed recently by our local independent VW specialist (ADP in Starbeck) and with a limited budget available to us we had begun to think that for us at least restoring her wasn’t viable.

I say that because despite having been a car fanatic for many years, I’ve never gained any mechanical skills. I am a total novice and so to restore her properly I would need to get much of the work done professionally. And given that with any such project labour forms such a large part of it I thought I was finally going to have to let her go.

However, despite putting her onto eBay to try and find her a new home, we have not been able to bring ourselves to part with her. Instead, we’ve decided to keep her and I’m going to sell my 2009 Mazda 3 Sport, which is the only car I’ve had from new, to finance Poppy’s rebuild/restoration. After we’ve cleared off the outstanding finance the intention is that what’s left will be for the 'Poppy Fund'.

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My relatives all think I’m totally mad, which is always possible, but I’m hoping to find some kindred spirits within this site that might even be able to help me deal with what lies ahead.

Externally the body is generally in reasonable condition though the paintwork is scratched and the bonnet needs replacing. The GT body kit is undamaged, but needs some restorative work doing to bring it back up. Internally, she is also still in reasonable condition for a 23 year-old car with almost 200,000 miles on the clock.

Her main problems lie underneath where much work will be required. Initial inspection by ADP suggests that she’ll need: 2 front springs; welding to the back suspension; fuel lines; lower suspension arms; welding to the offside rear inner wheel arch; and the clutch appears to be on its way out. In addition, she would need servicing and possibly a new cambelt fitting. All that before I even consider what I’d like to alter or update.

So, she is indeed a poorly old girl, but like I've said we are serious about getting her back on the road. We want to do her properly and the intention is that she’ll become my daily driver as she was throughout the late Eighties and Nineties. To achieve that I’m thinking we need to:

• Make her sound: by getting all the crap and rust cut away underneath and any necessary panels repaired and/or replaced so as to provide a sound platform upon which to justify spending more money.
• Make her safe: by getting all the mechanical faults identified in the pre-MOT check sorted.
• Make her reliable: by getting the engine and running gear looked at - not sure yet whether to just patch up the engine as is or look at a rebuild.
• Make her pretty: by sorting out the bodywork, replacing the bonnet etc and getting her re-sprayed.
• Make her comfortable: by sorting out the interior - new seats etc.

Having said all that, this will be our first ever restoration project so progress may be slow. In which case please be kind with your comments - I’ll need all the encouragement I can get.

By the way, if you want to see what Poppy looked like in her prime and more importantly what she’s like now, please check out the following sets over on Flickr:

How she used to be

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How she is now

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:wave:
Last edited by Cpt Custom on Mon Apr 22, 2013 6:38 pm, edited 1 time in total.
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1987 D reg Mk2 Scirocco Tornado Red GT 1.6 8v
1987 E reg Mk2 Scirocco Alpine White GT 1.6 8v

Cpt Custom
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Posts: 117
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I drive a: Mk2 1.6 Carb
Location: Northallerton

POST 2 - Mon Aug 02, 2010

Post by Cpt Custom » Mon Apr 22, 2013 6:19 pm

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Pleased to report that I’ve taken a few small steps forward over the last few days. Firstly, after much deliberation, I’ve decided on what to do about the front brakes. I’m going to upgrade them to 256mm discs. I really fancied going for 280mm G60s, but apart from the looks I couldn’t come up with any sound arguments for going down that route. It might be different if I was planning to drop in a much bigger engine, but I reckon 256mm will be more than adequate for the stock 1.6. In fact, even if I drop in a 1.8 or 2.0 lump I think the 256mm discs will suffice.

One small concession to looks might be to change the back drums to discs. That’s if I can pick up a back axle from a Mk2 Golf GTi.

I’ve also managed to pick up a few replacement panels, all of which are better than what I have at the moment …

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In addition to the above panels, I’ve also bought a replacement bonnet and a set of Hockenheim wheels. Unfortunately, they wouldn’t all fit into the wife’s Fiesta so I need to pop back down in a few days time to pick them up. This time I’ve got a van organised so getting them home shouldn’t be a problem.

The wheels have got a few knocks, but as I’m not sure the original steels will get though an MOT I thought they were worth buying. It means that once she gets her ticket I can run her on those without immediately needing to dash out and buy new wheels. They’re kind of a stop gap and as such will do nicely.

:wave:
Last edited by Cpt Custom on Mon Apr 22, 2013 6:40 pm, edited 1 time in total.
Image
1987 D reg Mk2 Scirocco Tornado Red GT 1.6 8v
1987 E reg Mk2 Scirocco Alpine White GT 1.6 8v

Cpt Custom
Scirocco UK Regular
Scirocco UK Regular
Posts: 117
Joined: Sat Apr 30, 2011 9:14 pm
I drive a: Mk2 1.6 Carb
Location: Northallerton

POST 3 - Mon Aug 02, 2010

Post by Cpt Custom » Mon Apr 22, 2013 6:20 pm

Forgot to mention the braided hoses. Even if I was sticking with the 256mm I would have gone vented with hoses. As for where I'm sourcing the bits, I've been scouring the net looking for the best prices as I want to put on EBC Ultimax on the front. Will post details once I have everything sourced.

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:wave:
Last edited by Cpt Custom on Mon Apr 22, 2013 7:25 pm, edited 1 time in total.
Image
1987 D reg Mk2 Scirocco Tornado Red GT 1.6 8v
1987 E reg Mk2 Scirocco Alpine White GT 1.6 8v

Cpt Custom
Scirocco UK Regular
Scirocco UK Regular
Posts: 117
Joined: Sat Apr 30, 2011 9:14 pm
I drive a: Mk2 1.6 Carb
Location: Northallerton

POST 4 - Wed Aug 11, 2010

Post by Cpt Custom » Mon Apr 22, 2013 6:20 pm

Just a quick update as I start to gather some of the parts I need to progress with the work on Poppy. :arrow:

A few days ago I got a loan of a van so I could go back down to Leicester to get the ‘new’ bonnet. Picked it up along with a set of 15” Hockenheim wheels wrapped in 195/50 rubber.

The bonnet, like the wings and doors I got the week before, is already prepped somewhat and in white primer. Compared to what’s on Poppy at the moment it’s like new - I love it!

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Gave the Hockenheims a clean today and really happy with how they’re looking. They’re not perfect, a little worse for the wear inside and kerbed somewhat on the front. However, they’re better and bigger than what she’s wearing right now so that’s a start until I get something better sorted.

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Even better today, I took delivery today of a set of shiny Girling 54 calipers and matching carriers from Brakes International.

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Still waiting on the discs and pads coming from DC Performance and then I have everything for upgrading to 256mm discs up front.

At the back I’m getting rid of the drums and going for discs there too. Picked up a rear brake conversion from a Mk2 Golf on eBay at the weekend, which should also arrive soon.

:wave:
Last edited by Cpt Custom on Mon Apr 22, 2013 7:26 pm, edited 1 time in total.
Image
1987 D reg Mk2 Scirocco Tornado Red GT 1.6 8v
1987 E reg Mk2 Scirocco Alpine White GT 1.6 8v

Cpt Custom
Scirocco UK Regular
Scirocco UK Regular
Posts: 117
Joined: Sat Apr 30, 2011 9:14 pm
I drive a: Mk2 1.6 Carb
Location: Northallerton

POST 5 - Thu Aug 12, 2010

Post by Cpt Custom » Mon Apr 22, 2013 6:21 pm

More goodies arrived today. This time the Ultimax discs and the Green Stuff pads. :thumbup:

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Interestingly, though I ordered online from DC Performance the boxes show Euro Car Parts.

:?
Last edited by Cpt Custom on Mon Apr 22, 2013 7:27 pm, edited 1 time in total.
Image
1987 D reg Mk2 Scirocco Tornado Red GT 1.6 8v
1987 E reg Mk2 Scirocco Alpine White GT 1.6 8v

Cpt Custom
Scirocco UK Regular
Scirocco UK Regular
Posts: 117
Joined: Sat Apr 30, 2011 9:14 pm
I drive a: Mk2 1.6 Carb
Location: Northallerton

POST 6 - Fri Aug 20, 2010

Post by Cpt Custom » Mon Apr 22, 2013 6:21 pm

Just got these too ...

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I did wonder initially if I’d got the right ones even though it says Golf GTi Mk 1 / Scirocco Rear Disc on the packaging. Happily, since then Mazellan has confirmed that these are indeed the brake lines required for the rear disc conversion and you can still use 4 of them if you retain the drums!

:eh:
Last edited by Cpt Custom on Mon Apr 22, 2013 7:27 pm, edited 1 time in total.
Image
1987 D reg Mk2 Scirocco Tornado Red GT 1.6 8v
1987 E reg Mk2 Scirocco Alpine White GT 1.6 8v

Cpt Custom
Scirocco UK Regular
Scirocco UK Regular
Posts: 117
Joined: Sat Apr 30, 2011 9:14 pm
I drive a: Mk2 1.6 Carb
Location: Northallerton

POST 7 - Sun Aug 22, 2010

Post by Cpt Custom » Mon Apr 22, 2013 6:21 pm

Okay folks, a quick update on where I’m at with Poppy and what my thoughts are on taking her forward.

She’s now been in for a pre-MOT check. Stuck her in for this not so much because we think she’ll be back on the road soon, but to help ascertain the extent of what needs to be done just to make her safe and legal.

The main things she failed on are …

Nearside front Coil spring fractured; Offside front Coil spring fractured; Nearside rear Coil spring fractured; Both front Suspension arms corroded and seriously weakened; Offside front Brake pipe excessively corroded; Nearside front Brake pipe leaking; and the Offside rear (inner wheel arch) body or chassis has excessive corrosion, seriously affecting its strength within 30cm of the body mountings.

In addition the brake efficiency came below requirements and she needs numerous bulbs replacing.

Now that might sound pretty grim to some, but I don’t reckon it’s too bad – certainly a lot less than I was expecting. Plus the upgrades we were already planning to make to the braking system and suspension system will sort out a lot of those issues right away.

As for getting the chassis sorted, I’m going to strip out the interior over the next few days with a view to getting the welding done soon afterwards.

Oh, and I think we’ve now got most of the bits needed for the rear brake conversion …

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Just need a few new bolts and handbrake cables.

We’ve also decided that while we could maybe get all the mechanical stuff sorted within the next few weeks there seems little point pushing things just to put her back on the road in time for the winter.

Instead we’re going to take things more slowly with a view to getting her on the road in time for the shows next year. That way I can probably do more of the work myself and maybe even get some things done that might be overlooked were we to put her back on the road too soon.

Will let you know how I get on stripping out the interior. Wish me luck … I might need it!

:wave:
Last edited by Cpt Custom on Mon Apr 22, 2013 7:28 pm, edited 1 time in total.
Image
1987 D reg Mk2 Scirocco Tornado Red GT 1.6 8v
1987 E reg Mk2 Scirocco Alpine White GT 1.6 8v

Cpt Custom
Scirocco UK Regular
Scirocco UK Regular
Posts: 117
Joined: Sat Apr 30, 2011 9:14 pm
I drive a: Mk2 1.6 Carb
Location: Northallerton

POST 8 - Tue Aug 24, 2010

Post by Cpt Custom » Mon Apr 22, 2013 6:22 pm

After a few weeks sourcing parts and life just getting in the way, as it does, I’m pleased to say I finally got a few hours today to start working on Poppy. :clap:

As she needs some welding done underneath I thought I’d start by removing the rear seats and all the trim. As I’m not mechanically minded at all it turned out to be a nice way of starting … just a matter of nuts, bolts and screws.

And here she is laid bare for all to see …

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After that I thought I’d start trying to remove some of the body kit … deep joy.

I thought battling with the adhesive would be the difficult bit, but it turned out to be some of those damned little screws. The ones around the arches and on the inside of the door edges came away fairly easily. However, the ones underneath the chassis proved too good for me today … hard as I tried I just couldn’t get the little buggers to move. So, if anyone has any ideas how I can get them out please let me know. I’ve tried WD40 to no avail and I can’t really try applying heat or I’ll melt the body kit!

At least I got the offside arch section off. Looks like I might need to replace the arch as its shot somewhat on the outer edge. Here she is before I removed it …

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And here’s what was hiding underneath … :shock:

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Looks even worse when viewed from the inside …

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Tomorrow, I hope to get the rest of the kit off.

:wave:
Last edited by Cpt Custom on Mon Apr 22, 2013 7:29 pm, edited 1 time in total.
Image
1987 D reg Mk2 Scirocco Tornado Red GT 1.6 8v
1987 E reg Mk2 Scirocco Alpine White GT 1.6 8v

Cpt Custom
Scirocco UK Regular
Scirocco UK Regular
Posts: 117
Joined: Sat Apr 30, 2011 9:14 pm
I drive a: Mk2 1.6 Carb
Location: Northallerton

POST 9 - Sun Aug 29, 2010

Post by Cpt Custom » Mon Apr 22, 2013 6:22 pm

I finally managed to get some more of the body kit off. This time I removed the sill covers and the rear valance only to find more nasty rust! :shock:

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So I decided Poppy is going to need not only her rear arches replacing, but most of the rear panel too. Unfortunately, as most of you will know the arches at least aren’t available from VW or any of the other main suppliers. However, through the power of the internet I discovered there’s a guy in Belgium who has produced a rear arch repair kit.

At least I eventually figured out why I was having so much trouble removing the screws that fix the body kit onto the bodywork. If you look at the photo below you’ll see how the screw goes through a small rectangular slot in the body kit. However, instead of going straight into the body as I thought was the case they actually go into small rectangular fixings attached to the body.

If these stay still like I now reckon they’re meant to then there’s no real trouble removing the screws. However, most of mine were loose meaning that they were turning with the screws and so no matter how I turned the screws they weren’t ever going to come out.

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My wife ended up pressing a screwdriver head through the slot in the body kit to hold the plastic fixings in place and then I was able to unscrew the screws.

Just need to get the front arches, the spoiler and the bumper off next. I wonder what delights I’ll uncover when I do that!

:think:
Last edited by Cpt Custom on Mon Apr 22, 2013 7:30 pm, edited 1 time in total.
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1987 D reg Mk2 Scirocco Tornado Red GT 1.6 8v
1987 E reg Mk2 Scirocco Alpine White GT 1.6 8v

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