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

Keep a diary of your rebuild or project here.
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 30 - Mon Apr 11, 2011

Post by Cpt Custom » Mon Apr 22, 2013 6:30 pm

A pretty good weekend by all accounts. On Saturday I travelled across to Preston to pick up a replacement dash I’d bought, which was stripped out of an old Scala.

I now have a crack free dash for when Poppy finally gets reassembled. The one that came out of her only has minor cracks around the air vents that are located along the front top edge. However, this one has no cracks at all. :clap:

It does unfortunately have a bust lock, something that, like the cracking, is apparently a fairly common occurrence. However, I might be able to swap the glove box door for the one that was in Poppy before … I think it was okay, but I’ll need to check.

Then yesterday, I was considering going along to a HDVWC meeting, but decided in the end that my time would be better spent up at the workshop catching up on things. And on the whole I think I made the right decision as it was a productive afternoon, even though everything didn’t go quite as I’d hoped.

I started off where I’d finished last time, if that makes sense, by carrying on stripping out the passenger door. Then I started on the driver’s door. Everything went okay, but getting the socket head bolt out of the front guide rail has surely got to be one of the most awkward little jobs I’ve encountered so far! :x

Anyway, it came out easier than the other side and so then I could get the glass out, followed by the quarter glass and then the wing mirrors. Then I took the doors off. Straightforward enough on the passenger side as the pin on the check strap simply popped out with a couple of taps. However, the one on the driver’s door really didn’t want to come out and took a lot of force to break it free. In the end the two pieces of metal that the strap slides between may have gotten slightly twisted so a little concerned as I’m not sure if these can be removed and replaced?

Next job on the list was to get the rear side windows out. Here I followed advice, taking the tried and trusted method of loosening the seals all the way around before lying inside the car and pushing the glass outwards using my feet. :shock:

I’ve got to say I really wasn’t sure about this approach as it means you need a ‘glamorous assistant’ waiting on the other side to catch the glass as it breaks free. In this case that role was filled by my wife and I was quite concerned at one point as it seemed to be taking so much pressure to even get it moving. I was sure that when it did go it would happen so quickly that I’d not be able to stop my legs shooting through the gap and had visions off the glass shattering as it went flying towards my wife. Anyway, eventually it started to break free and she was able to catch it in one piece.

Thankfully, the other side came out intact too. So there you go, it does work!

With all the side glass out I then unpicked the headlining where it was stuck around the window apertures to reveal the wire structure in the roof space that holds the whole thing in place. Basically, for those that haven’t done this before there are little fabric ‘tunnels’ on the topside of the headlining through which these metal wires/rods run. The tension on the rods is maintained by means of small metal clips that are inserted into the side of the roof.

Now I’m guessing you could pop the rods out from behind the clips like I started to do with the one in the photo below, but I eventually chose to remove the clips thus releasing the rods.

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At the back of the roof the fabric is caught on a row of little metal ‘hooks that are positioned along the edge of the hatch area …

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Then I discovered my mistake … I should have postponed removing the headlining until the windscreen was out. By not doing that it meant I was wrestling with it hanging down whilst trying to remove the front screen, but more of that in a moment.

The headlining came out pretty much intact. There’s some damage where it came down into the corner of the tailgate, but that was already there. It could be reused, but given the time and effort going into the project overall I reckon she deserves new, but I imagine this will serve as a useful template.

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Right then, the front windscreen … it’s out, but it cracked! :cry:

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I was gutted when it happened, but can’t say it was unexpected as I know many people have had the same problem. I did as people had suggested, loosened all the seals and then began inserting screwdrivers along the top edge to gently begin prising it out. However, there were conflicting theories on where to start and I ended up putting the first screwdriver into place in the corner. As soon as I did this it cracked so I’d really recommend anyone else doing this job to start in the middle and work their way out towards the corners. :thumbup:

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I decided to leave taking the hatch out for another day as the prospect of breaking two screens in one afternoon was too much to bear!

So here’s how she sits at the moment now with the bonnet, doors, wings and glass all removed …

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And, finally, a shot of the inside now that the headlining and the foam that lies behind it has been removed …

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:wave:
Last edited by Cpt Custom on Mon Apr 22, 2013 8:18 pm, edited 2 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 31 - Fri Apr 15, 2011

Post by Cpt Custom » Mon Apr 22, 2013 6:30 pm

Finally got around to taking out the rear screen this afternoon. I was a little anxious given that the windscreen cracked on me last weekend, but this time we took a slightly different approach and I’m pleased to say it came out intact! :clap:

This time using a single blunt screwdriver we worked on the inside of the tailgate and just coaxed a small section of the seal out at a time. Last time around I tried to wedge several screwdrivers in at various intervals, but this time like I say we were working with just one.

And the secret here was to not to leave the screwdriver wedged in position, but instead to just use it to fold the seal back in on itself so that it sat snugly against the edge of the tailgate.

The tricky bit is to get that first piece tucked in, but once you have it started you just keep carefully inching your way around the frame. As you do this the seal itself will start to raise the glass slightly out of the frame on the other side. You can keep doing this all the way around or, like we did, just do up one side and along about ¾ of the top edge at which point you should be able to coax the screen out.

Hopefully, the photo below will be clear enough to let you see what I mean by tucking the seal in on itself …

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And then in no time at the entire screen was out …

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And just in case you thought it didn’t come out in one piece here’s the proof …

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Just remember the technique we employed here was all about letting the seal prise itself out.

A big thank you to Andy for suggesting this approach and doing most of the coaxing. :thumbup:

And that was that really for today apart from getting a loan of a couple of trolley jacks and an engine stand from a friendly garage. All set for tomorrow’s mini meet when ianaudia4, mazzellan and stu.gtx are going to help me finally get this out …

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:wave:
Last edited by Cpt Custom on Mon Apr 22, 2013 8:19 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 32 - Sat Apr 16, 2011

Post by Cpt Custom » Mon Apr 22, 2013 6:30 pm

Well today was the big day, the latest North East mini meet and the day Poppy’s engine finally came out. :clap:

Ian (ianaudia4), Tony (mazzellan) and Stu (stu.gtx) had all volunteered to come down to the workshop and come down they duly did. Although had they known how long the dastardly deed was going to actually take, thanks to an engine mount that did not want to come out, they might have not been so keen!

I’d already felt guilty that they’d come all that way to help me and yet with my lack of mechanical knowledge I wasn’t going to be very hands on. So when the problems kicked in and it took much longer than expected it really made me appreciate their help even more. I could never, in a month of proverbial Sundays, have gotten to the point we’re now at without the fantastic help and support of the aforementioned “three wise men”. :thumbup:

Things started off well enough though at a brisk pace and they soon had a lot of the ancillary parts stripped off …

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Here’s the boys hard at work with me lurking with the camera :lol:

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Shortly after this we ran into problems as the bolt that goes through the engine mount on the driver’s side wouldn’t come out as it had become seized and the knackered bush was also making matters more complicated.

In the end drastic measures were called for and we had to hacksaw through the engine mount itself so as to be able to free the engine and thus allow us to finally hoist the engine out.

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After much effort on the part of the boys though it did indeed finally come out and the bay is now almost ready for being blasted. There are just a few bits still to remove …

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And so the engine was left for the night resting on an old pallet awaiting the next stage …

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And finally, the shot Stu said I just had to take …

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:wave:
Last edited by Cpt Custom on Mon Apr 22, 2013 8:20 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 33 - Sat Apr 30, 2011

Post by Cpt Custom » Mon Apr 22, 2013 6:30 pm

Managed to get the servo unit off yesterday along with all the gubbins including the bell cranks plus the push and pull rods. Had real problems with taking the right bell crank off as two of the pins were seized and refused to come out even after the retaining clips had been removed.

Eventually we got the larger of the two, which goes through the centre of the bellcrank to come out, but the other we had to remove still attached to the push rod. I’ll need to try soaking it even further with WD40 and hope that loosens it up.

Got stuck though with removing the long bracket arm that runs between the two bell cranks. I don't think it's got a name so we'll call it the pesky bracket …

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The arrangement of fixed bolts both coming off and into the bracket seem to make it impossible to remove without first removing the steering column and pedal bracket from the other side. Any advice or thoughts on this aspect of the task much appreciated.

Like I say, the bolt arrangement is a pain. There are two that come through the bulkhead that imply you need to bring the bracket forward to remove it …

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But then there are two fixed onto the bracket itself that project down underneath the bodywork …

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These imply you need to move the bracket upwards for removal, but you can’t do that because of the two bolts I mentioned previously … :eh:

Things didn’t go much better this afternoon. I thought I’d give myself a break and try something more straightforward, like removing the driveshafts. I mean with everything disconnected from the inside all that remained for me to do was remove the driveshaft nut and then I should have been able to remove the unit.

I did read first though that Mr Haynes said “the nut is tightened to a high torque and a socket extension may be required”. Socket extension …. I through everything at it and it just would not budge and that was after leaving it to soak overnight with some anti seize oil.

So yet again I’m stuck. Not really sure what to try next? Maybe I need an air gun or something similar?

At least I managed to cut out the seized bolt on the engine mount, so I achieved something! :D

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:wave:
Last edited by Cpt Custom on Mon Apr 22, 2013 8:21 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 34 - Sat May 07, 2011

Post by Cpt Custom » Mon Apr 22, 2013 6:31 pm

I had a reasonably productive couple of hours at the workshop today. Borrowed an old T-bar and a piece of pipe from Poppy’s landlord to form a make-shift breaker bar so as to get the leverage I needed to finally get the driveshaft nuts loosened off.

It was either that or £27.99 from Halfords! :roll:

At first they still put up a fight, but that was more because with no brakes and only a couple of small chocks the shell was rocking a tad back and forth. However, I then put a piece of breeze block behind the wheels and managed to get them off …

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I also took the old exhaust off this afternoon …

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Like so much on this car it’ll be getting replaced so I just hacksawed through it as close to the rear beam as I could get so it could be jiggled free.

Hope to get back up tomorrow so I can have a go at dropping the steering column, which it seems should let me get that pesky bracket out.

:wave:
Last edited by Cpt Custom on Mon Apr 22, 2013 8:21 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 35 - Sun May 08, 2011

Post by Cpt Custom » Mon Apr 22, 2013 6:31 pm

Had hopes that I’d get the steering column dropped today so I could get that pesky bracket out the engine bay, but things didn’t go very well.

Despite trying several places I wasn’t able to get a cutting disc for my Dremel or a screw extractor, which I thought I needed to remove the shear-head bolts from the steering column. Then someone suggested I try using a hammer and a punch or something similar to tap the thread around to get it to a point where I could get at it with a pair of grips.

However, that didn’t work either! :x

Then I sat in contemplation. The view from above …

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The view from below …

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And the more I contemplated the more confused I got … not helped by never having come across this type of bolt before.

If I cut a notch in it with the Dremel, do I do that on the underside because I don’t think I can get in to cut it on the topside?

Alternatively, if I try to drill it out using a screw extractor do I do that from the top or the bottom?

And which direction am I trying to turn it?

:?
Last edited by Cpt Custom on Mon Apr 22, 2013 8:22 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 36 - Wed May 11, 2011

Post by Cpt Custom » Mon Apr 22, 2013 6:31 pm

The saga of the pesky bracket continues ... :wtf:

Got a stud extractor set, but still not managed to get the nut on the steering column off. Because of how thick the extractor is it fouls the steering column, which is just enough to knock it off line and so prevent the mechanism from catching!

So, I've now ordered up a screw extractor set and a tap wrench. Stay tuned for further developments!

:wave:
Last edited by Cpt Custom on Mon Apr 22, 2013 8:22 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 37 - Mon May 16, 2011

Post by Cpt Custom » Mon Apr 22, 2013 6:32 pm

Well the screw extractor set and the tap wrench arrived! :clap:

So on Saturday, armed with those tools plus my electric drill and a centre punch I set off to try (yet again) to get those bolts out so I could drop the steering column. I started by using the centre punch to create a small hole in the end of the bolt so as to give the drill a start …

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With the hole drilled, I selected the second smallest extractor from the set and slowly and carefully using the tap wrench began to screw it into the inside of the bolt. Seems these things are meant to screw in anti-clockwise and when they tighten fully the idea is you continue to try and turn it at which point the bolt itself should then be forced to turn.

Everything went fine until it was fully tightened and I tried to turn it further at which point it snapped thus leaving a piece of hardened steel stuck in the centre of the bolt head! :roll:

Can’t say this surprised me though as I’d read they have a habit of doing this.

Hacked off, I decided to come back to that one and turned my attention to the one on the passenger side of the column. This time I thought I’d try using the smallest extractor to see if I could get a better result, but that snapped too, but at least the end piece dropped out.

So next I went for a larger extractor and would you believe it worked a treat … coming out just as it’s meant too! :clap:

Right I thought; let’s try using the larger extractor on the first bolt. However, with the broken piece from the first extractor still inside it I just couldn’t get a new hole drilled anywhere near the centre.

I was really worried that if I continued in that vein I’d end up damaging the thread on the column bracket itself, but then I had an idea … what about filing the bolt head down?

After a few minutes filing I got to the point where the bolt head was flush with the washer at which point it fell away leaving enough bolt protruding for me to grab hold of it with the mole grips …

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You can see how little of the bolt was left and just how close I must have come to damaging the column threads …

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Finally, after I hate to think how long I was able to drop the column …

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The damned pesky bracket was finally removed …

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And the engine bay is almost clear enough for the blasting to be done …

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This has probably been one the most tedious, drawn out and frustrating tasks I’ve undertaken so far on Poppy. However, on the plus side I have gained some useful knowledge and even some new tools along the way so a result in more ways than one!

:D
Last edited by Cpt Custom on Mon Apr 22, 2013 8:23 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 38 - Fri Jul 01, 2011

Post by Cpt Custom » Mon Apr 22, 2013 6:32 pm

Just got back from my workshop having taken a call earlier this morning to say there'd been a break in at the yard where it's located.

Absolutely gutted as the thieving b******s have taken nearly everything of any significant value including the engine and gearbox too!

Now I’m guessing they just took that for scrap whereas some of the other stuff they might flog through eBay or autojumble. However, to me it’s the sentimental value they’ve stolen as I wanted to keep that part of her original … it feels like they’ve just ripped the heart out of her!

A quick calculation based on receipts kept shows the cost of what’s been nicked at just under £2,000 and to be honest I don’t know what I’m going to do now.

Sure, most of what they’ve taken can be replaced, but whether I can afford to buy it all again is another question entirely. And even if I can it’s going to mean the restoration will take a lot, lot longer than anticipated as the parts were bought with money I had available at that time. It could be months before I can make that up.

Gutted don’t come close!

:x
Last edited by Cpt Custom on Mon Apr 22, 2013 8:24 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 39 - Sun Jul 10, 2011

Post by Cpt Custom » Mon Apr 22, 2013 6:32 pm

Hard to believe that it’s only a year since I joined the Register and introduced everyone to Poppy, our much-loved 1987 D Reg 1.6 Volkswagen Scirocco GT Coupe, which we’d owned since 1992.

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I came on here as a total ‘noob’ with no mechanical knowledge, just a novice with a dream of restoring a car he loved and couldn’t bare to part with - despite the fact that from a purely practical point of view that would have been the best thing to do.

My relatives thought me totally mad, but I joined the Register and SUK hoping to find some kindred spirits that might even be able to help me deal with what lay ahead and that’s exactly what I got.

In fact, thinking it through I got much more than I could ever have hoped: a wealth of information and tips were suddenly at my disposal; people I’d never met came forward to offer advice and encouragement; spare parts were offered and supplied not just at reasonable rates, but often free; people even took time to come down to my workshop and help with the tasks that were beyond me such as removing the engine; and, most importantly, the hand of friendship was offered by many.

And so I was able to take Project Poppy from a rusting, dilapidated scrapper to a sound, solid shell ready for sand blasting and prepping for paint.

What was a dream was becoming reality and I felt I was getting so close to turning the corner, to the day when we’d actually start putting her back together.

Sadly, as we all know Mr Fate has a habit of sneaking up on you when you least expect it, smacking you in the face and pulling the rug well and truly from underneath your feet.

For Jan and I that was the recent break in at our workshop when nearly every single part we’d gathered together for the restoration were stolen along with a vast array of tools. Around £2,000 worth of stuff gone in one night just because some scumbags thought it okay to help themselves to our possessions. Just because some barstewards either didn’t think, or more likely didn’t care, about the impact their actions would have or the dreams they were perhaps about to shatter.

The tools and spare parts could in time be replaced as we still have money left in the ‘Poppy Fund’, but as that money was there for the remaining works to be completed that would mean we’d need to push back indefinitely getting her on the road. As we’re not well off, what with me having lost my job last year through ill health that could mean it might be years before Project Poppy could be completed.

Add into the mix, uncertainty about my wife’s job and the fact that I’ve now been told I might need to move out of my workshop in the very near future and suddenly, instead of feeling we were about to turn the corner we feel like everything is conspiring against us.

And, perhaps the biggest blow over the last couple of weeks has been the fact that during the break in the engine and gearbox were also stolen. I say that because those of you who have followed this thread from the beginning will remember the section below:

“The one other thing I am sure of is that I don't want to swap the engine for something bigger. I might get it tweaked, but I see that as the heart and soul of the car so removing it would seem to go against what I set out to do, which is breathe new life into Poppy. Maybe that sounds a little daft, but I'm just not sure I'd feel the same about the car if I swapped the engine over.”

So, given all that’s happened and all the uncertainty which surrounds us I’m afraid we’ve decided to stop the project now. I know there will be many that will question if this is the right thing to do, perhaps as many as questioned the merits of the project to begin with.

However, we have to do what we feel is right for us and right now that feels like taking time out to re-group mentally, selling what we can to recover some of our losses, keeping what we are sure we will need in the future and looking to move forward.

Before we do though, I just want to say a big thank you once again to everyone who has taken time to help, support and encourage us along the way.

There are too many to mention specifically, but hopefully through this thread you know who they are and I’d like to think on a personal level they already know how much we appreciate their input.

At least there’s a positive end to this story given how much I’ve learned in this last year and how many friends we’ve made. I hope to continue that education and I certainly hope to maintain those friendships meaning that Project Poppy will have a legacy.

And we still have Lily!
Last edited by Cpt Custom on Mon Apr 22, 2013 8:24 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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