We can rebuild it. 91 Golf

[renngolf]

Long time without any updates but the rustbox is still alive and slowly being converted back to being somewhat presentable.

The rear apron parts are still very rough. Just metal with smoothed welds and primer sprayed on for the time being that will get taken off and the weld seams filled over with some duraglass to fill any pinholes etc. Sanded out and finished with a lightweight bodyfiller/glaze/primer/paint etc.

The rear tow hook on the passanger side was cut out because it was in the way of cutting out existing rust and I just closed it off.









Remember this piece of crap? (gas tank support)


That got cut out along with the right side of the gas door
which was rotted around the opening and where the screws for the gas door go. Fail






On a stock mk2 they just use a shitty self tapper to hold the tank up there on the left side. I just ended up using a 8mil flanged nut on the inside.





Did a ton of test fitting with the tank to get it right. Using a mk3 tank in a mk2 makes it sit low in the opening and I wanted to raise it up a little. Happy enough with how it came out.



Gas door obviously still very rough. Had to use a carbide burr to get into the edges and corners to smooth it out as best as I could. Filler will take care of any low spots.



Inside of the arch. Stupidly enough the inner fender is part of the gas opening



Had to seal it up and I couldn't wear a helmet in such a tight spot so I had to keep looking away while welding it up. Doesn't look the greatest but its a complete weld all around that will just get painted and seam sealed so its not too much of a big deal.




After all that I can concentrate on putting the outer back on with extending the inner out first.



Still a long way away from being finished and stanced thanks for looking.

[projektzwo]

well done! keep it up!

[loudest03cavi]

inspiration, sir, pure inspiration.

[renngolf]

Another small update. Cutting out the inner housing and extending it to meet the outer lip is a whore. Once it was all together I ended up rolling the lip over the inner and stitch welding it in. Its looking a bit better then originally.



















I still need to buy some rust bullet for the inners, seal the the lip seam, and cover in some rockerguard/paint. Smooth the outside with some body filler and move on to the other side. Ill be pretty happy once both sides and rear floor portion is done. Thanks for looking.

[renngolf]

Another small update from today. Got the other side cut out, took out the old gas tank and changed the oil on the daily.



That strip of rust along the inner was removed.


Arts and crafts


This is how each bolt/strap looked like.




Old tank


Upper support for the tank. Looks like I will have to remove it and fab up a new one. VW used one self tapper on the left for the gas tank.






Thats all for now. Thanks for looking.

[7elephant]

waiting for the next update..really nice build thread

[NerdCore]

Holy Christ is that thing covered in rust. I haven't seen a rear suspension covered that bad.

[snake24]

Very nice build. If I had the money I'd love to restore my old rabbit.

[iliescu]

I would love to come check this build out with my buddy who's rebuilding his Mk2. We're in KW.

[loudest03cavi]

Hope to have some more updates soon.

excellent, (im)patiently awaiting. :P

[renngolf]

where were you able to cut the well off of? parts car? junk yard? i have a whole rear quarter panel that needs replaced!

Hey sorry I missed your question. I got the quarters off http://www.typ-17.de
The klokkerholm panels they sell in general are a pretty good fit and quality.
As for the inners I will have to make a template first then use sheet metal and extend the original inner to meet the outer arch.

If that's not an option for you, you can always cut a quarter out of a parts car if it's in good shape and you have a steady hand. I didn't want to dick around with finding a suitable replacement.

Moooooaaaaaaarrrr

Hope to have some more updates soon.

i love seeing shit done right, and this build delivers. keep up the good work, this is gonna be mint when its finished.

Thanks. Appreciate it. 'When' is definitely the key word since I don't get to work on it as often as I'd like to mostly because I **** the fucking cold.

[340i]

i love seeing shit done right, and this build delivers. keep up the good work, this is gonna be mint when its finished.

[loudest03cavi]

Moooooaaaaaaarrrr

[206929rr]

lol at that prop valve hahahah. good lookin build, props for savin it

[Chase Otter(:]

where were you able to cut the well off of? parts car? junk yard? i have a whole rear quarter panel that needs replaced!