Rebuild

You want the type of spot weld drill that looks like a little hole saw. Tool Town will have the kit.

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Robert.

"You are way too normal to be on Rally Anarchy." Eddie Fiorelli.

OK I's a simple minded machinist type, no fixum sheet metal but somma youse ex-spurts straighten me out so I don't make Max mad.. Here's what I's thinking: the crumpled up shit has to go, it's going to get cut out, and replaced with un crumpled stuff.
What's the point in wasting money to pull shit that is gonna get cut out?

Where's Jim Breazeele?

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John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.

It's a judgement call in the end but you need experience to decide. From what I see in the pictures it's probably not worth the time to try to pull it out. I would start fresh at the fire wall. I strongly recommend taking some measurements to see if the rest of the shell is straight. The dimensions are in the Bentley manual.

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Robert.

"You are way too normal to be on Rally Anarchy." Eddie Fiorelli.

I've done both firewall forward and partials. Sometimes the new replacement parts are more economical than drilling and fitting used stuff (which may be tweaked also). I cut malcolms Talon at the strut towers and had the shell sent to the body shop and straightened to that point. Welded on used inners and core support. Really all you need is a pretty level floor, jackstands, cheap porta power and maybe a come a long or two. I've done complete firewall forwards in the same fashion, no frame shop involved and had cars that aligned fine . It is amazing how much you can get away with and have a car still drive ok at our speeds. 200mph is a bit pickier.

2 hours and the fender finally came off.










im seriously thinking this front end is glued together, not spot welded.

I went over and looked at Max's car. Since I have a prior career in body shops and have done what he needs to do on several cars so I have some experience.

The frame rail is pushed all the way back into the firewall. Meaning the firewall is pushed back a bit in that area as well. Possible movement of a-arm rear mount. I recommended stripping everything out of the engine bay and having a frame shop give it a yank. Frame time is not all that expensive and could save him a bunch of labor and headaches. They can measure suspension mounting point dimensions and get the important bits back into alignment. He'll still have to splice in some bits and most certainly the core support but that can be minimized. If he just cuts off the frame rail what he's welding to isn't in the correct place and everything will still be wonky. At the very least he needs to get a shop manual with all the body dimensions and do a lot of careful measuring every step of the way.

http://www.vwmotorsport.com/vwtech/jig/Golf%201%20jig.pdf

Golf 1 bodyshell jig dimensions from vwmotorsport.com

some quick 1 person measurements, still need to get the skids off to get a more accurate measurement.
these are all approx..

a=27"
b= P- 14.5" D- 14 5/8"
c=9"
d= havent taken
e=43ish"
f=8.25"
g=7 5/8"
h=58 1/4"

thanks for the link. the bently has an obscured version of some of the measurement points.

Max, there are a bunch of great articles on this site. A lot of MK1 stuff. There's even a prep section or two. Anyways, you should have fun for a while.

http://www.vwmotorsport.com

The "Golf 2 GpA Preparation Pictorial" has some devent chassis prep that you might want to do on your car. Especially reinforcing the front horns and stuff.



Edited 1 time(s). Last edit at 07/09/2013 11:33PM by Robert Culbertson.

getting it close is all you need, remember, you WILL bend it again, rabbits are bendy.

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-Tom
DemonRallyTeam | Fine Tuning | CTS Turbo & RP Turbos | RalleyTuned | JRM | Meister Autowerks
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Add us on Facebook | Next Event: 2013 Olympus Rally June 22-23 Olympia, WA

Anyone have a cherry picker i could borrow?

Quote
Racinkid13
Anyone have a cherry picker i could borrow?

Yeah. But before noon tomorrow.

---

John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.

Donor car resized to fit in the garage...





Motor out of rally car...







I dont have a good feeling about this. Every engine mount is screwed in some way. Either bracket twisted of mounting point twisted.

Cars aren't built as precision instruments, people just think they are. Engines and trannies, that's one thing, but the chassis, plus or minus 1/8", not a big deal, 1/4" still not that big of a deal as long as you can get all the wheels into relative alignment.

-Jon