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Build thread - `85 Postal Service Golf Resto

16484 Views 127 Replies 19 Participants Last post by  dubchester
Hello to you all,

My name is Steffen, I come from south Germany and I`d like to share my build with you - perhaps somebody finds it helpful or interesting or inspiring :) I hope I find the time to post in a timely manner.

The car is a`85 Golf C which I bought to have something cheap to get through college. It is mostly in its original paint (R132 ginster yellow) and was used by the german postal service as delivery vehicle (that`s why there is the logo of the company on the door). It has around 450k km on the clock, which equates to around 280.000 miles.
It has a 1.6 Diesel engine trying to produce aroung 54hp. Since it was a delivery vehicle it is registered as a truck, which makes running costs incredibly low.

I drove it with coilovers and 7/7.5x15 MTI Wheels which was a bit of a struggle because it was so low (especially for a daily) but it looked the part.

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Since it had some rust spots on the underside and engine compartment that needed attention plus I wanted to keep the car since it had grown on me for bringing me through some tough times, I decided to restore it.

Another topic that never really left me was building a 16V with ITBs in a driveable package with good components.

So I decided to ditch the 1.6 (tbh it is really slow and not that fun to drive, however the 1.6D sounds cool) and put in a 16V ABF with ITBs and all that stuff.

But first I had to take care of the underfloor, I opted for dry ice blasting to get rid of all the gunk and to properly asses the rust damages... :poop:

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With the shell stripped and cleaned, I started putting in new sheet metal where needed. Turned out to be quite a bit 😂:coffee:

First the rear cross member had rust damage, so I opted to exchange it completely since VW Classic parts still has it as OE part
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The drivers side frame beam also had the typical rust damage between the sheet metal parts and also needed some attention:
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Hello to you all,

My name is Steffen, I come from south Germany and I`d like to share my build with you - perhaps somebody finds it helpful or interesting or inspiring :) I hope I find the time to post in a timely manner.

The car is a`85 Golf C which I bought to have something cheap to get through college. It is mostly in its original paint (R132 ginster yellow) and was used by the german postal service as delivery vehicle (that`s why there is the logo of the company on the door). It has around 450k km on the clock, which equates to around 280.000 miles.
It has a 1.6 Diesel engine trying to produce aroung 54hp, and because it was a delivery vehicle it is registered as a truck, which makes running costs incredibly low.

I drove it with coilovers and 7/7.5x15 MTI Wheels which was a bit of a struggle because it was so low (especially for a daily) but it looked the part.

View attachment 211642

Since it had some rust spots on the underside and engine compartment that needed attention plus I wanted to keep the car since it had grown on me for bringing me through some tough times, I decided to restore it.

Another topic that never really left me was building a 16V with ITBs in a driveable package with good components.

So I decided to ditch the 1.6 (tbh it is really slow and not that fun to drive, however the 1.6D sounds cool) and put in a 16V ABF with ITBs and all that stuff.

But first I had to take care of the underfloor, I opted for dry ice blasting to get rid of all the gunk and to properly asses the rust damages... :poop:

View attachment 211645 View attachment 211648 View attachment 211649 View attachment 211650 View attachment 211651
Steffen:

Nice work! Where are the engine pics? Is the car finished or you stoll working on it. Give us the updates.
Great work, and nice welds! Looking forward to seeing how this progresses.
@Jettaguynj thanks a lot, the car is not finished at the moment, in fact it might be some time until it is finished but I`ll get you up to date in the next couple of days/weeks. Engine is currently waiting to be picked up by me, since I don`t have the tools (and the knowledge) to build the engine myself I gave it away to an engine builder.

Rough information about the engine:

2.0l 16V ABF Base engine
Wiseco pistons 13:1
Forged rods
Head ported etc.
292/279° CatCams w/ 12.45mm valve lift
Mechanic valve train with titanium spring plates
Crankshaft machined for lightweight; CNC 4kg flywheel
Jenvey DTH Throttle bodies 45mm
Link G4X engine management

Gearbox etc is also being hopped up a bit, that I can do by myself or at least I think/hope it works afterwards 😅
Since I want to make the exhaus, intake and cooling by myself this is not going to be a job finished in 2 weeks, so please bear with me 🤣
Thanks fo the other replies, too! I try to make it worth your while :)
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Trying to keep things in chronological order:

Front beam underside had also holes where they where not supposed to be, so again, plug in the welder!
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Also one hole meant to be there but the metal was too far gone for my taste so I also replaced it with some homemade special:
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Passenger side beam was also gone with the rust, and since I had a NOS replacement part, I replaced it completely and spared me from the hassle of making small replacement sheets. I just had to change the towing hook since I wanted to keep the old version from `85:
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I thought the rust in the engine bay was done (of course I was wrong) so I moved onto the rear. black replacement parts are OEM, the zinc plated garbage is from Klokkerholm and while I am happy watching my bank account go to rot while my MK2 starts to bloom, I seriously regret buying it. It needed so much remodeling that I could`ve done it myself from the start.

The seams left and right of the rear panel are always a problem concerning rust, so I bonded it in place with Sikaflex 2k panel adhesive also used to glue side panel onto newer cars. Hope that`ll do the trick...
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NOT in chronological order - the donor vehicle which was parted out in 2021, before I started working on the MK2.
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I will use, engine, gearbox, pedals and rear axle as well as some other bits and bobs.
Also not in chronological order some pictures of the bolts and parts after zinc plating. Yes, this is not gonna be finished in some time 😂
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@Jettaguynj thanks a lot, the car is not finished at the moment, in fact it might be some time until it is finished but I`ll get you up to date in the next couple of days/weeks. Engine is currently waiting to be picked up by me, since I don`t have the tools (and the knowledge) to build the engine myself I gave it away to a engine builder.

Rough information about the engine:

2.0l 16V ABF Base engine
Wiseco pistons 13:1
Forged rods
Head ported etc.
292/279° CatCams
Mechanic valve train with titanium spring plates
Crankshaft machined for lightweight; CNC 4kg flywheel
Jenvey DTH Throttle bodies 45mm
Link G4X engine management

Gearbox etc is also being hopped up a bit, that I can do by myself or at least I think/hope it works afterwards 😅
Since I want to make the exhaus, intake and cooling by myself this is not going to be a job finished in 2 weeks, so please bear with me 🤣
Thanks fo the other replies, too! I try to make it worth your while :)
Steffen:

13:1 compression?!!! Wow! I've never heard of any VW/AUDI engine with that high compression!
That baby is going to scream. Great progress. Excellent work! Can't wait to see finished pics.
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@Jettaguynj The pistons are rated at 13:1 CR, but the combustion chambers in the heads are also remodeled slightly which reduces the compression to around 12.5-12.6:1 (I will get the exact value when I`m going to get the engine).
Still yes, a relatively high value. I could run the engine on 98Octane, however I plan on running on 102 Octane (Aral Ultimate). It is available at normal gas stations from the Aral company, so I don`t have to compromise much. Best option in terms of performance would be E85, but it is not easily available and for me it would compromise the car too much.
(Also thanks for the kind words)

While I`m at it: Last bigger rust spot were the floor pans and inner wheel wells in the front, where they meet thepassenger compartment and longitudinal beams. I had to fabricate quite some parts myself but after a couple of days, I was finished. Main reason why this area had severe rust damage was that from factory, the factory floor carpet is one giant rubber mat which perfectly traps humidity that just eats through the metal.

At this time, it was January `22 (I started somewhere in November `21)
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If you are wondering what that foamy gel on the metal is: It is H3PO4 or Phosphoric Acid. It is an excellent rust converter, which leaves back nothing but bare metal. I treated every rust spot on the car that was not worth welding with the acid. You can also try it, but please be careful as this stuff HURTS you (please don`t ask how I know).
Rust gets black and most often loosens itself when you wash the acid from the surface with lots of water. If some rust remains, apply the acid again.
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The rust removal post are nearly finished, I promise!

The areodynamic flap or whatever this wants to be called was also rusted and heavily damaged. New one is from the facelift model which allows a bit more room for the exhaust later, which was kind of a plus considering I could`ve just cut it and gone my way.
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The driver side end of the undersill (rocker panel? I don`t know) was also replaced as well as all the factory holes no one needs were welded up. Cleaning up the rest of the underlflorr, removing sealant etc probably took another couple of hours of my life which I otherwise could have enjoyed 😂

I pre-painted all the gaps between the panels with 2K Epoxi Primer (just to fill them up and not leave any option for air or moisture coming in) before coating the complete underfloor as well as the passenger compartment (this I did with a brush since the carpet will go over it and I do not care THAT much).

Coating used: 2K EP MIPA 100-20

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That's an amazing amount of work, well done
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Wow! I can't wait to see how this turns out.
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It will turn out very yellow I can promise you that

While asking myself why I am doing this to a car that is worth less than a cow in mediocre medical condition, I tried to replicate the oem stone chipping protection as good as possible.
My route to go down was buying a spray gun and use SikaFlex 529 AT, which has the same texture and colour as the original stuff (well it is the same essentially).
First I sealed all the overlappings etc. and did the broader surface coating afterwards.
Paint is the original RAL132 Ginster Yellow, I opted for Glasurit Row 68 2K paint in semi-gloss, I ordered without asking how much it costs (I mean, how expensive could normal 2K paint be??) so I had a small stroke when I got the receipt but hey, the paint is super nice to work with and the finish is spot on. Enjoy the yellowness!

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Damn this car got banana'd
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Excellent work! Very cool to see that Ginster Yellow was available so early in Germany, i do'tt believe it was available in the states until around 96. The quality of your rust repair is excellent. I've been fixing a lot of rot on my rabbit and although I can weld very well, I'm having a very hard time forming well fitting patches. Looking forward to updates!
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Excellent work! Very cool to see that Ginster Yellow was available so early in Germany, i do'tt believe it was available in the states until around 96. The quality of your rust repair is excellent. I've been fixing a lot of rot on my rabbit and although I can weld very well, I'm having a very hard time forming well fitting patches. Looking forward to updates!
Appreciate the kind words!
In Germany, it was even available on MK1 Golfs since they also were used as postal service cars (also on Beetles and Fridolins, of which the latter were sepcially made for the postal service). The color is kind of quirky and i like the look of the early base model MK2`s, I am literally a man of simple taste :p

For the sheet metal work I highly recommend filling an old airbag with sand (I use seat airbags as they have a nice size). They make a great pounding pad (for sheetmetal work!!). Then I use some old wood chisels which i filed round at the end to form bends etc. For shaping I use old shoesmakers hammers. I can show you some more of that once we get to the engine bay :cool:
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Appreciate the kind words!
In Germany, it was even available on MK1 Golfs since they also were used as postal service cars (also on Beetles and Fridolins, of which the latter were sepcially made for the postal service). The color is kind of quirky and i like the look of the early base model MK2`s, I am literally a man of simple taste :p

For the sheet metal work I highly recommend filling an old airbag with sand (I use seat airbags as they have a nice size). They make a great pounding pad (for sheetmetal work!!). Then I use some old wood chisels which i filed round at the end to form bends etc. For shaping I use old shoesmakers hammers. I can show you some more of that once we get to the engine bay :cool:
That’s a great idea, I never thought of dulling down wood chisels. I’d love to see whatever you can show us in regards to the metalwork


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I`ll try to take some pictures and make some sort of info post about the tools. I already did some restorations (more or less extensive) and during college I was really on a tight budget, so I needed to get as much as possible done on myself and also as cheap as possible. Perhaps a little detour on my previous projects:

My first project was a MK1, on this car I learned how to weld and generally how to work on cars. It took me about 5 years and from start to finish the car never left my parent`s garage (also paint was done in the garage) and it just is something special having done everything on your own and on a budget. The car cost me a total of around 5k including the 16V ABF swap etc. I sold it to finance my college fees.
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After it, I had some cars where I tinkered with but did not much to them. At one point I got hold of a Civic which had been confiscated by the police because it was too low and the wheels on the car were not registered. I made the car road legal again and drove it from Germany to Marrakesh/Morocco. I always wanted to do a trip to Africa in a car, and while it seemed to be the completely wrong choice of car to go with, the Honda held up just fine. A friend of mine works at Heckler&Koch and he gave us some ammunition boxes which were perfect for storage because they were water tight so we put them on the roof rack for tools etc., which was in hindsight not that great of an idea because the european border control held us at gunpoint as soon as they saw the boxes. In Africa nobody really cared, but the looks on the faces of the european tourists in Marrakesh (which all traveled by plane) when seeing us driving around with german numberplates was just gold.
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Since the paint was not in the best condition and my leopard spray paint was flaking off, I decided to paint the whole car and make it a bit nicer. This was the last stage and I drove it to Worthersee before trading it in for the postal service MK2 which this thread is about. The picture was made on top of Villacher Alpenstrasse (Road of the Alps of Villach), which some may know from storys.
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After that, I helped some friends working on their car, from which I was able to gain more knowledge and experience. A special project was a Nissan 200SX (S13), which we converted to a S15 front end and a rocket bunny kit.
I got hold of a cheap VW K70 and repaired it, painted it but never drove it on the road before selling it. I didn`t really restore it since there still were some issues but overall it was a nice car.
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After that, I got lucky and could buy an Audi 100 from 1970 from a friend. It has been sitting since 1986 without registration and the body was solid but brakes, engine, suspension etc. needed a complete rework. Currently it is not finished because I am still waiting on the official papers and decided to not go further until I have them.
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I also bought a W124 Wagon from a friend who didn`t want it anymore. It is a 7-seater, sportline, 3l 24V with a 5-speed automatic and I had to have it. I did also quite some bodywork and repainted the complete car. Currently it is sitting on some BBS RF 17" and is my only vehicle at the moment I can use for car shows.
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Having a bunch of cars is all fun until you realise that the day only has 24 hours and old cars need a lot of work and maintenance, so maybe I need to let go of the Merc at some point to focus on the cars that are on my to-do/wish-list.
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