Hi guys just found this forum so thought I'd post up my build which has been slow and changeable but I'll get there hopefully this summer. I picked up this car half finished from another forum but the guy didn't really have a clue what he was Getting in to then gave up and I bought it nice and cheap.
The car barely fitted on the trailer but we got there in the end
So it begins, I had a look at the loom which was the main issue and it's alot worse than thought as the guy has not just cut and soldered it but done this in three sections along the long so it's just a mass of half soldered connections and electrical tape. I'm not willing to risk it so I'll be on the hunt for a full loom from the fuse box to engine.
Thought might aswell keep going with it so we went out and picked up some lifting gear for the engine. Doors off, bonnet off, seats taken out and put in the back so when it comes to leaving the car in the garage it'll be easy to gain access.
Car back in and started getting everything undone to lift the engine out, was going well until we realised we didn't have the 12 spline torx tool to undo the drive shafts so it'll wait until tomorrow.
Managed to get more done today after getting the spline tool for the drive shafts. Wheels off and changed for mk3 bbs ones, interior taken out, knackered wing off and all the curse word parts taken to the dump as the garage is abit too small to keep it all.
Got cracking on the loom tonight. Old one ripped out and new tidy one fed in ready to tidy it all up and make sense of it. Fuse box was a right state so it was all unplugged and untangled as it was just too tight and unable to work with.
Alot tidier
Started on the engine harness but didn't get round to finishing it as I need to turn the lump around so maybe on Sunday
Heated washer jets cut out, crappy stereo loom taken out ready to make up a new one when ready, started taking the centre console out but left the grips at home so couldn't get the matrix out which needs to go to get the carpets out the front.
Well been out of the garage for abit but it's had a big clear out, parts hung up to make use of the *cough* space. Afew trips to the dump and for comfort underlay and carpet put down
The only bit of work I done on the car was cut the bolts off that held the cat on as they were badly rusted and couldn't get a grip on them. Out came the dremel and after 20 cutting discs and 2 hours later the stubborn git came off!
Yes that's a grinding drum in the picture but it made for a good picture
Thanks to a new set of tyres I'm broke and my partner in crime has legged it to Barcelona so I'm stuck with cleaning until I can think of something else to take off the car.
I attacked the rusted battery tray which we thought to only be a small section but is quite rotten after digging through the dirt and top layers of rust. So it looks like the whole section to be cut out and another welded in or weld a flat plate over each side and leave it smoothed.
I took out the looms, heater matrix and clutch slave cylinder to make space to clean the whole engine bay plus it keeps them out of the way for engine trial fits.
Well the shell is going on Saturday so it's been gutted ready for the swap just in case anything is needed. There will be quite alot for sale once I've worked out what's needed and what's not so keep an eye on the for sale section some time next week. Didnt get any pictures was too busy then tired to remember but ill post them up soon.
While it's all on hold I got this in the post and it's pure cnc pornography duff you the man!
The new shell turned up today and sods law it a raining all day while were outside working on the cars.
Today was swap the mk3 beam and subframe from the red shell to the new grey one, then mk2 onto the red one so it could be towed away later. It all went well thanks to having four of us to life and move everything, the only down side was working in the rain laying on the floor getting soaked atleast it's done and the build and move forward now.
As it turned up Rear beam done Subframes coming off Going back on Sad to see her go It begins
Got started on the new shell today been waiting all week to start it. Wanted to get it dry as the passenger foot well was full of water, turns out it's all coming from the heating matrix so that'll need replacing. With all the bits coming out I could get a better look and found out at some point it's had a crash and a repaired with a new door and looks like a full respray which can be flatter to look new again so not so bad.
Rolled the car out and worked in the sunshine which was such a nice change to get the doors off
Soaked carpet after a year of sitting
Dash out
The doors came off easier on the 5 five which was a surprise
Engine bay before I took out the servo, clutch cable and other little bits that are just on the way at the moment
Before and after of the engine bay being cleaned, there is alot of built up grease and wax in there so I done some much until I get a heat gun to save the paint.
Having got out of work early it was off to the garage for more fun. Took an angle grinder to the old manifold as the centre section was stuck we bolted the subframe up with it in place and even if I did free it up it wouldn't come out. The cutting wheel was too small so I had to cut it at different angles and took an age but got there in the end, shame the centre is still stuck so that's as far as that Job goes for now. Out came the sound deadening as it was soaked and mouldy thanks to a knackered heater matrix going pop. Engine and lighting loom in got some way through plugging it in but my brain isn't up for finishing that tonight. Pedal box in but I need to mark up the bulk head to drill and cut new holes for the hydraulic clutch.
Cut and drilled the holes for the clutch shame it went abit side ways at the start but nothing abit of sealant won't fix when all fitted.
Armed with my heat gun I got to work on removing the wax and grease as the engine bay was totally caked in it. Once it all started coming off I noticed more and more rust spots so took out the wire wheel and I wish I didn't start! The sealant takes forever to come off and there's loads of it but it'll be worth it in the end.
Got some new wire wheels on order including a knot one to go on the angle grinder
Mk3 universal joint fit Had to cut the bulk head to bolt up the pedal box as the top mount is 15mm over It's so nice to have steering again instead of kicking the wheels to roll her out Started working on the rust on the floor panels and sorting the flaking tar with a heat gun ready for when I fit the new sound deadening. Had enough of not finding anything so it all came out and a good cleaning while th sun was out
Decided to stop fussing about and got on with fitting the engine harness and dropped the engine in which isn't that fun on your own without the crane.
Well the plan for getting the engine started this weekend went out of the window thanks to not having a 109 relay so got on with cutting the exhaust out, engine out and drive shafts out of the way then back in, gear selector bolted up.
Need to repair the loom I wrecked with the wirewheel on the angle grinder whoops. Main positive and ground need to come out of the lighting loom then charge the battery and fresh fuel hopefully!
Managed to repair the loom I clipped with the wire wheel luckily it was only one wire that got cut in half the rest were light grazes so nothing major.
I stripped the lighting loom back to take out the main positive and found so previous damage from the last owner hidden by some tape
For afew months ive been fighting with this ground anchor from last owner and today had enough of it getting in my way so attacked it with the grinder haha!!!!
Bolted up the cross member and noticed my engine mount doesn't line up it's too far back not sure what's up with that
The day started with the plan of getting the old back box cut off and hang the system that came with the red shell. First thing noticed was the centre section was a good 12inches too long so cut it down and now the pipe is the same width as the de cat so will need a sleeve to hold this up properly.
Once the engine was running we noticed It was stuck in gear but the previous owner had unbolted the selector on the gear box so decided to take the engine out ,gear box off and try the spare I bought the other month. It's always a big gamble buying secondhand from eBay so back in and running.......Ching Ching Ching Christ it's knackered!! We were abit confused as what this is inside the bell housing Turns out I had not put the spring on the bottom of it so it was flapping about so be warned always clip it on and held in place. After having a long day on the car we really coildnt be bothered with it but carried on gear box back on, engine back in and running. The noise has gone and the hesitation on power has stopped so it must of been the maf and lambda causing that. Shes sounding like a Vr even with the huge blow from the centre.
Well the time has come me and madmanluke dusted off the tools and cracked on with this build. It was left on hold until lukes new engine was confirmed and near being collected.
All of his running gear was put on my shell today ready for the real work to begin. I wanted to change it all again that way it's all from one car which we took apart when he vr conversion was first done two years ago.
Once the old beam subframe and engine are out of my garage we can carry on pushing this one forward.
Been awhile. Cut the leg and run the engine loom from the inside, started plumbing the engine in makin sure everything still works and it cranks over. Fitted the fuel lines and pump but we has no power from the back of the fuse and the same from the spare box so not to sure what that is about just yet.
After ditching the old exhaust set ups that came with both shells I found a magnex system from a 16v mk2 which should be with me in afew days then hopefully we can get this engine running up to temp.
Well the engine now runs smooth again in this car after it came out running lumpy in Luke's. Not sure why it's stops popping and banging but it's early days. The exhaust is a good 6" too long so will be chopped up and welded this week then hopefully it'll hang nice.
Been spending again since my last update:
A set of weller steels to be banded were thinking 7.5" to keep the gti arches eBay special coil overs Willwood bias valve Slim rad fans Top shock mounts all round Rear discs Exhaust coupler Cv boot (managed to rip the new one) Brake lines and unions Spark plugs and filters
Oh yeah here's why my car has been on hold I bought a new toy
Well today was a big push on the car we bolted up the drive shafts, run all new brake lines including a willwood bias valve, put the calipers back on and fitted the exhaust up. Nothing really went to plan as I've gotta replace afew bits now and get the exhaus chopped up yet again but never mind. The main thing is the car drove under its own power for the first time ever an the first time this shell has driven in atleast 4 years!
Straight to the garage after work. I cut the bias valve and plumbed it in with the adapters and flexes, ill tody up the fitment when ive got the rear bench to hand. I went round all the unions checking for leaks and bled each corner aswell as swapping the front calipers around (yeah the left on right and right on left!) it's nice to have working brakes I'll get round to fitting the new discs and pads once I know everything is fine.
Welcome aboard.Look forward to seeing this progress Nice "write up" I enjoyed reading about the true life situations that always occur when messing with cars!!!! ;D
Great project. Love how you talk about taking doors off as if it's routine when working on any car, bit like the Haynes 'disconnect the negative terminal' advice before every job.
Ha needs must I hate fighting with things so if it can be unbolted and slung somewhere out of the way itll be done
At the moment I'm sourcing some spigot rings to fit the wellers properly, I've sent jamesp on here a message about banding them I'm thinking 7.5" all round should be good enough without cutting too much out of the arches. Ill be on the car tomorrow so hoping to crack on with the brake lines and what not.
Nice thread ,I feel your pain,I did my mk2 1.8t swap in my old dears garage the first time around and it was a f#*kin ball ache!! ;D,got there In the end tho!,it almost feels a bit more rewarding when you have the first thrash after all the struggling ,keep up the good work!!
On a rubbish rainy day where best to be than the garage wasn't really sure how much would get done with the car being stuck in but it was a good day. I load more organising and binning the doubles of parts from both shells.
It was random odd bits being ticked off on the long list of what to do's such as carrier bolts, rounded bleed nipple etc. cracked on with plugging more looms in testing what works and what's knackered. luckily most work but I'm somehow missing a rear left bulb holder. The ever going list has been extended and I've got more to buy as always each week!
While the seats are at work we have a make do (which works much better than the floor)
Wanted to get the spare drive shaft out but not having a vice to hand we made do of the mx5
Could help but make it look more finished but it's oh so far away. I will paint the slam at some point.
Spigot rings 57.1-64mm Hella lights as my spots are looking tired Loads of loom tape/wrap Decat gasket Washer bottle
I'm hunting around for a power steering hose at the moment turns out I'm missin just one which sucks. If the weather is alrigh later I'll pass by the garage to start mocking up the radiator and slim line fans.
Webt armed with a bag of bits thinking I'd get alot done and ended up doing more costing myself more! Drove the car out of the garage then rad dropped down and caught on the garage defender bending it a nice curve atleast it still holds water for running it up.
So on with it I went at the front top mounts again as you can see that packet of haribo isn't there for nothing it's actually hiding the damper rod sticking out of the top the new mount had come apart so the old one went in and the new one went on the otherside now both hold I'll get a replacement.
Losing the will with tonight and the clouds were looking ready to let rip I tested the a weller with the 64mm spigot and yeah its too small so looks like i need a 68mm (the verniers didnt fit so it was guess work when I ordered these)
Only positive of tonight was a 3dr mk2 coming Saturday to be split so I can finish this one
Nice project, prefer ABF swaps personally but still enjoy reading about other people's scraped knuckles on mk2s, makes me feel better about my sore hands after doing the heater matrix on mine today
Well it's just gets better! Douche bag jobs worth child catcher looks resident has filed serial complaints about me using the garage and now has pretty much put a nail in the coffin moving his step up to now written letters. I'm using the garage and he's bitched about oil stains noise double parking etc. the owner has got the hump so now I need to jump ship and relocate this build which won't be easy or cheap.
,I feel your pain,I did my mk2 1.8t swap in my old dears garage the first time around and it was a f#*kin ball ache!! ;D,got there In the end tho!,it almost feels a bit more rewarding when you have the first thrash after all the struggling 
the new mount had come apart so the old one went in and the new one went on the otherside now both hold I'll get a replacement.
