This customers Mk1 Scirocco GLS was very rusty and borderline saveable. The below is a snapshot of the major work involved.
The photos above were the tip of the iceberg. With so much rot we had to start somewhere -the floor seemed a good place as that would allow access to the sills also.
The process was repeated for the RH floor pan also.
The new floors provided datum points and solid metal to weld to, so the rotten old sill was chopped away and a new inner sill fabricated and welded in place.
Which then led to to the crucial rear axle mounting, which looked like below. The inner sill around the area had disintegrated and the axle mount itself was hanging on by the thinnist of rusty metal. Datum points here were pretty much non existent.
The solution was to use the rear wheel tub as the datum point and install a complete new rear axle mounting/rear chassis leg assembly.
The new assembly lined up perfectly to continue building the new inner sill.
All inner areas were rust proofed and the new outer sill welded in place.
This process was repeated for the sill and chassis mountings on the other side of the car.
Attention was then turned to the rear of the car. Both sides required the inner rear corners of the wheel tubs remaking. LH side shown.
And the outer corners welded. RH shown below.
Both rear wheel arch lips were crusty, so were cut back and new arch lips welded into place.
And the final large job to do at the rear was a new valence.
Now to the front. Time to replace that rusty windscreen cowling with a good used panel recycled from a scrap car.
And rusty inner wings dealt with. Progress pics here.
Repairs were also made to the front panel, front cross member and the bottom of the ‘A’ pillars.
After all welded repairs the car was stripped back to bare metal to begin panel work in preparation for paint.
Once happy with the panel work the car was painted with an initial coat of primer and fixed to a chassis tilter so that the underside of the vehicle could be attended to.
The underside was painted with primer, all joints with seam sealer then the whole underside was lathered in Volkswagen OEM underbody protection.
Once back on its wheels and new front wings hung, the car received its final primer coats.
The primer was flatted back and top coats applied. Bonnet was painted both sided and fitted after paint. The customer has requested B&W pics of the clour at the moment as he is still building the mechanical and trim items of the car. As soon as we can share colour pics, we will do so!
Once the paint had cured it was flatted and polished.
The customer is currently installing custom mechanicals into this car, more updates as soon as we can!