Custom Scirocco GLS Project

This customers Mk1 Scirocco GLS was very rusty and borderline saveable.  The below is a snapshot of the major work involved.

 

As delivered:

As delivered

As delivered

inner wings rotten

inner wings rotten

rusty front cross member

rusty front cross member

rusty sills

rusty sills

rear panel parting company with body

rear panel parting company with body

holes in windscreen cowling

holes in windscreen cowling

 

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.

Rusty, holed floor

Rusty, holed floor

LH floor cut away

LH floor cut away

New LH floor pan installed

New LH floor pan installed

The process was repeated for the RH floor pan also.

new L and R floor pans welded in

new L and R floor pans welded in

 

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.

old sill chopped away

old sill chopped away

 

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.

dead LH rear axle mounting point.

dead LH rear axle mounting point.

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.

rear axle as point for new rear portion of inner sill

rear axle as point for new rear portion of inner sill

Complete new rear chassis leg/axle mount welded in place

Complete new rear chassis leg/axle mount welded in place

The new assembly lined up perfectly to continue building the new inner sill.

fabricated LH inner sill being welded in

fabricated LH inner sill being welded in

All inner areas were rust proofed and the new outer sill welded in place.

new outer sill welded in

new outer sill welded in

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.

LH inner rear corner fabricated

LH inner rear corner fabricated

And the outer corners welded.  RH shown below.

RH rear corner

RH rear corner

 

Both rear wheel arch lips were crusty, so were cut back and new arch lips welded into place.

new wheel arch lip. LH shown.

new wheel arch lip. LH shown.

And the final large job to do at the rear was a new valence.

New rear panel

New rear panel

 

Now to the front.  Time to replace that rusty windscreen cowling with a good used panel recycled from a scrap car.

new windscreen cowling

new windscreen cowling

And rusty inner wings dealt with.  Progress pics here.

new section for LH inner wing

new section for LH inner wing

new section for RH inner wing

new section for RH inner wing

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.

Mk1 GLS bare metal.

Mk1 GLS bare metal.

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.

GLS flipped on tilter

GLS flipped on tilter

The underside was painted with primer, all joints with seam sealer then the whole underside was lathered in Volkswagen OEM underbody protection.

underside etch primer and seam sealer

underside etch primer and seam sealer

Underbody protection applied

Underbody protection applied

 

Once back on its wheels and new front wings hung, the car received its final primer coats.

NS primer

NS primer

OS primer

OS primer

engine bay primer

engine bay primer

interior primer

interior primer

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!

engine bay paint

engine bay paint

OS paint

OS paint

NS paint

NS paint

Interior painted

Interior painted

 

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!