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#1 RandomPrecision

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Posted 30 May 2017 - 09:11 PM

About time I got a thread started for my new(ish) steed :)

 

She's a late (04) model MK4 SDI, 136k on the clocks and in fairly good nick. I bought the car three weeks ago on the basis of having owned a Lupo SDI for over a year and finding it to be uttery indestructible. I developed a real affection for the SDI marque cars and wanted to replicate my success with the Lupo in a larger, yet broadly similar vehicle (The Lupo remains in our family and is now my Wifes car!)

 

The objective is simple, to create a no-nonsense reliable beater to munch miles in with minial fuss and in the most economical way possible.

 

SAM_5234_zpset3u3iby.jpg

 

So far I've...

 

Had timing belt/aux belt and waterpump changed.

Changed engine oil/filter.

Fitted new air filter.

Changed fuel filter.

Changed gearbox oil (VW G50 spec)

Sourced a good set of Avus 2 wheels and fitted new Toyo NanoEnergy3 tyres.


Edited by RandomPrecision, 31 May 2017 - 06:35 AM.

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#2 RandomPrecision

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Posted 31 May 2017 - 12:14 PM

Small update.

 

Bought and fitted a set of tailored rubber car mats.

 

Carpeted interiors are very nice but I have to be realistic about this car's purpose and with an active toddler in tow it's likely we'll be clambering in and out with wellies come winter time :ph34r:

 

SAM_5229_zpsagtk5ycd.jpg


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#3 RandomPrecision

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Posted 06 June 2017 - 08:02 PM

Another small update....

 

Factory Gamma head unit/cd player installed this morning.

 

SAM_5281_zpsxxtgyvv2.jpg

 

Ok, fairly padestrian, we all know what they look like, none the less it represents an upgrade in spec (The car originally came a simple Beta tape player) A fairly decent improvement in terms of sound quality and also aesthetics :) They cost me the princely sum of £10 from a breaker car locally, and with a code provided gratis from my friendly VW parts guy it was easy to get up and running.

 

Nasty aftermarket head units are one of my pet hates, the one fitted to the car when I bought it was a particularly tacky  'light up like a christmas tree in Las Vegas' styled example. Glad to be shot of it...

 

SAM_5286_zpsb8pnznhn.jpg


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#4 RandomPrecision

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Posted 10 June 2017 - 08:19 PM

After a weeks worth of chirping/squeaking sounds it became clear that my alternator had seen better days! The issues were compounded by the fact the alternator clutch pulley was locked both ways and the tensioner had all but given up the ghost :ph34r:

 

Fortunately alternator removal is nice and easy on the SDI models with loads of room, pulling the old unit out was simple...

 

SAM_5289_zpsgmqalbri.jpg

 

After a trip to Eurocarparts and the scene was set, a new INA tensioner and Delco Remy alternator ready to be fitted...

 

SAM_5294_zpsqijrp7hh.jpg

 

A couple hours working at a relaxed pace and job jobbed :)

 

SAM_5299_zpshbezr6z2.jpg

 

 

I'm pleased to report that all's now well. The SDI lumps are noisy/agricultural at the best of times, but the chirping and belt soundtrack had to stop! Normal service has been resumed and the car can now return to 'business as usual.' The original Valeo alternator was a lowly 70A item where-as the relacement boasts a mighty 90A representing an upgrade in charging power  ^_^

 

Now to find/fit a decent undertray to protect this lot from splashes/road muck etc....


Edited by RandomPrecision, 10 June 2017 - 10:30 PM.

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#5 Rob136

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Posted 10 June 2017 - 09:07 PM

is the sdi not a pd engine? That looks like a ve fuel pump. For some reason I thought they were pds unless there were different versions. What sort of economy are you seeing from it?



#6 RandomPrecision

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Posted 10 June 2017 - 10:26 PM

is the sdi not a pd engine? That looks like a ve fuel pump. For some reason I thought they were pds unless there were different versions. What sort of economy are you seeing from it?

 

SDI's are VAG's normally aspirated (No turbo) diesel option, they use the Bosch VP37 pump IIRC.

 

To quote VW's marketing bumf from the time "The SDI engine is generally utilised in applications where reliability and fuel economy are of primary concern." Slow and agricultural (As mentioned) but uncomplicated and easy to maintain is probably the best way to sum them up.

 

RE economy, thus far the car seems to manage a reliable 55 mpg+ with mostly urban driving, I'd imagine mid 60's on a long motorway run although I'm yet to put that to the test TBH.


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#7 RandomPrecision

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Posted 11 June 2017 - 01:54 PM

Blanking plate removed and late type cup holders fitted this morning.

 

Trim level/spec is improving ^_^


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#8 RandomPrecision

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Posted 18 June 2017 - 07:01 PM

New wings this weekend for Project Slow :) The old ones had rotted out like so many do, largely due to the daft bits of foam VW saw fit to put behind them as new. Having found a pair of LA7W items in pristine nick locally (£15 each, I don't think the seller realised what a rarity he had stumbled upon) the scene was set.

 

New rust free front wings ready to be fitted.

 

SAM_5341_zpsgwjdautf.jpg

 

Getting started and first things first, the bumper, rusty wings and arch liners were stripped off to reveal this....

 

SAM_5321_zpsl43yy7ti.jpg

 

Every car I've ever pullled to bits, irrespective of manufacturer has looked like this, about 2 kg of soil and road grit, pull your arch liners and have a look people ;)

 

 

All was washed down with a 1/10 solution of Aldi's own brand APC, regular car shampoo just won't cut jobs like this IME...

 

SAM_5353_zps1e6hyut2.jpg

 

After cleaning a four part process was adopted for any corroded bodywork revealed having removed the bumper and wings. First a going over with a rotary tool with various sanding wheels/wire brushes, follwed by Bilthamber's Hydrate80 rust converter, then paint, then Dynax UB underseal (Another Bilthamber product) spread over the high stress areas.

 

SAM_5370_zps1ujjq0hz.jpg

 

Dynax UB was also spread liberally around the inner arch area of the new wings to protect agains future issues...

 

SAM_5367_zps6hphynb0.jpg

 

New wings fitted and job jobbed ^_^  Im amazed at how good the colour match on the new wings was, particularly given it's a silver car (Usually one of the toughest colours for matching)

 

SAM_5376_zpsew0ur7vv.jpg

 

And closer to show the match/condition of the new panels...

 

SAM_5377_zps9qs5n8ev.jpg

 

 

Overall I'm really pleased, opting for an SDI on the basis of reliability/simplicity is futile if corrosion ends play before mechanical issues do. This represents another rough edge knocked off and also another step towards 'futureproofing' the trusty oil burner for years to come.


Edited by RandomPrecision, 18 June 2017 - 07:06 PM.

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#9 Glendil

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Posted 18 June 2017 - 08:46 PM

I like the fluffy rug lol good find

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#10 jamesm86

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Posted 18 June 2017 - 08:56 PM

Good find on the wings, If that seller happens to have a pair in lc9z let me know haha!

you're a man after my own heart going full protection on the wings, good job. Exactly what i plan to do when i finally find a pair that are in a good state



#11 RandomPrecision

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Posted 19 June 2017 - 06:04 AM

I like the fluffy rug lol good find

 

Thanks, it's the rug that makes it all possible ;)

 

 

Good find on the wings, If that seller happens to have a pair in lc9z let me know haha!

you're a man after my own heart going full protection on the wings, good job. Exactly what i plan to do when i finally find a pair that are in a good state

 

Yup, protection is essential. Coming from MX5 circles where rust really is an issue, I've found Bilthamber products to be amongst the best.

 

RE finding decent wings, I had saved searches on Gumtree, Ebay, Facebook and Preloved for Golfs breaking and ran the search two or three times a day so it did take a bit of work to find good ones. After about five weeks of this method I struck gold and found the holy grail, completely rust free original wings!

 

In other news, bills for the car are now starting to mount up....

 

The car itself                     £380

Front wings                       £30

Timing belt & waterpump   £300

Alternator                          £110

Tensioner                          £40

Wheels                              £50

New tyres + fitting              £140

Gamma radio/CD units      £10

Cup Holders                      £5

Oil/gearbox oil, Filters etc £80

 

TOTAL                              £1145

 

I must admit to being slightly shocked that the car now owes me over a grand! Ah well, the objective was/is to create a no-nonsense reliable working hack to last for the next five years or so, and given even the most basic new cars depreciate by over £1k a year I still feel like this route is the lesser of the evils...


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#12 jamesm86

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Posted 19 June 2017 - 09:48 AM

And the fact you carried out the work yourself saved a few £££'s
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#13 Rob136

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Posted 19 June 2017 - 11:38 AM

Most of the cost is for service parts which would need doing on any car, and would potentially cost you a lot more in the future if not done!


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#14 RandomPrecision

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Posted 19 June 2017 - 01:00 PM

Most of the cost is for service parts which would need doing on any car, and would potentially cost you a lot more in the future if not done!

 

True.


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#15 RandomPrecision

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Posted 05 July 2017 - 03:06 PM

A couple more rough edges knocked off of the past week or so :)

 

First things first (Pun intended) I often find it's tough to get first gear when at a standstill. With a slight roll it's fine and with engine off also fine. I would usually look towards a dragging clutch in a scenario like this, however the age old 'Does it crunch/grind going into reverse?' test yields no noise at all. Strange, and perhaps down to a slightly worn synchro on first, or maybe something as simple as a tired release bearing or pushrod... One thing I was sure about was that the selector carrier was FUBAR with all bushes showing extreme wear and leading to extreme slop at the gearstick. Only one thing for it, the slector carrier/console had to be replaced...

 

35736992865_14224cc7df_b.jpgSAM_5444 by

 

Good news is that gearchanges feel much improved and positive, unfortunately first gear is still stiffer than I'd like -_-  I will probably wait until it's time to replace the clutch to investigate this further.

 

Next job was to replace my old/manky expansion bottle. With the original tank it was very difficult to see the level of coolant in the tank without having to remove the cap, and given a new EIS branded replacement can be had for £10 from EuroCarParts using one of their discount codes it seemed daft not to.

 

Old vs new...

 

35737008825_f0e537c15d_b.jpgSAM_5451 by

 

And fitted...

 

[url=https://flic.kr/p/WrXxNH]35737016025_7a4ec291f7_b.jpg[url=https://flic.kr/p/WrXxNH]SAM_5454 by [url=https://www.flickr.c.../[email protected]/]

 

A big improvement! Next job, clean that grubby engine bay ;)


Edited by RandomPrecision, 05 July 2017 - 07:47 PM.

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#16 jwrb

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Posted 06 July 2017 - 07:39 AM

Loving this! Simple maintenance and tidying up can make a great daily driver!


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#17 equalizer

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Posted 06 July 2017 - 08:07 AM

great tip about arch liners i'll be cleaning my car this weekend weather permitting will strip out mine & have a look



#18 RandomPrecision

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Posted 06 July 2017 - 08:20 AM

Loving this! Simple maintenance and tidying up can make a great daily driver!

 

Thanks :)

 

TBH the objective here is pretty much chalk and cheese when compared with the majority of the "Kierons bagged/chipped smashed my sump bruv" style builds ^_^ 

 

All pretty dull stuff TBH, the thread is/was inteneded more as a place for me to keep a record of work I've done really. Rescuing old cars and giving them love when everyone esle has given up on them gives me a lovely warm feeling inside :lol:  This old SDI smoker was teatering on the edge and looking really down on it's luck, therefore it made a good candidate for an 'intervention'.


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#19 jwrb

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Posted 06 July 2017 - 08:25 AM

Thanks :)

 

TBH the objective here is pretty much chalk and cheese when compared with the majority of the "Kierons bagged/chipped smashed my sump bruv" style builds ^_^

 

All pretty dull stuff TBH, the thread is/was inteneded more as a place for me to keep a record of work I've done really. Rescuing old cars and giving them love when everyone esle has given up on them gives me a lovely warm feeling inside :lol:  This old SDI smoker was teatering on the edge and looking really down on it's luck, therefore it made a good candidate for an 'intervention'.

 

Absolutely! My Golf is mostly stock. Aesthetic and simple mods, engine will remain the same for now as it runs quite nicely.


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#20 RandomPrecision

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Posted 09 July 2017 - 05:49 PM

Right, another busy weekend with project slow.

 

After spotting what looked to be a tiny spot of corrosion at the bottom to the rear arch/sill area on either side of the car I decided that the nettle had to be grasped and the issue neeed to be nipped in the bud sooner rather than later.

 

The products...

 

35009255753_2a0beb2287_b.jpgSAM_5517 by

 

First part of the job was stripping back damaged factory stonechip. As is often the case the area effected by corrosion is usually much greater than expected, here's a shot mid-way through the stripping back of the damaged OE paint...

 

35649825542_d8ce070a06_b.jpgSAM_5477 by

 

Any rust found was taken back to good metal using a rotary tool/drill with various wire wheel and sanding drums and given several coats of BiltHamber's Hydrate80. I've used this stuff on various projects over the years, I find it's very effective at killing/converting any traces of corrosion providing a good surface for primer/paint. When applied initially it starts out life as a milky blue colour...

 

35778561186_8bb1035298_b.jpgSAM_5478 by

 

And as the chemical reaction takes place the product forms a black/stable compound...

 

35009233443_257fc4c0be_b.jpgSAM_5493 by

 

Hydrate80 is ready for overcoating after 24 hours, in the meantime I got busy with another BiltHamber product, this time their Dynax UB underseal. Again, I've found this to be really good stuff, outperforming Waxoyl or Dinitrol products by a mile IME. UB was applied to the inside rear arch area and also the inner edge of the sill rails...

 

35687007001_04d97fec5e_b.jpgSAM_5482 by

 

Killing time at this stage, I washed down the arch liners with APC...

 

35819216455_cba56f460c_b.jpgSAM_5472 by

 

Fast forward 24 hours and it was time to piant :) A couple of coats of etch primer first...

 

[url=https://flic.kr/p/WvCFBd]35778601126_24beeac360_b.jpg[url=https://flic.kr/p/WvCFBd]SAM_5508 by [url=https://www.flickr.com/photos/[email protected]/]

 

Followed by five coats of Refelx Silver, geting progressively heavier towards the last coat. Halford's off the shelf aerosols proved to be a very good colour match...

 

[url=https://flic.kr/p/Wjgc4L]35649926302_a346f2303a_b.jpg[url=https://flic.kr/p/Wjgc4L]SAM_5538 by [url=https://www.flickr.com/photos/[email protected]/]

 

Wheels back on down from the stands. The car will be left on the drive for a few days before being used to give the paint a chance to properly harden off.

 

[url=https://flic.kr/p/WnxAWV]35687077921_7188971c8c_b.jpg[url=https://flic.kr/p/WnxAWV]SAM_5531 by [url=https://www.flickr.c.../[email protected]/]

 

All done and job jobbed. Time for a beer :)


Edited by RandomPrecision, 09 July 2017 - 05:51 PM.

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#21 jwrb

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Posted 11 July 2017 - 12:10 PM

Lovely! I need to do this quite soon with mine! Mild corrosion on a couple of panels but nothing major!

 

Keep up the good work! :D


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#22 RandomPrecision

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Posted 11 July 2017 - 12:35 PM

Lovely! I need to do this quite soon with mine! Mild corrosion on a couple of panels but nothing major!

 

Keep up the good work! :D

 

Cheers.

 

It's one of those jobs that's pretty thankless and boring but worth doing.

 

I did similar work on the wifes Lupo a couple of years back and the corrosion that was present shows no signs of returning, meanwhile my neighbours Transit van goes in to have rust on the arches treated/painted by a 'profesional' every year and the rust is always back within 6 months.

 

In short, the BiltHamber products work very well.


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#23 RandomPrecision

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Posted 04 August 2017 - 12:32 PM

Not much going on of late.

 

Stripped down front brakes and greased sliders/moving parts + chamfered brake pads because of a nasty squeeling on light braking, all's now silent ^_^

 

Made a 41 mile round trip of mostly 50mph dual carriageway to ick up some seats, brimmed tank before setting off, then again on return.

 

41.2 miles covered and 2.64 litres to bring the tank back to the brim. Details put into this online calculator http://www.mpg-calculator.co.uk/ giving me a respectable MPG for this journey of 70.95 MPG B)


Edited by RandomPrecision, 14 August 2017 - 01:47 PM.

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#24 RandomPrecision

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Posted 05 August 2017 - 06:35 PM

I've  been lucky enough to find a couple of sets of 'Sports' seats on breaker cars locally for £30 and £20 respectively, with interiors going so cheaply and so many Mk4's breaking at present it seemed rude not to :)

 

Both sets of seats were merged to make one good lot and the scene was set. Work was carried out on a friends drive as it's slightly more spacious than mine.

 

Depressing poverty spec seats on the way out...

 

35553934614_02cba4443e_b.jpgSAM_5597 by

 

All out...

 

36221422952_8a09b300ae_b.jpgSAM_5606 by

 

And sports seats in...

 

36389352115_de1dfc02d1_b.jpgSAM_5617 by

 

35992833850_9e011987de_b.jpgSAM_5618 by

 

Really pleased with them, they're much more supportive than the originals and add a further spec upgrade along with the TDi alloys, CD player and cupholders. One thing I will say is that despite being dull the basic seats that came with the car had done incredibly well and were in near perfect nick after just under 140k of use.

 

I celebrated by returning to casa Precision and giving the rest of the fleet a wash and wax ^_^

 

[url=https://flic.kr/p/VGm13f]35243470914_8bd2eac356_b.jpg[url=https://flic.kr/p/VGm13f]SAM_5567 by [url=https://www.flickr.com/photos/[email protected]/]

 

[url=https://flic.kr/p/WYBuZF]36083915705_3fe9f1f1b8_b.jpg[url=https://flic.kr/p/WYBuZF]SAM_5560 by [url=https://www.flickr.c.../[email protected]/]


Edited by RandomPrecision, 06 August 2017 - 06:56 AM.

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#25 RandomPrecision

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Posted 20 August 2017 - 09:30 AM

A few more rough edges knocked off this weekend :)

 

New parts from Volkswagen to rebuild/repair my rear driver side seat latch.

 

35876055423_6464fcbcf2_b.jpgSAM_5632 by

 

New centre caps direct from China to tidy up my Avus wheels (These turned out to need some machining with a Dremel to fit properly)

 

35876061103_f992d883aa_b.jpgSAM_5638 by

 

And a new gearknob/gaiter to replace the tatty original item, again a China special coming in at less than £7 posted. Surprisingly it seems ok in terms of fit and quality.

 

[url=https://flic.kr/p/WEfdAX]35876066283_ea8d198797_b.jpg[url=https://flic.kr/p/WEfdAX]SAM_5640 by [url=https://www.flickr.c.../[email protected]/]


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#26 RandomPrecision

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Posted 25 September 2017 - 12:42 PM

After some slow/reluctant starting of late I bit the bullet and fitted a new battery...

 

37306466411_c339a19507_b.jpgSAM_5689 by

 

At £60.08p from TPS it was a no brainer and actually far cheaper than ECP/GSF or the local motor factors.

 

Also blead the PAS system and replaced the fluid with fresh/genuine OE spec.

 

37276959652_e3c57b4c33_b.jpgSAM_5704 by

 

[url=https://flic.kr/p/XPsQca]36636732583_dec01da916_b.jpg[url=https://flic.kr/p/XPsQca]SAM_5709 by [url=https://www.flickr.c.../[email protected]/]


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#27 RandomPrecision

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Posted 13 December 2017 - 12:47 PM

Long time without updates here....

 

Very little going on I'm afraid other than a new LUK clutch fitted around 2K back The job was farmed out and came in at £256 all in, that's made up of £106 parts and £150 labour, It was nice not having to fork out for a replacement DMF (Not present on SDI models) :) I also renewed the clutch fork and shaft oil seals at the same time as a preventative measure. The car is for the most part doing it's job faultlessly, now just short of 10k miles covered since May, it recently ferried the family on a winter trip to the Lake District without any issues, although when all packed with gear space was perhaps a little tighter than I'd have liked.

 

The only real news on the car front is that I've added another to the fleet, this time a 2004 Passat TDi 130 Highline... The car has some issues that I'm working through at present but the intention is that it will serve as a more luxurious family barge for weekend trips etc whilst the Golf and Lupo SDI's will continue to be used as hacks for the weekly grind ;) It's a very comfortable/lovely place to be with heated leather seats, electric everything and oodles of room....

 

38883427802_717afc3f5e_b.jpgSAM_6011 by [url=https://www.flickr.c.../[email protected]/]


Edited by RandomPrecision, 13 December 2017 - 12:49 PM.

"What doesn't kill me makes me stranger"

 

https://uk-mkivs.net/...4-project-slow/


#28 TomasLT

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Posted 13 December 2017 - 04:45 PM

But it has dmf?


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#29 RandomPrecision

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Posted 13 December 2017 - 04:49 PM

True, but it's not a car I'm going to rely on as daily transport, and as such if DMF or Turbo do go West I'll have the freedom to leave it in whatever proverbial ditch it dies in :)


"What doesn't kill me makes me stranger"

 

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#30 TomasLT

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Posted 13 December 2017 - 04:52 PM

Oh how the tables have turned


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