look at that this week we’ll have some fun in the snow when i go to norway to get a golf gti back on the road absolutely that’s fantastic but there’s a slight problem with the engine i can’t help noticing one tiny detail you’ve actually removed the eye from the gti to restore an old car back to its former glory can easily become a bit a bit of a nightmare of course that means that dream car is going to end up in a garage collecting dust and never ever getting completed in ed china’s garage revival we’re going to be visiting people who’ve got stuck on a project for whatever reason and the plan is to try and revitalize reinvigorate them to get that car back where it should be on the road today i’m in a rather wintry norway on my way to see a young car enthusiast called stian juergensen now he sent me a distressed video about his 1983 mark one golf gti i had i need some help with my golf ball after two years of hard work the project has rather ground to a halt on account of a problem with the engine so ed please come to trekstar and help me out with the golf twenty-three-year-old norwegian bricklayer diane jurgensen lives together with his wife tonya and two-year-old daughter sybil in rural trogstad just east of norway’s capital oslo if you drive through these parts be sure to stop and enjoy one of this region’s absolute gastronomic highlight the hot dog in a waffle yeah really interestingly should you find yourself completely smitten by trogstad’s interlandish charm and want to stay for a few days please be advised there are no hotels however the local prison might be able to fix you up froggstand’s biggest employer has 90 beds available for your disposal for me all that will have to wait i have a car project to revive when it comes to alterations rules and regulations tend to vary between countries so i’ve actually made an appointment to see a local golf expert to give me some insight as to how i might better get steven’s project back on track and hopefully find a way through and i think i’ll do that before i go and see steam two years after the successful launch of the first golf in 1974 volkswagen decided although a bit reluctantly at first to also introduce a souped-up version the golf gti with a fuel-injected 1.6 liter engine capable of 180 kilometers per hour the gti was the first high-performance hatchback to hit the market the result was a sensation volkswagen only planned to make 5 000 gtis but by the end of the original run they had made 420 thousand me well i noticed you’re in front of a beautiful beautiful mark 1 golf yeah this is actually the oldest mark 1 golf which is restored and on the road in norway really yeah wow it’s really rather lovely 78 so it’s quite old that’s very special and obviously there’s a slightly newer one over there so is that why we’re here what this display is all about yes it’s actually a kickoff for the representatives in norway working for volkswagen as as a golf expert obviously we have this champ stan who has his nice little 1983 golf now steyn wants to do a little bit something special with his car he wants to try and shoehorn in a 16-valve engine into that sort of eight-valve engine space and i understand that the authorities aren’t that keen in this country of actually allowing that extra bit of performance but there is perhaps a way around it i mean do you have a solution for me well it’s it’s not a quick way to do it to do it it’s uh it’s uh quite pity because you don’t have the papers from the factory to implant that engine so you have to go around it and it could be possible to upgrade the car in the same way as

uh for example a shadow called 16-volt which has this 16-volt engine as standard or big open some until um has it been done before at all it has been done before with some few cars in norway but uh so there is some hope that’s good yes it’s as i hope but uh not every car has been legally registered with that engine okay also so that’s yeah that’s tricky important to mention somewhere fantastic well thank you very much for your help brilliant good luck with the show thank you thank you wow now this is quite exciting so it seems we do have a possible solution it’s not as easy as i was hoping and there’s a bit more paperwork and stuff but there is a way can’t wait to tell stan well this looks like it might be the place [Applause] so this is the right place hi hi are you stan yeah fantastic good to meet you sir thanks for your video i realize you’ve got a few problems i think i’ve got some answers but been brilliant actually to see the car yeah fantastic is it in here i guess yeah warm garage in this snowy climate of course oh look at that oh she’s lovely yeah that’s fantastic so is that the original paint yeah that is amazing how long have you been working on this project two years two years that’s pretty good going then okay and this looks like the this is the eight valve engine that you’ve actually taken out of the car yes fantastic and i guess that one over there would be the 16 valve engine you want to put back in oh yes so now the thing with this obviously you’ve got a bit of an issue i think i have a solution okay which is great but we might also have a look at the rest of the car i mean so she’s actually in really good nick and you’ve obviously been working on stuff as you’ve been going you’ve got the grill it’s all back in place obviously you’ve done the brakes and stuff what about wheels the wheels look a little sorry yeah so have you got have you got the original wheels i get the the snowflakes oh yes okay so they need a bit of work still yeah right okay that makes sense but it always makes sense to work on scrappy wheels anyway so that’s fine but yeah i mean the paint is really good i mean there’s a few little tiny little blemishes perhaps little bits of polish but um i think it’s all kind of there and the interior looks really good nick as well doesn’t it that’s lovely so have you had to do much work on her not on rust or anything but uh just off the little things everywhere here and there okay no fair enough now i notice you’ve got the windows out at the moment why is that headlining oh the headlining of course you know that is a tricky job yeah it’s got to be said and i think it’s one of those things where you could really do probably with two people maybe easier so while i’m here i’m happy to give you a hand oh that would be great fantastic and if you’ve got all the parts we need yeah and he’s at it over there on the other side of the workshop yeah brilliant okay well let’s crack on okay sir some gloves on before we start work thank you fantastic before we get started on the headlining we remove the seats to ease access the roof of the gulf makes a useful space to lay out all the bits and pieces that we’re going to be using so we protect it with an old blanket well these are all the pieces we need for our headlining so we’ve got all the bits that go on all the b pillars april c pillars and hopefully we can work out where they’re all going to sit also we have a whole load of new metal stays as well they obviously sit inside the roof now the problem we’ve got is that normally when you change a headline you have the original headlining at least bits of it to use as some kind of pattern but more crucially than that you’ll also have the stays in the right position at the right length now these are all the same length i suspect we’re gonna have to cut them down to get them all to sit correctly but we have no pattern and no idea where they’re supposed to go so the first thing we’re gonna do

is fit all of these and then the idea is then we can hopefully make sure we can shorten them so they sit beautifully in the roof and then we can start actually attaching them to the roof itself right so these little chaps here as we know go into there now what’s interesting you see they are way too long and that’s a good few centimeters now looking at the roof you can see we’ve got this little groove in the sort of the the insulation so actually i mean when you look how far along it’s really quite tight isn’t it so if you actually put that out like that brush it in so it kind of emulates the same thing and it gives us a mark of about there so that actually has to go in really really tightly so i think we need to do on each of them and then we’ll just cut that trim there and it’s going to sit on that little shelf of metal there as well that’s i’ll go to the side it won’t be happy with that let’s hope your cutters are up to the job line up in that groove so the next stage once this is finished is to thread each of these down we know which position they’re going to be in through our headlining and then put the headlining back into position and what we’ve done i’ve left the clips all on one side of the car and on the other side we’ll actually put the clips in as we go let’s just see if this one fits brilliant all right so the next thing we need to do is actually establish where the center line is on the front and the rear of our roof then do the same thing on the car so we can keep everything aligned and probably the quickest way that’s just to fold it onto itself like so just put these ends together so they’re pretty close to being symmetrical at this stage i don’t know how much we’re going to have to pull through just a little mark on there we then repeat the process on the other end of the headlining before we mark the same center line on the car itself right so it’s the same procedure around the back of the car as well of course the seal tailgate is in the way so get rid of that now the good news is i’ve actually got some reference points here with the hinges so it’s slightly easier to measure up right so the next thing we can now do and unfurl our roof again and now we’re going to slip in our little rods so we need to keep them in order so let’s just get the last one first right i’ll take it to you start at this end perhaps so let’s just pop that into there like so i’m just gonna try and feed that so having now got all our rods in position the next thing to do is actually get the tension right so the first thing we’re going to do is actually pull this rod the front as far forward as it’ll go in its little slot then we can then clamp the headlining to the windscreen frame or at least to that front edge of the metal and then what we’ll do is we’ll start kind of getting the tension all the way to the back we can then clamp the rear of our headlining to the metal work of the car but of course then we need to make sure that our center lines all match up front and rear so we’re getting there so just going to offer this up and you can see we’re just a little bit over this side so we need to check the whole headlining in that direction so if you give it a bit of a tug over there hopefully it’ll go so now what we need to do is get a little bit more tension on the front in sort of the outward direction but at the same time also up a little bit as well so we’re tensioning it along the line of the headlining but also on the way towards the outside of the car all the way along here just want to maintain tension as i go of course eventually this is going to be glued in position but until we get it exactly right these clips are very very handy right so it’s looking better as a start so now what we need to do is go through every single little spa there and actually kind of tension them make sure that they’re still centralized a little bit and also with us work our way all the way to the back and then make sure that the back is centered and then taut and hopefully it’ll take a long time but it’s going to get better

and better and better now before we try and tension things from front to back i’m just going to make sure our position on the rear here actually that’s looking pretty good i’m going to do i’m just going to clamp one clamp in the middle just so we have a little frame of reference so then we’ll tighten from the front to the back right well actually it’s not looking too bad there’s something a little bit squiffy at the back there so have a look at that but also i think we’re slightly so this this needs to go slightly further fall on that side but this side here needs to go slightly further back so we just need to do a bit more adjustment and things but i think it’s actually not playing too badly considering we’ve only just started this i think the other thing is it’s nice and warm in here in the workshop but it’s possibly not warm enough we are in the middle of a norwegian winter which is quite chilly so if there’s any way you can crank up the heat in the workshop yeah no problem that’d be cool okay so while we’re waiting for that to warm up and we’ll do some more fettling later on should we crack on with the engine for a bit brilliant right stan now the reason your project stalled is really about the engine wasn’t it yes so this is the eight valve engine that came stock with the car you’ve taken that out you want to fit the 16-valve engine now the thing is i can totally understand why that because out of the factory this is 110 horsepower 137 newton meters of torque whereas this is 137 horsepower and 168 newton meters of torque so it’s obviously a lot more sporty now the downside of all of this unfortunately is of course the norwegian authorities as i understand it don’t like you to sup up your engine without doing some checks now what’s great news is the german tuning company called uttanga and actually what they did is they made about two and a half thousand mark one golfs fitted with 16 valve engines but to cope with the extra performance they actually uprated the rear brakes from drums to discs now handily volkswagen france officially approved that conversion and because of that the norwegian authorities are going to let you fit your 16 valve engine into your mark one golf as long as you fit the uprated rear discs as well that’s great news it’s very very cool should we pop this thing in oh yeah i think so it’s about time this fold away engine hoist is very useful but using luggage straps to support the engine is not so great it’s well worth investing in a load leveling engine sling it’ll actually allow you to tilt the engine to exactly where you want and gives you much more control brake pipe in the way there how we doing is that going to go down there and it has to come towards us well let’s go down just a little tiny bit um really yep uh one second we’re stuck on something stuck here yeah we may be moving well either we unbolt the socket for that i don’t know if that’s easier i’m not sure can we get to that rubber tip easily just two bolts here and perhaps we’ll lift it up a little tiny bit and put that onto there first then drop it back down and then connect it again so 17 i guess that’s just cheating i might have to steal that okay let’s go down again just a little bit less faster than that oh so this engine mount is about a sort of i don’t know 250 mil from where the engine mounts got to go in the lower one this lower mount has got to go all the way up so here it’s kind of handy if we could tilt the engines a little bit so we’re just going to use a trolley jack to try and actually get that a little bit higher i’m just now going to just put a ratchet strap on here we’re going to try and rotate the engine in our favor because at the moment it’s looking a bit tricky nice yep oh look at that that’s lovely straight in well done that’s fantastic so now we should be able to jack that back up again this is pretty exciting stuff so our 16 valve engine nearly nearly in the engine bay we’re just going to lower it down take off the stress it’s going to then put it onto the engine mounts and then it should be safe to work on later you ready

and relax look at that wonderful she’s in well we’re in great shape we’ve now got your 16 valve engine in your mark one golf all you’ve got to do is connect up all the wiring the plumbing the brakes all the other bits and pieces it’s actually quite a bit of work so i’m not going to leave you on your own i’ve been waiting for your mates to come down you’ve got canute and thor axle to give you a hand and while you boys get busy i’m going to sort out your nasty wheels so crack on and after finishing his supper a third friend robin also dropped him to give the boys a hand and together stan and his mates get stuck in finishing off the installation of the engine and doing the final adjustments to the headlining while the boys crack on with stan’s golf no doubt working through the night i get busy smartening up his tired looking wheels they desperately need a fresh coat of paint powder coating is a dry painting process that uses powdered plastic instead of paint particles suspended in a wet solvent the first step of the process is to remove the old flaky paint and metal corrosion by sandblasting the wheels down to the bare metal then any residue is cleaned off before the powdered paint is applied using a static charge this makes the paint particles spread out evenly over the surface of the wheel even round corners to the back the static also causes the particles to stick to the metal in readiness for the curing process in a special furnace the final step is to heat up the wheels to between 175 and 190 degrees celsius this melts the paint into a fluid state allowing it to flow together evenly over the surface of the wheel and also bonding it to the metal surface the wheels are then left to bake for 10 to 15 minutes and then allow to cool looking good so we’ve now got the wheels back from the powder coaters which is great they’ve even put tyres on them which is wonderful here they are look at that that is really lovely i think students will be really really tough with those and the interesting thing is of course he could at any time actually finish them off with a little bit of diamond cutting but actually the outworld look is kind of cool too and really fits with what he’s doing so let’s see what he thinks hi stan how’s it going i am you being a busy boy oh yes well as have i check it out look at that so i think obviously we’ve gone for the black completely for now obviously you can do the diamond cutting yeah whenever you feel but i think that that look is going to really suit the car quite nicely isn’t it so i think so too let’s have a look and see how you got on it looks like you’ve been quite busy oh very so lots and lots of plumbing and wiring and everything else i mean looking good i can’t help noticing one tiny little detail now obviously you know this is a gti and the eye standing for injection yeah they’re two whacking great carburetors on here you’ve actually removed the eye from the gti yeah why have you gone for the carbs just because of the sound it’s more like more bob and i like that that’s a good answer no i mean they look great they are going to sound absolutely fantastic who cares about field economy and retuning fine fair enough and that’s cool and also i noticed the clips have gone too look at that you’ve actually finished the headlining as well that is wonderful i mean how long did that job take three hours uh-huh now it’s quite a tough one but i think also probably it was a bit more pliable once the workshop was warmer yeah which is good so fantastic well well done with that so really just to finish that job off all we need to do is to fit a windscreen just give it a go right now first thing if you’ve got any paracord or some thick wire or something yes the idea is use a paracord or a little bit of wire or cable and actually get it in between the gap and the rubber here that’s going to go over the lip the metal lip on the car itself and the idea is we can work it all the way around and make sure you get a really good seal so you can start pretty much anywhere and what you’re doing is just putting the wire or the cable all the way through paracord and sort of stuff that actually attaches parachutes to people it’s slightly better than wire but this will work it’s quite thick what you risk with normal electrical cable or wire is that you could tear the rubber on those really tight corners you don’t really want to do that another thing you can do is you can always put an old biro actually thread wire through the bar and

use that to actually part the rubber as you place it in but this is just as quick really so now we’ve got our cable all the way around we can now place the screen onto the actual car itself what we want to try and do is hook this bit of rubber over the bottom edge of the screen first because that’s the most important bit because then the weight of the screen helps push it in place and then we can start pulling the cord around and hopefully get a rubber where we need it so what we’re going to do is just put it on the edge there ease it over with a bit of fiddling between us we get the channel in the rubber over either side of the metal lip of the bottom of the screen frame then we can start pulling out the cord it’s easy this is where you can tear the rubber if you pull too tightly you kind of cut it against the metal just case of just teasing it just a bit of gentle persuasion there’s no need to rush it just take your time because again we don’t want to rip the rubber but also we don’t want to pull all the headlining out either and it’s just a case of judging making sure that the glass is sort of being pulled into the car because if it isn’t start again so i’m just going to roll the rubber so the whole thing levers the screen into place obviously i’m not using a hammer i’m just using the palm of my hand to pull my hand so what’s happened here we’re all excited and i’ve actually pulled it out so we can see that the rubber isn’t quite in position so just a bit more working hopefully we should get it in the last bit i’m using the back of a hook rather than a screwdriver so i can safely get hold of the rubber lip again and then gently stretch it into place one last push and the screen is now in the headlining is done but there is one crucial job we still have to do and that is convert the drum brakes to disks [Applause] right well now we’ve got that wonderful 16 valve engine in your mark 1 golf to get you street legal to get the authorities happy what we need to do is change the drum brakes on the rear here to disc brakes now i’ve actually taken the liberty of getting those parts they’re in the van but i noticed unfortunately you’ve already gone to the trouble of renewing your drum brakes that’s a shame hopefully you can get some money back maybe selling them or sell them to a mate or whatever but in the meantime i’ll go get the bits you can crack on the other side now on the way here i did actually go to the trouble of getting our new brakes that we need for the back of the golf now these ones are actually the same spec as off the mark to scirocco which is kind of interesting which obviously means that they are readily available first i need to remove steyn’s brand new drums offer the dust cover then remove the split pin the locking cap and finally the hub nut with the washer removed i finally get to pull off the bearing with the drum okay that’s a bit of a shame so obviously you’ve got our dust seal here that stayed as part of the drum but the actual bearing the back of the bearing has stayed on the shaft so i need to remove that before i can get the back plate off well i didn’t really have to take that bearing off it’s a bit tidier it obviously means it’s easier for us to end to use this stub axle again so now rather than take all the brakes off here all i need to do is disconnect the handbrake and undo these four bolts then i should be able to take the back plate off complete with all the braking because i also need to disconnect the brake pipe at the back with the bolts loose but still attached i undo the brake pipe from the slave cylinder so there is a little stub axle and then hopefully you can get

the lever forward you can see i can then get to the handbrake cable so well our drum assembly has now been removed now in the kit we now have a special new stub axle and you can see it’s got the bits for the carrier for the caliper now that is going to sit like so but you can see there’s quite a lot of corrosion here i’m just going to clean that back make sure it’s a really good fit because otherwise your wheels going to be all in the wrong place so luckily because all these new parts are actually dust free that’s handy but at the end of the day this rust is still going to make a bit of us so by wetting it with some brake cleaner that will definitely help minimize any further dust well that’s got rid of maybe some of the dust or dirt at least but i can still feel a bit of a lip so i need to do is just take that metal back just a little bit more i’ve just gone over it really lightly so i don’t want to change the shape but i have now got down to some sort of solar metal and any corrosion there has now been removed so so now we can place our new stub axle in position just put it in finger tight first right so they’re all nipped up i’m just going to torque them up properly very important right so now our stub axle is in position we can pop on the disc and i’ll clean it once it’s finally in position nice tight fit just great it’s important to use a new split pin rather than to reuse the old one otherwise it could break from fatigue and the hub nut could get loose okay so that’s now in position i’m just going to check the run out on our disc just to be absolutely sure it’s seated nice and parallely and for that i need another tool from the van excessive run out can cause unpleasant vibrations when braking now for this next stage i’m going to need one of these a dial gauge that’s to check the run out of the disc right so i’ve now positioned our dial gauge so the probe is touching the surface of the disc now what i’m worried about is that there might be some kind of wobble or run out as it’s called and of course that would mean you’d have horrible breaks and we’re looking here when i spin it around we’ve got a movement of about two maybe three thousandth of a millimeter so we’re really good while i’ve got access it’s a great time to use some brake cleaner to clean up any grease or dirt from the surface of the new discs then the caliper carrier can be fitted first we’ll just pop on the caliper carrier and it’s held on with two bolts on the back that go into our new stub axle plate okay so then put the brake pads in now this is where i need to use a little bit of brake grease just on the edges here but just on the parts that are going to be sliding in and out the caliper so now we just bolt the caliper to the carrier right perfect the next thing we have to think about is our new handbrake cable obviously this was operating inside the drum brakes we need now is a whole new cable which is actually going to connect over here and then because this obviously normally roots on the outside and is clipped to the suspension arm this is actually going to thread on the inside of this tube which is rather natty and keeps it nice and tidy so it’s very handy having undone the handbrake cable from the lever inside the car i can pull the old cable out from the guide tube in the chassis then i thread the new cable through the inside of the suspension trailing arm and then the inner cable is threaded back through the guide tube that runs inside the car the outer sleeve of the handbrake cable can then locate into the end of the guide tube so now i have to do is connect this end to the caliper and that’s popped oops into that there we go that’ll tighten up nicely as soon as we start using the handbrake so our new emergency brake cable is now

in position so the last thing to connect up is our hydraulic brake pipe of course that will ultimately connect this caliper all the way to the brake pedal inside the car via the master cylinder okay so that’s now lipped up so i’m now just connecting the hard pipe from like the coolifier or perhaps sometimes it’s steel or copper i’m just connecting that to the flexi pipe that way of course when the suspension goes up and down the flexi pipe takes up all the slack and the hard pipe is less compressible so that’s all connected up now so we’re gonna have to attach that to the chassis to stop it moving around but now our brakes are pretty much complete all we have to do now is bleed the system so now i just need to put some fluid into the reservoir and it’s okay to fit it over the maximum up because of course we’re going to bleed a whole load of it out through the system to get rid of all of that air we need to remove the air because of course it’s compressible which means the brakes don’t actually work that we get really horrible and spongy so with the car as fast as this is going to be we want to be able to stop up down one more up down how’s that good nice fantastic after bleeding the air out of the brake system from all four corners the only thing that remains is to get those great looking outlaw wheels on fitted with winter tyres of course okay so we’ve now got our brakes in order our newly painted wheels are in position got our snow tires on so all the remains really is to take this beautiful 16 valve gti for a bit of a spin probably quite literally in the snow [Applause] [Applause] so are you ready yeah here we go then come on sounds good sounds good let’s go you absolutely hooligan that is fantastic what does it feel like to finally feel steam valve gti the first time you’ve ever driven this car is it what you were hoping for oh yes that’s fantastic and it definitely has that noise i think your neighbors are going to really love it go and give it something nice oh that’s fantastic well that was fantastic well done sir awesome [Laughter] so here is your wife tanya and little sibling how old is sybil two years two years so you actually started this project when you started that project pretty much that’s fantastic well look it’s been wonderful i think you guys deserve a go in this wonderful car but there’s one last thing i need to give you before i let you go check it out this is a gti child so you can see it’s the same fabric that’s actually in your car already so it fits beautifully thank you [Laughter] awesome should i give you a hand put again in the car is that the way is everybody safe and secure yeah fantastic well thanks so much it’s been wonderful thank you have a great trip one last thing i want to do though now gti big brackets i think okay safe to go see you later well that was another successful garage revival if you want me to help you with your unfinished project then do send me your distressed video and preferably from somewhere a little bit warmer


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