Project: Singh's Rocco

[d.singh]

Up in the air still started working on removing the engine.


Front view and taking off the discs & calipers


Discs & Calipers off now.


Its back on the ground now after a long time up in the air, pretty much unplugged the engine from the rest of the car and needed to lower it. we couldnt do any more work on removing the engine without help so started on the interior.
Oh and if your woundering i have a twin brother its not camera trickery. :lol:


Just chilling in the car, Are we heck we are ripping the Dash apart, no i mean gently removing parts from the dash.


Look How much i got out from just my side of the car. Way to much plastic in this car, it will be put back in at a later stage but i want to see how it runs with bare minimum and not all the extra weight.


Passenger side door, looks pretty good considering its age.


Passenger side under the Dash. spaghetti junction at the moment and its scaring me.


Across the seats to the drivers side is a similar story.


Drivers side door is in good condition. Oh also surprised this things got electric windows.


Oh the wires, they scare me but dont wory i have taken pics and vids of where they have come from.


between this point the camera batter was dead and not plugged in anywhere and we managed to lift the car using the box sextion steel pipes it was sitting on and a fork lift. lifted it mid height and dropped the engine. I mean quite litterally, we didnt do it on purpose it was semi supported. i will explain that in a minute but we got the front and bottom rear engine mounts off easily, and it was swinging (forward and back) on its side engine brackets. The Passenger engine bracket was unbolted easily but sure wasnt the same story for the drivers side bracket. For some reason it was seized and not even air gun could get off, it didnt help all the weight on just the side brackets and it not being alligned because of the swinging. So "SAY HELLO TO MY LITTLE FRIEND" the blow torch, i didnt want to have to do it but it needed to be done so the rubber bush and engine bracket was melted off. The chassis bracket is ok but the engine bracket is horrible and hard to look at :cry: . Then it fell down like 15 cm onto a hydraulic engine table and proceeded to fall on its back off the table onto the floor. its seems ok, just some scuffing on the air intake hole and some little thing snapped off behind it, hopefully its alright but we should be able to get a new air intake manifold (i think its this) if needed.

Empty engine bay.


Empty engine bay from below.


Empty engine bay looking into front passenger corner.


The horrible horrible melted off engine bracket :cry:. Should be fixable.


Empty engine bay looking into front drivers side.


The scorched symbol, the side where the bracket was.


The scorched chassis engine bracket.


The radiator & air filter off.


The car currently with major bits under the car.


A used passenger side wing in better condition than mine for £15 from STK German Spares also known as and more updated on ebay is Dubs R Us


A bit of repairable rust on the wing.


A nice white bonnet so i can tinker with, i dont want to ruin the orginal for £35 from STK German Spares also known as and more updated on ebay is Dubs R Us


The un noticed VW emblem on the white bonnet that i dont have on my Storm (i believe).

[d.singh]

Driver side Wing comming off and what the hell is that flippin stupid glue or rubber sticking it to the car :x it bloody took us 40 min to figure out how to prise the damn panel off the car.


You can see the residue left from that stupid Glue / Rubber crap and the end result.


Passenger side Wing took half the time once we got the idea.


Steering Rack off but only after finding you have to actually remove the bolt that actually stops its comming out and is not only there to tighten it.


Forklift time :thumbup: , absolutely nothing to do under the car, because its all off.


Oh and its me operating it because lets say Bro is better at stabilizing the car than driving a forklift. :lol:


Those Truck / Coach stands are coming away, the cars loved being so high like a monster truck i swear.


Dont worry we wont drop you, i would dare :silent:


Come on your coming down.


Get on the floor!!! :P


Wipers off.


Start inside now.


Driver seat out.


Passenger seat out.


Look at the space.


Dash was already half disconnected and unscrewed but out now.


Is this what it really would of looked like in the factory. :|


Get those wires out the way.


Look at those wires, scary!!!


Blowers been dropped and the pipes from the engine bay pushed through.


Remove that damp stinky carpet. :sick:


Some progress.


The interior outside.


The Rest.

[d.singh]

So currently looks likes this.

[d.singh]

Rear number plate & plate holder removed.


Car tilted back after all the weight was over the pivot point so the car nose was in the air. :lol:


Me relaxing, NOT we just removed the rear speakers and the carpets covering the shelfs.


Rear passenger window kicked out, dont worry it was prised out first and a little pressure needed from my foot.


Rear driver window came out with less force we made sure teh window seals are not damaged in the process.


Remember i said the car had been sat in the rain for 4 odd years, well it turns out after trying to remove the boot that you have to take out some of the roof lining to access the boot bolts. That was the only way we could see or access any bolts to get the boot lid off, so started cutting up the roof lining and the 4 years of rain had been soaked into the roof lining foam. so decided to remove it all and found it was secured in by the windows so took the windows out then could really get the lining off. As you can see the leather lining goes over the window edge and the window sits ontop of that. We abandoned removing the boot because we cant find an easy way of disconnecting the wires that run into it from both sides, can anybody help :?:.


We but some wooden block at the back of the car to stop it tilting back with excessive weight and doing that see saw thing. Driver door removed easily.


We nearly rounded the nuts on the passenger door hinges, thats how much force we had to use on it, bit of wiggling, swinging of the door and WD40 and the nuts unscrewed. :thumbup:


Run out of things to do on the car without superivision so back to the boot and remove the spoiler and all the nuts apart from 1 came off, we used so much force with the screw driver to unscrew it. got harder and harder to uncrew, used mold grips which tested our strength to get a grip on that damn screw. the mold grip moved it fractions until it actually snapped off the welded nut on the other side of the bracket so it was just spinning attached to the nut so had to get the grinder out. :crazy:


Rear passenger interior wheel arch cover removed which was all nice and new beneath.


Different story on the rear driver side wheel arch. Oh the rust, i going to faint.


closer look at those rabbit holes. :x


Not happy but it will be repairable i hope. rob:


No Comment. :***:


Can see the wheel arch rust from inside.


Oh God Why?


Its like an earth quake that tore a fault line all the way to the back of the car.


So currently, we had to put the stuff back in the car because we havent much room to put the parts as it is a working garage.


It made sense to put the tank in the engine bay.

[vwolf]

Damn.. serious Kudos to you my friend What are your plans with it?

Look forward to seeing the progress

[chody]

brave man that is a serious amount of rot at the back end, good luck looking forward to watching your progress

[d.singh]

Who ever previously repaired the car couldnt be bothered sorting where the cables for the pedels go into the cabin.


This is what they couldnt be bothered repairing behind that hideous plate.


view of where the dashboard and blower were.


It was a nightmare but all the wires are out of the engine bay.


Looks no wires.


i am so proud of my self.


Even the fuse box is out the way with its wiress, but cant track down that one wire that goes up the left of that picture.


This is the end result.


All the car wires, even from the boot end all in one pile.


I have just got to show you more. it wasnt particularly hard either just have to be methodical.


Thats all of them apart from that one i cant find or bother to find damn you.


the Boot is off and the wires intact, both wires feed down the roof struts to the back which plug in next to the boot light and the other plugs next to the rear washer bottle.


I am glad the boot lid is off in one piece without having to cut wires, another proud moment.


current view inside.



The car is also a storage space for a some parts i have taken off.


The boot view.



All i have left to do now is get the front windscreen out which i have got a quote of £65 ish from a company but cant garentee they will get it out without breaking the glass or the seals because they are old.

&

The sunroof, but i do not have a handle for it so i can open it up to take a look. desperate for a sunroof handle. all that is there is a gear sticking out of the roof, couldnt use mold grips to open it because theres like a latch stopping you turning it full 360 when you hold onto it.

Parts i NEED!!!!
Sunroof Handle
Windscreen Seals

HELP ANYONE!!!

[d.singh]

Hi Guys, a long awaited update!!!

Attempt at removing the Windscreen, saw a post somewhere they lined the top of windscreen seal inside with flat screw drivers so obviously i wanted to try it. So BEFORE


Oh dear, i was too heavy handed with the first screwdriver and it was in the top drivers side corner which was a bad mistake.
The RESULT


Ended up smashing the Window wit a hammer so we could remove it buy pushing it out with feet and kept the rubber intact.


The empty front.


Drivers side bottom corner.




Passenger side bottom corner.


Windscreen out the way we get on with fabricating the car rotisserie. Using Huge 75mm x 75mm box section.


And the sparks Fly!!!


All we could manage on the frame and i got to test me Mig welding skills.

[d.singh]

Hey guys, its another day on the project, unfortunatley there is nothing much to do on the car yet until i can get it on the Rotisserie, The sunroof is still to come off and i am in the middle of purchasing a Chrome Golde Sunroof Handle if the price is right.

Back on with welding the Rotisserie, just the feet & chassis leg forks to weld. We used 2 coach stands (big yellow stands that the car was on earlier in the project) and a white plastic sheet so people visiting / working in and around the garage did not get Arc Eye (i believe its called) / protecting peoples eyes from the bright welding light if anyone wanted to know what that was there. We had to make due with the small Mig welder with 0.8 wire i believe. there was another Mig welder that was 3 times the size but it had 0.6 wire. Anyway following are the pictures. They say "picture paints a thousand words" hopefully these will just save me explaining everything we did.

Oh and by the way i was doing the majority of the welding as i picked of the knack of it really quicking, impressed even if i say so myself.



The front chassis leg forks welded.



And the sparks fly!!!





It burns!!!





Testing the front chassis leg forks.


Fits like a glove.




What it will rougly look like.


All we needed to do was thread through M12 bolts for the feet so the Rotisserie could be flat packed. we tried drilling like a 7+mm hole through 4mm ish steel box section and that didnt work so we tried 5mm HSS-R drill bit but it was blunt. so bought a new 4.5mm HSS-R Bosch bit from Screwfix not B&Q because they are really expensive because i checked (Screwfix are owned by B&Q aswell so its abit odd for Screwfix to be cheaper) for £1.69 that did a few holes until we put to much pressure on it and it snapped and half of it dug into my leg. Dont worry it was only a puncture on the leg. so tried the blunt 5mm HSS-R bit and we snapped that bloody thing too. Argghh!!!

Mad Dash to Screwfix bought a 5mm HSS-R for £1.69 aswell and finished the holes then widenened them with the 7+mm drill bit.

Just need to widen it again with a bit for the M12 Bolts and we are done.

And all this FAF without a pillar drill.


And the end of the day.

[d.singh]

Hi Guys sorry for not getting back to any of your questiosn been so busy at work and home but i am uploading the last 3 days of work now finally.












Basically just did some cleaning and cutting on the Near (Passenger) Side rear axle mount.