DC's 8v mk2 Ibiza GTi Cupra Sport *Back on the road!*

[Naz]

First time ive seen this mk2, all i can say is very very clean and love the OCDness!!

needs tiger stripe interior or recaros and a drop, but excellent work mate.

 

[LMJ]

How did you (or what did you use) on the inlet manifold? I just can't seem to get mine looking like new.

(Here's mine as a reference);

 

[C11PRA DC]

That's the way it's always been since New! I just keep it lightly oiled to stop it corroding.

That's a very tidy engine bay you've got there! They look identical !

DC

 

[C11PRA DC]

Further progress to report!

Well I decided to jump in feet first into a complete rear suspension/running gear overhaul as I just couldn't bear to see all the work I'd put into the new suspension and front be let down by the shabby looking back!

So began the most depressing and messy part! - Using my trusty Haynes manual I began stripping all the components, cleaning, assessing and labelling.

Rear beam and splash plates:

Decided that I would get these blasted and then powder coated.

After pressing out the old bushes they were blasted (Twice - don't ask!), zinc primed and then powder coated in Satin Black for a more OE look! I gave instructions for as near to 100% coverage as possible inside and out and I was quite pleased with the results! New genuine VW bushes carefully pressed in at a local garage:

 

[C11PRA DC]

As a detail I had the brake pipe brackets powdercoated in a colour near to the original:

More to follow soon!

DC

 

[C11PRA DC]

Stub Axles

I had made a real pigs ear of cleaning up the stub axles a few years ago and it hadn't lasted:

This time I was trying to achieve a more thorough and lasting finish.

I started by chiseling off all the loose flaking rust followed by a session with a dremmel, wire brush and grinding stone. Predictably the ABS sensor was seized in and then broke whilst trying to remove so the remnants had to be drilled out.

Next step was a soaking in Bilt Hamber Deox-C rust killer for 24 hours:

After a wash/scrub with water, a stiff brush and drying the results are amazing:

I then gave them two coats of Bilt Hamber's Hydrate 80 coating to resist further rusting:

This dries black and provides a base for a top coat which for this I used Eastwoods Extreme Chassis Paint - Satin applied in two brush coats to finish:

 

[C11PRA DC]

Used the same method to restore the Handbrake cable hangers that push into the rearbeam. Two coats of Eastwoods Extreme Chassis paint were applied by aerosol.

Before:

After:

I'am replacing every nut, bolt and clip with new from VW along with new Febi ABS sensors from AVS.

Quick image of collective parts:

 

[Cupra Kid]

Workmanship on this is fantastic!!

Is the rear beam a bugger to remove? Mine is in the same condition as yours and could definitily do with the same treatment.

 

[LMJ]

Christ! As always, yet another amazingly flawless overhaul! Beautiful job mate!

 

[gezmeister]

Hats off to you for the effort going into this project, well done mate

 

[ather`s]

Christ! As always, yet another amazingly flawless overhaul! Beautiful job mate!

+1. love it!

 

[ather`s]

any chance you could get part numbers for the brake pipe brackets please and where you purchased them from??

 

[CraigW]

Christ! As always, yet another amazingly flawless overhaul! Beautiful job mate!

+1. love it!

+2. This car is going to be like it left the factory when its complete, possibly even better!!

I wouldnt want to drive it after doing all the work you have though!

 

[LMJ]

I wouldnt want to drive it after doing all the work you have though!

+1. Is there any way you could get another daily? Seems a shame to use this everyday with it being SO immaculate. But a big fairplay to you for keeping it this immaculate!

 

[Mythbuster]

I so wish I can EVER in my life own a car with this age in this condition, I really really do... Everything is so perfect. And I agree, it seems a shame that this gets used every day. Seems like one of those cars that should never even see rain... Big respect to you sir!

 

[C11PRA DC]

Hi all,

Thanks for all the positive comments!

I just get great satisfaction and enjoyment from being as thorough as I can with what ever work I've done - its very addictive!!

True the daily use does take its toll eventually and a lot of work gets undone so another car would be the solution but I never intended that. I'am just hoping I can keep on top of it in terms of condition and mechanicals - but I'll see how it goes!

Besides I like driving it to much!

With regards the brackets I don't know the part no's as they are the originals blasted then powdercoated.

With regards removing the rear beam its pretty straight forward so long as your methodical, patient and have a Haynes manual. The difficult bit is resisting the urge to refurbish/renew EVERYTHING!

Thanks again - more progress to follow!

 

[C11PRA DC]

More progress!

Before re-fitting the refurbished rear beam I gave the underneath/hidden areas, arches and suspension turrets a clean and some protection.

The factory protection has lasted well with very little if any corrosion so all I did was apply AG Engine Cleaner, rinse, wash with Megs shampoo/washmitt and apply AG Vinyl and Rubber care. In the arches/turrets some localised use of Tardis to remove tar spots, polish with AGSR and a coat or two of Collonite insulation wax.

After the photo's I applied a spray coat of Waxoyl clear protection to some of the more venerable areas.

 

[ather`s]

as always mate, top work and looking absolutely fantastic. love it!!!

 

[C11PRA DC]

Maneuvering the beam into position before lifting and attaching at the pivot joints.

Having been supplied with the wrong springs (Polo) I ordered a correct new set directly from FK and these were built onto the rear shocks using new genuine top plates which were treated to two extra coats of Eastwoods Extreme Chassis Paint.

After questioning the fitment of the spring to the lower spring plate FK supplied me with these alloy spacers to prevent any lateral movement. These were not supplied originally so useful info for others.

These were then fitted and secured to the beam.

 

[C11PRA DC]

New Febi ABS sensors fitted to the stub axles.

And then attached to the beam with the splash plates using new genuine bolts. The greasy looking coating in these images is the Waxoyl.

Also fitted new genuine handbrake cables using new clips and brackets and re-connected the brake lines.


At this point I turned my attention to refurbishing the Brake Calipers, Carriers and disks.

Update on these to follow soon!

DC