Jump to content

Project Doris... Lupo SDI


NornIron
 Share

Recommended Posts

With starting up the new business, I don't really need a car as I'm driving the van, and SWMBO has a rather nice Golf for the family. However there are times when a man needs a little project... plus my daughter will soon be 17 so something small, safe and economical was needed.

Enter... Doris ...a 2004 VW Lupo SDI :wave:

Pulsing 60bhp naturally aspirated diesel, £30 per year road tax, eleventy billion miles to-the-gallon and a mere £100-odd quid to insure. Full service history (76,000 miles), MoT'd for a year, four new tyres, towbar (ideal for the bikes) and as scruffy as a scruffy thing...

DSCF0069_zpsf26b5a9d.jpg
DSCF0070_zpsbcdf5839.jpg
DSCF0071_zps54828efb.jpg
DSCF0072_zpsf1d654e0.jpg
DSCF0075_zps2970ec32.jpg
DSCF0079_zpsa4fee5a3.jpg

Welcome to my blog-type thread covering Doris' titivation and rejuvenation :thumbup:

  • Like 3
Link to comment
Share on other sites

No major plans, just a little OEM+... no lowering, tinting or transplanting :shades: Doris got treated to a quick wash to clean the moss off her, and while I was at it the extremely dodgy, cable tie fitted wheel trims were removed... and binned :twisted:

Leaving this
DSCF0128_zpsa6bf7ddb.jpg

When viewing and buying the car, I knew there were various bits and pieces which needed replaced in the longer term, however through the forum I discovered fatass is breaking another red Lupo with the bits I need, namely:

Replacement top steering cowl
DSCF0129_zpsb207ccba.jpg

An OSF arch liner
DSCF0131_zpse867caea.jpg

Passenger seat trim
DSCF0133_zps163421f0.jpg

OS Door Mirror
DSCF0135_zpsd3a514b1.jpg

NS Door Mirror
DSCF0134_zps1a350e28.jpg

NSR Light Unit
DSCF0136_zps3dc8c6bb.jpg

The replacements will be with me next week :thumb:

In addition I need to replace the door check straps, and eBay got me a NOS fuse holder to replace this modification :Angel:
DSCF0132_zps8f3a4a25.jpg

The passenger door needs a little adjustment
DSCF0138_zps38ca8073.jpg

The brakes will be stripped and overhauled for peace of mind, then the cleaning will begin! Just a taster of how the paint is looking at present:
DSCF0139_zpse0835928.jpg
DSCF0140_zps5a3ac8c9.jpg

Thanks for looking!

Link to comment
Share on other sites

i have some OE wheel trims if you want them. They even came off and SDI! Pm me if interested :)

Thanks for the offer... just sourced some NOS trims for a slightly OEM+ look :thumbsup:

Edited by NornIron
  • Like 1
Link to comment
Share on other sites

So remember this modification?

DSCF0132_zps8f3a4a25.jpg

eBay scored a hit with this NOS item for a few pennies

DSCF0143_zps7e8b264d.jpg

So disconnect the -ve terminal

DSCF0141_zps47938e2e.jpg

Cut the cable ties disconnect the specialist cover and fittings

DSCF0142_zpsb35b2b98.jpg

Disconnect and whip off the fuse box

DSCF0144_zps7b64072c.jpg

Fit and connect the new fuse box

DSCF0145_zps9cffa212.jpg

Trim blanks for cabling

DSCF0146_zps52e04c1b.jpg

Reconnect -ve terminal and job done :thumbsup:

DSCF0147_zps0a363e03.jpg

Edited by NornIron
Link to comment
Share on other sites

  • 3 weeks later...

Well work on Doris has been embarrassingly slow to date, with a straightforward oil & filter change, cooling system flush and renewal and washer fluid replacement involving these:

DSCF0336_zps0db5620b.jpg

Whilst renewing the coolant and washer fluid I took the opportunity to whip out the expansion tank and washer bottle:

DSCF0334_zps524ab688.jpg

A little work with very hot water and Milton Fluid, together with some Tardis on the outside resulted in this:

DSCF0335_zps974fec73.jpg

The popped back in and refilled, they are now officially the cleanest part of Doris:

DSCF0337_zpsbaf1024f.jpg

Got the paperwork through to confirm the registration transfer, so some more Tardis and a bit of fishing line resulted in:

DSCF0339_zps953a1b4e.jpg

and a PZ2 screwdriver for this:

DSCF0338_zpsea70ee0f.jpg

I won't bother attaching the new plates until I've had a chance to correct the paintwork...

Link to comment
Share on other sites

Looks good simple yet effective - nice little jobs on her. Most people don't realise a SDI is rather different to a 1.0 or GTI when it comes to modifications so you cant really go overboard :) but you've done her a treat! Enjoy the 60+mpg and £30 py road tax, well worth going that little bit slower I think

  • Like 1
Link to comment
Share on other sites

Enjoy the 60+mpg and £30 py road tax, well worth going that little bit slower I think

I was driving a Jetta Sport 2.0TDi 170 (remapped to 210) so these are exactly the reasons Doris has been acquired... together with a potential "L" driver soon!

Link to comment
Share on other sites

  • 2 weeks later...

Well the much promised parts still haven't arrived from fatass, despite payment and a number of follow ups :(

So I got a couple of hours to spend with Doris today, and the plan was to spend them on the braking system. So up she went on the axle stands, wheels off and I was faced with these luvverly arches:
DSCF0442_zps0abbae97.jpg
DSCF0444_zpsdcdf09d8.jpg
DSCF0446_zpsfe56b091.jpg
DSCF0448_zps5059c58b.jpg

Change of plan... I'd much rather be working in a clean environment... so off with the mudflaps and arch liners:
DSCF0450_zps146a88e0.jpg
DSCF0452_zps1a2f8915.jpg
DSCF0454_zpsd30a6231.jpg
DSCF0457_zps449590a9.jpg

Front O/S liner was hiding this in the rear of the wheel arch:
DSCF0455_zpsf2720cba.jpg

I decided the deep clean would be extended to the engine bay also, so Phase 1:
DSCF0458_zps7173bff6.jpg
DSCF0459_zps86aec75c.jpg
DSCF0460_zps032940b0.jpg

Let the Super Degreaser dwell for 5 minutes of so, whilst working arund the engine bay nooks and crannies with a ValetPro 1 inch brush, then the arches with my Vikan Arch Brush and all pressure rinsed off.

Phase 2 consisted of the same process, only a different ingredient:
DSCF0461_zpsab397131.jpg

Which resulted in this:
DSCF0463_zps4609b7bd.jpg
DSCF0465_zpsce9e0376.jpg
DSCF0469_zpsc4b039e1.jpg
DSCF0471_zps06485b51.jpg
DSCF0466_zps5dc711ad.jpg
DSCF0467_zps45366983.jpg

Gave the engine bay a thorough misting of AutoGlym Super Sheen and left it for a couple of hours:
DSCF0479_zps86f925a2.jpg
DSCF0480_zps4181d420.jpg

The liners were all cleaned also, but left off the car as I want to give behind them a coat or two of Bilt-Hamber Dynax UC... next up will definitely be the brakes!

  • Like 1
Link to comment
Share on other sites

  • 1 month later...

So I wanted to overhaul the braking system; new discs and pads, strip and overhaul the drums and change the fluid. Holidays meant an enforced break of a couple of weeks and then work started.

Stripping down the LH rear drum I was met with a leaking cylinder, so the plan changed to replacing cylinders and shoes on both drums. Unfortunately the original kit ordered was labelled correctly, but contained an overhaul kit for 180mm drums not 200mm :(

Called the guys at Opie Oils and explained the situation, and as ever their customer service was second to none. No problem with an exchange and of course we'll refund the return postage.

So today I cracked on with the front end instead, beginning with this:

DSCF3026_zps571eac5c.jpg

Everything necessary was given a dose of PlusGas, caliper off, pads out, disc off, piston pushed back and everything masked off. Wire-brushed and a couple of coats of Jenolite:

DSCF3029_zps94a4fc45.jpg

Then rummaged around in the half used aerosols and found some silver, satin black and clear lacquer:

DSCF3031_zpscaaab89e.jpg

Resulting in this:

DSCF3032_zps5cb1c44c.jpg

So after waiting a while for everything to dry, on with the new discs, and pads and refitted with new guide sleeves, bushes and allen bolts resulting in this:

DSCF3034_zps678b7f83.jpg

Finally a couple of light coats of Bilt Hamber dynax UC on the arches, ready for the liners to be refitted:

DSCF3037_zpsdbeefd04.jpg

I also gave my nuts a quick spray :argie: whilst I had the rattlecans out... from this:

DSCF3028_zpsf7172869.jpg

to this:

DSCF3033_zps8416c220.jpg

The wheel refurb is also almost finished... I'll update soon on this!

Link to comment
Share on other sites

Is it safe to pressure wash an engine?

As with everything in life, a little caution helps! Ideally the engine should be warm, but not hot and don't leave it running. I'd recommend covering the alternator and fusebox with cling film to prevent significant water ingress, and don't do anything silly like directly spraying water up the air intake.

I've done so many now though, I don't follow my own advice :unsure:

  • Like 1
Link to comment
Share on other sites

Just an update on Doris' wheels.... after removing the go-faster wheeltrims I was faced with a delightful set of crusty steels, including an odd Mk3 Polo rim as a spare:

DSCF0481_zps8e11db7d.jpg

DSCF0482_zpseb56e411.jpg

I had the tyres removed, then dropped the four matching rims off with a mate who has a blaster. Got a call a couple of weeks later to say he'd finished blasting them, picked them up and immediately got a couple of coats of rattlecan etch primer on them.

Then 3 coats of Hammerite Smooth Silver from a rattlecan and got the tyres fitted. A couple of coats of PB Wheel Sealant and the result:

DSCF0711_zps769a350c.jpg

DSCF0715_zpsaa9ef543.jpg

DSCF0713_zps18244808.jpg

As regards the spare, another eBay pennies scoop resulted in this:

DSCF0714_zpsacf195e8.jpg

Original Lupo spacesaver, with fitting kit and tools :clap:

Link to comment
Share on other sites

It is a thread to follow, as my own car needs this. Engine bay is even more dirty, as my mechanic said, I think the previous owner sprayed some silicone for the looks and now the dirt and everything is sticky, I don't even know if any degrease solution will clean it up.

Link to comment
Share on other sites

Anyone recognise these?

DSCF0724_zps95eb75f7.jpg

Due to the immense power available from the 1.7 diesel the Lupo is fitted with two air scoops for each front brake... of course three of the four were missing.

So four bolts and two plastic clips changed this:

DSCF0725_zps18398b2b.jpg

to this:

DSCF0726_zps1d8c503d.jpg

And this:

DSCF0727_zps7f10802b.jpg

to this:

DSCF0728_zpsf692b219.jpg

My braking confidence is restored!

  • Like 1
Link to comment
Share on other sites

Got a little bit more done today, in between the weekly maintenance of the car, the van and mowing the lawn...

I want to keep the towbar on Doris for a bike rack and also a little additional rear protection! So to tidy it up, off with the rear lights and bumper to reveal this:

DSCF0729_zps4ab4a6f5.jpg

A good scrub with a wire brush took off the surface rust:

DSCF0789_zps0abab2cb.jpg

And a bit of Jenolite left this:

DSCF0790_zps3fb47f8d.jpg

Break out the trusty Hammerite and a couple of coats later:

DSCF0791_zps37d185f7.jpg

At this point I was tired of taking things apart and needed a little bit of bling:

DSCF0792_zpsc67cb926.jpg

I then broke out the Super Degreaser and cleaned up the entire area (which will be sprayed with some leftover Dinitrol before reassembly) resulting in this:

DSCF0796_zpsb98b5500.jpg

DSCF0795_zps06c74662.jpg

All will be revealed regarding the black square later...!

Some dodgy towing electrics revealed, which I'm undecided what to do with?

DSCF0730_zps72bc4883.jpg

When the towbar was fitted Stevie Wonder (sorry, the professional fitter) decided to hack a hole in the bumper in the wrong place, off centre, with ragged edges and obviously since he had already fitted the electrics, decided to cut through the bottom lip of the cover rather than do the job properly... so first off I measured up to find the centre of the bumper, the correct upper cut level (at the bottom of the photo as the bumper is upside down) and then ascertain how I'll cut a clean aperture:

DSCF0797_zpse39ca605.jpg

The marks aren't terribly clear, so out with the masking tape... everything inside the masked rectangle needs trimmed out. This is the reason for the black painted square, as I figure the larger aperture will be less noticeable if black behind, rather than Tornado Red:

DSCF0799_zps03a38a88.jpg

I'm thinking a Dremel (or similar) would make a neat job of this, but I don't have one... :(

Link to comment
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

Loading...
 Share

×
×
  • Create New...

Important Information

By using this site, you agree to our Terms of Use.