NornIron Posted May 16, 2013 Report Share Posted May 16, 2013 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 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...Welcome to my blog-type thread covering Doris' titivation and rejuvenation 3 Quote Link to comment Share on other sites More sharing options...
tintin360 Posted May 16, 2013 Report Share Posted May 16, 2013 Nice car, so whats your plans for it? Quote Link to comment Share on other sites More sharing options...
NornIron Posted May 16, 2013 Author Report Share Posted May 16, 2013 No major plans, just a little OEM+... no lowering, tinting or transplanting 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 Leaving thisWhen 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 cowlAn OSF arch linerPassenger seat trimOS Door MirrorNS Door MirrorNSR Light UnitThe 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 The passenger door needs a little adjustmentThe 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:Thanks for looking! Quote Link to comment Share on other sites More sharing options...
James827 Posted May 16, 2013 Report Share Posted May 16, 2013 i have some OE wheel trims if you want them. They even came off and SDI! Pm me if interested 1 Quote Link to comment Share on other sites More sharing options...
NornIron Posted May 16, 2013 Author Report Share Posted May 16, 2013 (edited) 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 Edited May 16, 2013 by NornIron 1 Quote Link to comment Share on other sites More sharing options...
NornIron Posted May 18, 2013 Author Report Share Posted May 18, 2013 (edited) So remember this modification?eBay scored a hit with this NOS item for a few penniesSo disconnect the -ve terminalCut the cable ties disconnect the specialist cover and fittingsDisconnect and whip off the fuse boxFit and connect the new fuse boxTrim blanks for cablingReconnect -ve terminal and job done Edited May 18, 2013 by NornIron Quote Link to comment Share on other sites More sharing options...
Lupo-Joe Posted May 19, 2013 Report Share Posted May 19, 2013 10 times better! Joe 1 Quote Link to comment Share on other sites More sharing options...
NornIron Posted June 9, 2013 Author Report Share Posted June 9, 2013 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:Whilst renewing the coolant and washer fluid I took the opportunity to whip out the expansion tank and washer bottle:A little work with very hot water and Milton Fluid, together with some Tardis on the outside resulted in this:The popped back in and refilled, they are now officially the cleanest part of Doris:Got the paperwork through to confirm the registration transfer, so some more Tardis and a bit of fishing line resulted in:and a PZ2 screwdriver for this:I won't bother attaching the new plates until I've had a chance to correct the paintwork... Quote Link to comment Share on other sites More sharing options...
Lupo-Joe Posted June 9, 2013 Report Share Posted June 9, 2013 Good work so far! 1 Quote Link to comment Share on other sites More sharing options...
jadelauren Posted June 10, 2013 Report Share Posted June 10, 2013 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 1 Quote Link to comment Share on other sites More sharing options...
NornIron Posted June 10, 2013 Author Report Share Posted June 10, 2013 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! Quote Link to comment Share on other sites More sharing options...
loepan Posted June 10, 2013 Report Share Posted June 10, 2013 (edited) Reasons might go tits up tho' Turbo is slightly different'Ah re-read, l driver, been one of them days' Edited June 10, 2013 by loepan Quote Link to comment Share on other sites More sharing options...
NornIron Posted June 22, 2013 Author Report Share Posted June 22, 2013 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:Change of plan... I'd much rather be working in a clean environment... so off with the mudflaps and arch liners:Front O/S liner was hiding this in the rear of the wheel arch:I decided the deep clean would be extended to the engine bay also, so Phase 1: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:Which resulted in this:Gave the engine bay a thorough misting of AutoGlym Super Sheen and left it for a couple of hours: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! 1 Quote Link to comment Share on other sites More sharing options...
Lupo-Joe Posted June 22, 2013 Report Share Posted June 22, 2013 Clean. Quote Link to comment Share on other sites More sharing options...
coopersim Posted June 23, 2013 Report Share Posted June 23, 2013 Great work! 1 Quote Link to comment Share on other sites More sharing options...
NornIron Posted July 27, 2013 Author Report Share Posted July 27, 2013 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: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:Then rummaged around in the half used aerosols and found some silver, satin black and clear lacquer:Resulting in this: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:Finally a couple of light coats of Bilt Hamber dynax UC on the arches, ready for the liners to be refitted:I also gave my nuts a quick spray :argie: whilst I had the rattlecans out... from this:to this:The wheel refurb is also almost finished... I'll update soon on this! Quote Link to comment Share on other sites More sharing options...
Blue Loop Posted July 27, 2013 Report Share Posted July 27, 2013 Good progress! Is it safe to pressure wash an engine? I am cleaning mine little by little as I'm not brave enough to point the jet washer to it Quote Link to comment Share on other sites More sharing options...
NornIron Posted July 27, 2013 Author Report Share Posted July 27, 2013 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 1 Quote Link to comment Share on other sites More sharing options...
NornIron Posted July 30, 2013 Author Report Share Posted July 30, 2013 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: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:As regards the spare, another eBay pennies scoop resulted in this:Original Lupo spacesaver, with fitting kit and tools Quote Link to comment Share on other sites More sharing options...
Rich Posted July 31, 2013 Report Share Posted July 31, 2013 Sweet.I was simply going to harass but I'm enjoying this. 1 Quote Link to comment Share on other sites More sharing options...
JoeA Posted July 31, 2013 Report Share Posted July 31, 2013 Good work 1 Quote Link to comment Share on other sites More sharing options...
Danyutz Posted August 2, 2013 Report Share Posted August 2, 2013 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. Quote Link to comment Share on other sites More sharing options...
NornIron Posted August 2, 2013 Author Report Share Posted August 2, 2013 Anyone recognise these?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:to this:And this:to this:My braking confidence is restored! 1 Quote Link to comment Share on other sites More sharing options...
NornIron Posted August 3, 2013 Author Report Share Posted August 3, 2013 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:A good scrub with a wire brush took off the surface rust:And a bit of Jenolite left this:Break out the trusty Hammerite and a couple of coats later:At this point I was tired of taking things apart and needed a little bit of bling: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:All will be revealed regarding the black square later...!Some dodgy towing electrics revealed, which I'm undecided what to do with?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: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:I'm thinking a Dremel (or similar) would make a neat job of this, but I don't have one... Quote Link to comment Share on other sites More sharing options...
GTIChris Posted August 7, 2013 Report Share Posted August 7, 2013 Do you know anyone who's a sheet metal worker ?Tin snips would cut this and make a neat job of it Good work BTW, like it. 1 Quote Link to comment Share on other sites More sharing options...
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