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BigSexyRob

Harlekin rebuild. My resto-mod. This is Harleface

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BigSexyRob

You may remember my white 6n that I had for almost 7 years, well this is the build thread for my Harlekin that has replaced it.

 

I'd always wanted one, one of my oldest memories of seeing a car was one of these and after driving Travis' imported one at Polo Social lastyear...I knew I had to find one.

 

I bought this in July 2015 and it was completed in March 2016.

 

After talking to a friend of mine, he informed me he knew of one sat on a drive about 6 miles away from my work. I contacted the owner and went down that weekend with money burning a hole in my pocket. I was not leaving without it!! It had spent a chunk of its life been used as the courtesy car for the owners VW specialist business. But the last 4 years of its life had been spent sat on his drive unloved and not going anywhere. Reluctantly on his part, a deal was done (including him personally delivering it to my work) hands were shaken and money was exchanged. This is the story of the build.

 

Its important to note, that the majority of the work was carried out by myself. My boss did the welding and some of the mechnical. James Shelvey at CEVL Automotive sorted my notch and air ride. Ed Aldridge at Aldridge trimmers did my doorcards and also thanks to Jon Gallant for lending a hand and keeping me motivated over the 8 months it took me.

 

And also big thanks to my long suffering partner who I put through hell and back.

 

NOW LETS BEGIN..................

 

It arrived to me, nicely coated in a thick layer of dirt, mould, moss and grime. It hadn't to my knowledge been started in 4 years, I hooked a battery up and on the second turn of the key it fired into life

 

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Under the bonnet wasn't much better

 

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The interior was a different story. Ever surface was covered in mold. It was not a nice place to sit

 

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My own little fish bowl in the indicator

 

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Under arches had 105,000 miles worth of dirt stuck to them

 

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After a good going over with plenty of TFR, a pressure washer and some scrubbing. It all didn't come out to bad

 

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All the stickers off

 

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Scabby sills and scabby arches and a very poor attempt of a blow in on the roof

 

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First on the list was to give it a service

 

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The sump plug was giving us aggrovation. It was just turned in the hole. So out with the impact gun and air chisel

 

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New Vs. Old

 

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The first replacement panels arrived. Two brand new sills

 

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These were masked and a coat of epoxy was put on both the inside and outside

 

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Then came the partial strip down.

 

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Back outside where I could pressure wash the inner front arches and back panel

 

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Which all looked pretty solid

 

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I made a start addressing any rust/filler repairs to the drivers side doors

 

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I coated the rusted areas in a phophated rust inhibitor to prevent it coming back

 

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One back door repaired. It had been subject to minor accident damage so required quite abit of filler

 

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The front door was peppered with car park dings, so a full skim of filler was the easiest option

 

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Into the booth for some high build primer

 

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Finally after waiting for them to arrive for 6 weeks, the replacement rear arches turned up

 

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These to were masked and epoxy primed inside and out

 

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A trip to my local breakers gained me a passenger rear door to replace the rotten one I had and full set of door rubbers, as the original ones had perished

 

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Cleaned up the backs of the wings and the spare replacement I had

 

SNV15957_zpsrgfdo5nb.jpg~original

 

I made a start on rolling one of the front wings, until I realised it was rotten and full of filler. This wouldn't do, so I knew this one would need replacing aswell

 

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So another trip to the breakers got another front wing and another back door to replace the damaged one I'd already repaired

 

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Fully stripped out

 

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I marked up the rear door handles to get them made like the fronts I already had

 

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With two solid arches, I set about getting them ready

 

Lips flattened

 

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Side repeaters delete

 

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I'm not much of a welder, I'll stick to what I know best

 

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All filled

 

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Now the fun starts. I can't weld, so that task was left to my boss

 

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The sills and arches had seen better days

 

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My boss made a start removing the old

 

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Surprisingly solid inside

 

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Hand full of sealer where there should be metal

 

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Coat of stone chip on the inside of the new sill

 

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Old sill completely removed

 

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Masked up. A coat of weld through primer was applied to the edges, a coat of stone chip and painted yellow. To give as much rust protection as possible

 

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One new sill MIG and spot welded on

 

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Off with the rotten arch

 

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The void left by the rotten end plate

 

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And repaired

 

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New arch fully welded on

 

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Even spot welded the trimmed inner arch to the outer. Thats now this side rust free

 

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Wings and door handles went in for some primer (etch and high build)

 

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Now onto the passenger side

 

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Same rotten story here aswell

 

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Off with the old

 

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This end plate was full of sealer aswell

 

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Both replacement back doors filled and repaired

 

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The inner lip was missing, so that was repaired

 

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Replacement passenger sill stonechipped internally and same process to inner sill

 

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New sill end section made

 

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And sill welded on

 

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Lower rear corner repaired

 

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Time to repair the Hofeles, one was damaged years ago before I got them and the repair had become weak and snapped

 

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WIngs given a block throgh for a reprime

 

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Wheels swapped over

 

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Back doors in for a prime along with the wings, door handles, ABT splitters and Hofeles

 

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All done

 

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Replacement passenger arch replaced

 

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Both arches got rolled and fully seam sealed at this point

 

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While I was waiting on booth space, I made time to do a few more mechanical jobs that I'd forgotten. New fuel filter, pollen filter and coolant flush

 

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I also had a fuel leak, which I'd noticed for a while but not been able to find (dangerous when your welding) tracked it back to the fuel line in the engine bay which was missing its clip

 

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Time for more filler work. Passenger side getting the treatment

 

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Fast forward to the following weekend and the drivers side got the same

 

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With christmas rapidly approaching, which would be the deadline date for me to paint it. I finally got round to the roof

 

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While I was waiting on filler to dry, I also got the last door prepped for primer

 

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I blocked both 1/4 panels through to give them a second prime

 

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TODAYS THE DAY!!!!!!!!!!!!!!!!!!!!!!!!!!!

 

The day that put alot of strain on mine and my partners relationship...................

 

Today is christmas eve and I'm at work repainting the car

 

Fully unpanelled

 

SNV16241_zps4zjn2mwz.jpg~original

 

Guide coat applied and fully flatted all over

 

SNV16243_zpsx96ekzir.jpg~original

 

Once prepped and cleaned it saw the booth

 

SNV16245_zpsbjlpdicp.jpg~original

 

Masked

 

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SNV16249_zps6ewmpizi.jpg~original

 

I then seam sealed the edges and appertures and masked it for stone chip

 

SNV16251_zpskiowpngb.jpg~original

 

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SNV16253_zpsnrghot0g.jpg~original

 

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One final clean and were ready to go

 

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By this point, it was 6pm. I'd been working nonstop since 7am on my own and I was going a little bit mad

 

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Nice spot of Ginster Yellow

 

SNV16268_zpseonnqchw.jpg~original

 

And all painted

 

SNV16269_zpsyfgdxjdn.jpg~original

 

SNV16270_zpshtapyafv.jpg~original

 

SNV16271_zpsdxqaz1qp.jpg~original

 

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The face of a broken, exhausted man after pulling a 13hr day on christmas eve whilst my family and missus were in the pub

 

SNV16281_zps6abn4bnd.jpg~original

 

With christmas out the way, I was back in the day after boxing day to carry on

 

The ABT spoilers i managed to track down got a coat of primer

 

SNV16282_zpsd3hv5k2k.jpg~original

 

SNV16284_zpsfcwbqizm.jpg~original

 

SNV16287_zpso9eukn0r.jpg~original

 

The front arch lips and the back of the welded up side repeater got seam sealed

 

SNV16289_zpstdyskmpb.jpg~original

 

SNV16288_zpsh7kq3hq7.jpg~original

 

NOW FOR SOME RED!!

 

Bottoms of the wings and the lips got stone chipped

 

SNV16291_zpscnai4jck.jpg~original

 

SNV16290_zpsh2uwnzdn.jpg~original

 

SNV16293_zps7ltybzqq.jpg~original

 

SNV16292_zpsppdcypov.jpg~original

 

Rear door handles, Jap spec boot lid and Oettinger grill all in aswell

 

SNV16297_zps1om77s6l.jpg~original

 

SNV16296_zpsorfholug.jpg~original

 

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MMMM flash red

 

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The next day the boot lid was dry enough to fit

 

SNV16311_zpslx9c8xcc.jpg~original

 

NOW FOR SOME PISTACHIO!!

 

The ABT spoilers, splitters, DTM mirrors, Hofele rear light covers and front doors were all prepped and set up in the booth

 

SNV16313_zps0jmyzvam.jpg~original

 

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MMMM pistachio

 

SNV16321_zpsya7sqllg.jpg~original

 

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So with that all out the way and another new day. More booth action

 

Front door handles set up to be painted Ginster yellow and the Dietrich RS2 back bumper and back doors put in for some Chagall blue

 

SNV16333_zpscoor9yft.jpg~original

 

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SNV16336_zps2tu0d4eh.jpg~original

 

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MMM chagall blue

 

SNV16339_zpshcdz81vn.jpg~original

 

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And the front door handles in yellow

 

SNV16342_zpsohvtvwqp.jpg~original

 

I then spent what time I had getting the car repaneled. Doors rebuilt and fitted, boot lid on and green Hella magic colours on etc

 

SNV16353_zpsabrenn5d.jpg~original

 

SNV16354_zpscp81no5w.jpg~original

 

SNV16355_zps5abphgy0.jpg~original

 

SNV16357_zpsf5pfiwk4.jpg~original

 

After getting a replacement bonnet that I wasn't happy with, my last solution was to use the one off my white 6n

 

SNV16359_zpsd5f8qmvz.jpg~original

 

Some minor repairs to the front from where it had been pushed shut over the years

 

SNV16360_zpsknhnr2qw.jpg~original

 

Custom front bumper repaired and prepped

 

SNV16362_zpsknadmiro.jpg~original

 

Inside of the bonnet done

 

SNV16361_zps4ryouwju.jpg~original

 

All set in the booth, the bonnet and bumper will be high build primed and the inside of the bonnet will be wet on wet primed and painted Chagall blue, whilst the Hofeles will get a coat of gloss black

 

SNV16364_zpstswgmis7.jpg~original

 

SNV16363_zpse6opyjt1.jpg~original

 

SNV16367_zpscgytpocd.jpg~original

 

SNV16366_zpsosb3lqcl.jpg~original

 

SNV16369_zpscc09llmw.jpg~original

 

SNV16371_zps6rknvafu.jpg~original

 

SNV16370_zpsm9nmzbme.jpg~original

 

SNV16373_zps3moe648z.jpg~original

 

SNV16374_zpsq8sbnjna.jpg~original

 

Later on that night, I wrapped the side lights on the Hofeles yellow and refitted the cases

 

SNV16375_zpsldmytuap.jpg~original

 

SNV16377_zpsnmdbf8mg.jpg~original

 

SNV16380_zpsy4ugrsz0.jpg~original

 

Another day and more paintwork. This time more pistachio. The front bumper and a whole array of dash trim were prepped and set up

 

SNV16381_zpscklnzaky.jpg~original

 

SNV16382_zpshq17xvau.jpg~original

 

SNV16383_zpsrbfcvkpz.jpg~original

 

SNV16384_zps4ytxypno.jpg~original

 

SNV16387_zpscrtxbilz.jpg~original

 

SNV16386_zpsxdq4rlwb.jpg~original

 

SNV16388_zps9gschbmj.jpg~original

 

SNV16390_zpshyhycl2i.jpg~original

 

SNV16391_zpsh2snwu9l.jpg~original

 

Excuse the dusty interior. Once fitted I knew I had to do the clock surround aswell

 

SNV16397_zpsfro6obus.jpg~original

 

This was a sad day, but also a joyous day. My friend James Shelvey from CEVL Automotive came and collected the Harlekin. A few days previous the white 6n had left me to have the air ride removed. It will come back as a different car

 

SNV16398_zpswjo58wp8.jpg~original

 

In the mean time, I got round to painting the bonnet

 

SNV16400_zpsqm6gobz6.jpg~original

 

SNV16401_zpskzu8txxr.jpg~original

 

SNV16403_zpsom89yfsp.jpg~original

 

SNV16405_zpsizq8vdjy.jpg~original

 

A couple of weeks past and my dreams came true. Shelvey at CEVL dropped the car off freshly chassis notched and bagged

 

SNV16407_zpsqfi4nwv6.jpg~original

 

SNV16408_zpstfevledc.jpg~original

 

SNV16410_zpspapcvzix.jpg~original

 

I'd gone this far and done so much in the way of rust prevention, it would only be rude not to do the inner arches. They were all prepped and masked for a coating of stonechip and yellow

 

SNV16413_zpscfvv6bmt.jpg~original

 

SNV16411_zpsz68x4jk4.jpg~original

 

SNV16415_zpss0hjnhq7.jpg~original

 

SNV16417_zpssjx1vy2a.jpg~original

 

SNV16418_zpsgcosjlye.jpg~original

 

SNV16420_zpshyykhm0u.jpg~original

 

SNV16419_zps0e7wxwdl.jpg~original

 

SNV16422_zpshsys2eal.jpg~original

 

SNV16424_zps3wspupub.jpg~original

 

Whilst that was drying, I got the clock surround in and painted

 

SNV16425_zpshb3rqhng.jpg~original

 

SNV16427_zps46bul9z9.jpg~original

 

Freshly Ginstered arches

 

SNV16429_zpsyhyt6t1t.jpg~original

 

SNV16428_zpsgyr0fo7q.jpg~original

 

SNV16431_zpsghelrdpk.jpg~original

 

SNV16433_zpsqpvwykm0.jpg~original

 

Bonnet got a flat and polish

 

SNV16436_zps2jlpbpwm.jpg~original

 

SNV16438_zpszucqkepq.jpg~original

 

As did the wings

 

SNV16442_zpsg3j6xltz.jpg~original

 

SNV16440_zpsk5agoj3z.jpg~original

 

SNV16443_zps2g4n3ugt.jpg~original

 

So fresh

 

SNV16446_zps6wmi082m.jpg~original

 

Wings fitted

 

SNV16449_zpsgvm4czcl.jpg~original

 

Then the shell got a flat and polish (forgot to take pictures of the roof)

 

SNV16452_zpsj17wtczj.jpg~original

 

SNV16450_zps1kkv2rbz.jpg~original

 

SNV16451_zpsws1jjdpp.jpg~original

 

SNV16455_zpsmo6fodgb.jpg~original

 

Dietrich bumper got the same treatment and then fitted

 

SNV16457_zps0uprvyzp.jpg~original

 

SNV16458_zpsmqhv4t8o.jpg~original

 

SNV16459_zpshr4mkaul.jpg~original

 

SNV16461_zpsfonjoitq.jpg~original

 

SNV16463_zpslm8s4vkr.jpg~original

 

SNV16462_zpsyhucmqdk.jpg~original

 

Time for more mechanical to break things up a little. The brakes were shot, so all new all round including brand new calipers

 

SNV16465_zpsfzsfcqq0.jpg~original

 

SNV16464_zpskgvdajwp.jpg~original

 

SNV16466_zpse1ufvmoe.jpg~original

 

SNV16467_zps80j1y47e.jpg~original

 

SNV16468_zpso2lllguu.jpg~original

 

SNV16469_zpsgs3ifirk.jpg~original

 

I then went mad and refitted the whole front end of the car and the image I'd had in my head became a reality

 

SNV16470_zpsi706xctg.jpg~original

 

SNV16471_zpswughz3t0.jpg~original

 

SNV16472_zpsp63a6dli.jpg~original

 

SNV16473_zpsg5t5elbe.jpg~original

 

I then turned my attention back to the interior and with the help of my long suffering girlfriend, got the headliners and pillars retrimmed in blue suede. With all the mould that was on everything, I replaced the headlining and the pillars

 

SNV16474_zps305oxxye.jpg~original

 

SNV16476_zpsmsctpjyl.jpg~original

 

SNV16477_zpsnug4isol.jpg~original

 

SNV16485_zpshekls8ek.jpg~original

 

SNV16489_zpstwbr1fh6.jpg~original

 

SNV16490_zps8hbpoueq.jpg~original

 

All fitted in with black grab handles and Golf cabby black sunvisors

 

SNV16494_zpsze78vpvy.jpg~original

 

SNV16495_zps7okvj5n2.jpg~original

 

SNV16496_zpswwsiqwqi.jpg~original

 

Abit more flat and polishing action

 

SNV16492_zpsu7gtavxg.jpg~original

 

SNV16493_zpsbgeblxqt.jpg~original

 

SNV16480_zpsvv8mmnif.jpg~original

 

SNV16491_zpszcfoikhg.jpg~original

 

It was then back up in the air for more mechanical. In trying to take the sump plug out, we actually fractured the side of the pan as it was so rusted. So a brand new sump, gasket and bolt set were fitted

 

SNV16479_zpsm0gqtcch.jpg~original

 

SNV16478_zpsnnncv87t.jpg~original

 

SNV16482_zpsm1zfbi7j.jpg~original

 

SNV16487_zpswbmj8bpu.jpg~original

 

6n2 red roof strips went on

 

SNV16498_zpsse0d7fst.jpg~original

 

With all the under arch freshness, I couldn't leave the drums

 

SNV16500_zpsurbfbrkz.jpg~original

 

SNV16502_zpszhj3mhm4.jpg~original

 

SNV16503_zpsskl6w76m.jpg~original

 

Even the filler neck got the treatment

 

SNV16506_zpsowrdgofh.jpg~original

 

SNV16508_zpsrypuqrzl.jpg~original

 

Got the fogs all wired in and working as they should

 

SNV16510_zpshqnobzy5.jpg~original

 

I knew all the work myself and my boss had done would go to waste without proper rust proofing. So i spent the money well and ordered up a load of this stuff to pump into everywhere I could get

 

SNV16512_zpsrwu1ojiw.jpg~original

 

SNV16514_zps8krmm0ec.jpg~original

 

SNV16513_zpsxkjphfuq.jpg~original

 

SNV16515_zpsgxoy01bs.jpg~original

 

SNV16517_zps7lz5sqva.jpg~original

 

SNV16518_zpsakopdbv3.jpg~original

 

I knew I wanted the doorcards to be special. So i sent them to Ed Aldridge at Aldridge trimmers close to me for them to be done

 

Again, with all the mould, all the doorcards were replaced with new items.

 

Yellow leather with diamond stitching a different colour on each

 

SNV16520_zpsk5rqzcxn.jpg~original

 

SNV16521_zpskv4dyevb.jpg~original

 

SNV16523_zpsfo6q0ar3.jpg~original

 

SNV16525_zpsws2l7eey.jpg~original

 

A brand new old stock Polo badge and replacement Harlekin sticker was sourced

 

SNV16527_zpsjbjthf98.jpg~original

 

SNV16529_zps9thtkxdz.jpg~original

 

Hofele rear light covers fitted

 

SNV16531_zpsjy1nisrz.jpg~original

 

ABT spoilers and splitters bonded on

 

SNV16530_zps2m1tezgx.jpg~original

 

SNV16532_zpstfvu3y28.jpg~original

 

SNV16533_zpsuicda7ux.jpg~original

 

And thats it.

 

I will update this with some pictures of the car since the work was carried out

 

 

 

 

 

 

Edited by BigSexyRob
  • Like 1

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BigSexyRob

All about the colour coded G-Shock12976533_486278658230537_486600075_n.jpg

One from Stanford Hall

13113981_1045292395540179_1434379977_n.jpg

One from All Types     13277646_2001967020029035_2118366151_n.jpg

Rear fitment sorted with 25mm spacers to sit it on the lip12531079_1718547868423953_1293260520_n.jpg

FInal outcome of the interior. Harle inspired. Red Alfa 147 leathers and diamond stitched parcel shelf, yellow leather cards, blue suede headlining and pillars, Pistachio trim and Nardi steering wheel12965202_1710073525901236_891214209_n.jpg

Ace shot by Travis at GTI springfest where i managed to pick up Top 20 in show

12965915_989101624460323_1676281551_n.jpg

And finally a picture most people have already seen11372163_758977610905695_14190401_n.jpg

 

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madnemo

Looks stunning Rob :wub::wub:  and nice write up too .

Nimal

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spilz

Amazing work mate, didn't realise how much had gone in to it!

 

Has the previous owner seen it recently?

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Dean

Amazing work indeed! Dream car? :tongue:

Can't wait to see this at The Polo Social!!!!!!

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r10tz0r

Damn, huge amount of work, love it!

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kiran_182

Alot of work went into that, glad to see you got the car you wanted

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sean-1989-mk2

stunning build dude, I love the 90's look 

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