All Things Mk5 > How to Guides / Troubleshooting
Mk5 rust removal, new sills and subframe rebuild
D2TPP:
Nah it took fecking ages 😂 I only got to it the odd weekend here and there. But it certainly wasn’t a weekend task!
The trickiest part was welding the sills. The originals are laser welded from the factory. They are also made from pretty thin metal.. so experimenting with different techniques to make sure the continuous welds didn’t blow through and even just taking the galv off the new sills and priming and painting behind etc. took weeks and weeks to figure out and more weeks and weeks to execute! .
GilesWoodward59:
Good job on tackling that all yourself!!
D2TPP:
Managed to get a bit more done this week, got the interior back in, got the back of the wings cleaned and covered in Upol. One major PITA was the rear middle seat belt which was completely jammed. After a bit of research.. smacking it with a rubber mallet and leaving it for a while managed to sort it.
The interior wasn’t too bad going back in… although I had forgotten about some of the trim I had broken when removing.. so another £60 or so on bits and bobs off eBay it was!
In preparation for putting ignition on to bleed the brakes, I had a look under the bonnet.. which reminded me I hadn’t put back the wiring loom to the power steering rack :sad: I’ve watched a few vids on YouTube and it looks like it should be possible without dropping the steering rack *fingers crossed*.
Sean_ED30:
Great write up. I'm planning on doing something similar with the rear subframe on my car, In the picture it looks like you have used alloy hubs on the rear ?
D2TPP:
--- Quote from: Sean_ED30 on March 15, 2023, 10:37:18 pm ---Great write up. I'm planning on doing something similar with the rear subframe on my car, In the picture it looks like you have used alloy hubs on the rear ?
--- End quote ---
Yeah I’ve put on Alloy hubs all round.. not had the tracking set up yet.. but it all seems to fit! I believe they are from a Passat.. the alloy wishbones on the front are from an s3.. but i understand you can also get these from a Passat
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