Author Topic: Shed-esque Golf2 Syncro  (Read 80679 times)

Offline Diamond Hell

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Re: Caged, bucketed & harnessed Golf2 Syncro ABF
« Reply #730 on: 07 August 2014, 14:49 »
Hello.  Believe it or not, I still have this, just been busy with lots of other stuff.  Found another problem when trying to swap out the CVs on the longer front shaft.  Took off the O/S front shaft to replace the CVs.  There was slop on the inner one, but the outer one wouldn't leave.  Until it was sledge-hammered off by DannyP.  The splines on the end of the shaft were bent.

Now this sort of thing wouldn't normally be an issue - you just replace the driveshaft, but because this is a standard-track MKII with a Rallye gearbox and transfer box there's only one shaft that will fit.... the one from a Rallye.

Guess how available those are.

I had a couple of 2WD shafts hanging around.



Which look like they might be possible to shorten down.

So, I got in contact with The One True Brian at RH Machinery, who does quite a lot of fabrication on the Locost racers from the IOW.  He was a bit nervous, because he hadn't shortened a shaft of this type before, but he agreed to take the job.

I dropped the shaft off and got a text about a week later - all done and good.  Apparently the ends are fabricated somehow in a single piece and then the two halves are cut to the right length and friction welded by VW.

The shaft I had dropped off was well out of true when he spun it up in the lathe - this is possibly why VW fit thumping great rubber dampers to them from the factory.

Anyway, he cut the required length out, turned down some CDS to fit in one end, fitted it, checked it was true, then turned it down to suit the other end.  These were then puddle-welded at 180 degrees at one point and again at a second point (turned through 90 degrees).  The external joint was then welded and flatted back - one perfectly straight shaft, the right length for my car.



One end was a bit poxy, hence the pitting in that photo.  I've now insured this and once I've finished setting up campsite stuff I'll need to get it out and MOTed and on the road.  It is about time.
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Offline Diamond Hell

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Re: Shed-esque Golf2 Syncro
« Reply #731 on: 08 August 2014, 02:40 »


FINALLY back on four wheels.  Needs a numberplate bulb, indicator bulb, sidelight bulb, headlight alignment and a pin into one of the screenwash jets, then it's MOT time.
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Offline Diamond Hell

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Re: Shed-esque Golf2 Syncro
« Reply #732 on: 02 September 2014, 00:37 »
So, it now has two new numberplate lights.

New front indicator to the offside.

New lights stalk.

Nearside indicators that work without tooting the horn!

An unacceptable wobble on the angle-drive output on the offside.

Time to pop the offside shaft back off to investigate.  :rolleyes:
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Offline Wazzzer

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Re: Shed-esque Golf2 Syncro
« Reply #733 on: 02 September 2014, 17:36 »
good going mate, hopefully see it back on the road soon


1999 1.8T: R-Tech remap - 225bhp/256lb/ft : K03s : THS FMIC : THS PCR pipe : 2.5" stainless exhaust : THS FR3 Engine mounts : G60/VR6 clutch : Calibra Yellow injectors : VR6 MAF : Devils Own WMI : Forge 007p : Carbonio CAI : Leon Cupra R Brembos : FK AK Street coilovers : Votex skirts : Anniversary front : click ---> http://www.golfgtiforum.co.uk/index.php?topic=92175

Offline Diamond Hell

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Re: Shed-esque Golf2 Syncro
« Reply #734 on: 02 September 2014, 18:33 »
It's not this one that needs your attention  :tongue:
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Offline Diamond Hell

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Re: Shed-esque Golf2 Syncro
« Reply #735 on: 14 September 2015, 14:30 »
This is back up and running now.

Took it to Combe for a track day (Horney was there) in July.

It rained.  A lot.  Only one car was quicker than us all day and it was a 2015 RS4, which is fine.

We took an event shelter, so we could shelter from events, which is just as well as there was much rain event through the day:



Mrs Hell drove:



A great day was had.

I responded to a call for people to take people out on track for Mission Motorsport last week and did a few sessions with randomers on Saturday.  Keeping rather nicer company than the Golf:



It's been MOTed, taxed and insured all summer, which has meant it's been out for a few nice blasts .  Chuff says I should paint the cage.... and he's probably right, but I have a lot going on at the moment.  :grin:
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Offline Rhyso

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Re: Shed-esque Golf2 Syncro
« Reply #736 on: 14 September 2015, 17:16 »
Paint adds weight though!! :grin:

Offline JC

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Re: Shed-esque Golf2 Syncro
« Reply #737 on: 14 September 2015, 20:29 »
 :rolleyes: I will just get Gemma to paint it................ PINK  :kiss:

Offline Diamond Hell

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Re: Shed-esque Golf2 Syncro
« Reply #738 on: 14 September 2015, 23:26 »
She'll paint it black.

She likes black.
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Offline Diamond Hell

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Re: Shed-esque Golf2 Syncro
« Reply #739 on: 26 November 2015, 22:58 »
Shockingly I have painted quite a bit of the cage.

Black.

With a brush.

It's better than just exposed steel, rusting.
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