GolfGTIforum.co.uk
Model specific boards => Golf mk2 => Golf mk2 gallery => Topic started by: jv on 27 August 2006, 20:36
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here you go :)
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my pc has recently died, all my photos and writing are gone for the time being :sad:
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My names Matt, but everyone calls me Beavis, and this is my first car! Bought at the start of august, received the new V5 to the tune of 8 previous owners! But apparently the last one has been holding the car for a young couple who went travelling, and they need the cash so have asked for it to be sold. It's also passed through traders and that, and ended up in Brecon as well as Hereford, and now Bristol!
I'm still on a provisional at the time of writing after getting 19 minors, for menial things, was just a bit unlucky I guess, in my first test. Looked in the trade it, have always been after a 1.3 due to insurance costs, and suddenly, after 3 months of searching, I find the perfect car. A Mk2 Golf, White, 5 doors... Listed at 300 but bought for 2!
So my best mate, who's a mechanic, drives me over for a look, no tax, but an MOT to November (which we now believe to be bent) and instantly I love the thing, turns out to be a Ryder, everything is original, it's not been touched at all. The only change? The front number plate no longer is the original South Hereford Garages plate, while the rear remains... maybe one to replace?
Inside and out cosmetically beautiful but under the hood, the engine is covered with oil down the back, head gasket blown instantly though, but oh well, he knows a guy at work who can do it.. And the coolant is bone dry. I decide to buy it and the guy drives it over cheekily, as he couldn't care less just "wants to get rid of it". So it gets to my grandparents house, and thereÂ’s steam coming out, it's over heating, and the coolant reservoir has literally boiled over, release the cap, and poof a big cloud of steam and water spraying everywhere, not the friendliest greeting.
Inside its covered in crap, crumbs, ash, little bits of glass, it's not been cleaned in a long time, marks on the interior, passenger speaker pod smashed to pieces, radio doesnÂ’t work properly, wing mirror remote knob missing on passenger door, handle on near side rear missing the outside catch, sunroof arm above drivers seat, rotted away and fallen apart, but alas. Menial things that could be fixed, oh and a snapped off aerial!
Well, with seeing it like this, and how original and untouched it was, I decided that I would bring it back to life, making it look as if it had just rolled out the showroom 15 years ago.
Pictures to follow and a breakdown of what has been done so far :)
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(http://i89.photobucket.com/albums/k234/mattneck/IM000589.jpg)
so there she is, first things notice, side repeater to change, jsut a broken clip, the door handle off side rear was destroyed, as was the aerial, both now replaced so all in working order, speaker pod in passenger door looks like its been icked to bits, so have to buy a new one of them to install, and neds a dman good vacuum, these pictures are jsut from my cheap digi.. for now
Engine bay currently:
(http://i89.photobucket.com/albums/k234/mattneck/IM000588.jpg)
The dirt clogging the entire car:
(http://i89.photobucket.com/albums/k234/mattneck/IM000585.jpg)
View of dash:
(http://i89.photobucket.com/albums/k234/mattneck/IM000584.jpg)
Side view from rear
(http://i89.photobucket.com/albums/k234/mattneck/IM000582.jpg)
Through passenger door:
(http://i89.photobucket.com/albums/k234/mattneck/IM000580.jpg)
:smiley:
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So, discs and pads are first on the agenda, my best friend is teaching me all this as we go along so hopefully i'll be able to do it next time :grin:
Without wheels from front, better cam this time so i tohught i should post it:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00437.jpg)
I'll add a shot of the old discs and apds here, the state they were in, metal to metal and hardly a trace if any of a pad being there, the piston was so far out we had to grip it back in to push it into place as it had locked, and the brake fluid was pitch black, ho hum!
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(http://i89.photobucket.com/albums/k234/mattneck/DSC00439.jpg)
current cosmetic stae, dirty and faded, c*ckpit shine galore to come! remvoed the vents and cleaned them out, they look a lot better now, note the gear knobs current blacked out faded look.. took to it witha fine brush and my old airfix paints sunday night to come out with one very nice result, im quite proud of it i must say! remvoed the centre console for a clean and buff, and then temporarily replaced it to see what the gear stick looked liked aafter a bit of brasso..
artsy gearknob photo
(http://i89.photobucket.com/albums/k234/mattneck/DSC00463.jpg)
inserted console and knob
(http://i89.photobucket.com/albums/k234/mattneck/DSC00465.jpg)
wahey!
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(http://i89.photobucket.com/albums/k234/mattneck/DSC00440.jpg)
replaced the door speaker pod with a genuine one, coems without the single vw loo now, but the word aktiv alongside, have since found an original pod compelte with an original speaker! used for drivers door where the speaker had blown, leaving me with 2 fresh and clean original grilles, and a genuine spare left over :smiley:
oh and that windscreen knob is genuine, had to replace it doh! who pulls them off and doesnt put them back? christ.
radio out for repair, im havign a few probs, but after realising the speaker was blown and switch lubing the blance and volume it seems ok :smiley:
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grille and air filter gone:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00443.jpg)
battery next, look at the grime!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00444.jpg)
crossmember out
(http://i89.photobucket.com/albums/k234/mattneck/DSC00445.jpg)
bumper off and more disgusting grease and dirt appears
(http://i89.photobucket.com/albums/k234/mattneck/DSC00446.jpg)
manifold removed, attempting to remove exhaust but its stuck, fast.
(http://i89.photobucket.com/albums/k234/mattneck/DSC00447.jpg)
subframe and moutn gone, engine on jacks..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00448.jpg)
after this we attempted to remove it but the sheer weight was unbearable, return on monday with an engine hoist is on the cards!
i wrote this prior to this post so it seems a little out!
this was written when the old engine was still there and we had bought the new and began the replacement
originally we changed the head gasket, the ehad was skimmed down at this point to its limit, so it may still have been warped unfortunately, i can see oil currently seeping form the head gasket, after hardly running, but it was burning fuel extremely bad, mile per gallon maybe haha. well, conlcuion, carb gone, valve stems, oil seal, head dead.. i wasnt letting it go, so a new engine it was. weve been working on this this week, managed to get a hoist in the end for it as well.
This engine came from a Polo Mk2, its a 1.3 again, so the exact same block, just going to transplant it all together now, the new cambelt, fan belt, and sparks were added to the current block, so theyll be reused, and also going to move across the starter, exhaust manifold and the new gaskets and the alternator as its all in better shape. Should then be running by the weekend!
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a few menial things, resprayed air filter lid:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00449.JPG)
wind deflector destroyed, to be replaced, should help with the overheating problem!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00450.jpg)
handle damage
(http://i89.photobucket.com/albums/k234/mattneck/DSC00451.jpg)
speaker pod damage
(http://i89.photobucket.com/albums/k234/mattneck/DSC00452.jpg)
fe other destroyed bits to come, and sshots of the replacement work, why im unsure, just proof it standard i guess :wink:
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ok so the engine is finally up and on its way out on the hoist.. :cry:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00466.jpg)
and then it was gone, and the cleaning began inside the left wing and rear of the bay..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00467.jpg)
this soon followed all the way around
(http://i89.photobucket.com/albums/k234/mattneck/DSC00468.jpg)
and got a good polish up :grin:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00469.jpg)
the enw block sat there while being worked on.. we now have a new clutch in palce on it, the old one was bare, needs to be hoisted up tomorrow, gearbox slipped in and then remounted, couldnt be doen today due to needing to tap and die the mounts on the rear of engine on the driver side, so it should be in tomorrow, also as visible in the picture, restrapped and laid all the cables, will get a proper tidy and tieing up when the block is back in and the bodywork together. going to get some wirewool to sprakle up that head and block and gearbox once its back in to, should look nice and new!
hopefully thursday will get the bodywork back in at the front, bumper black on the cover and remount and we're getting soemwhere, the ballojoint for one side currently has a bolt stuck in due to my amt ebeing sued to working from underside, and turning the ratchet the wrong way, doh! so the the drive shafts will return and the wheels..
new cambelt, fan belt and spraks are currently on the old block, and a new water pump so will mvoe them over, for sake of doing so so everything is in a new state that can be. new oil and fuel filter to fit and oil upmp to clean as well, were sure its gonan be sludged right up and needing a good clean off. should be back in its original look soon! as soon as the front goes on the bodyworks gonig to get seen to, redefining that right hand curve aroudn the grille is a must. then glass, interior and vacuum, and blacken the trim to go..
armour door plates to, i hope! its getting there quick, will get some shots of the old gaskets, theyre in such bad condition they are worthy of a laugh, or cry for that matter :wink:
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So! Eventually we got the new engine in, with swapped voer exhaust manifold to fit the golf design. In the end we didn't go straight in for the weber, as it came with a pierburg and all that jazz bolted on, so tohught let's give it a go, bad idea, but i'll get to that.
new engine dropped in, subframe in and engine on mounts.. note strange looking polo mount on let hand side and bad condition looknig alternator, got the old golf one in better condition with a betyter mount to put in sometime though!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00470.jpg)
That's all we got done that day, took a fair whack of time out of us, and impending bad weather was also a bit of a unwanted treat :grin:
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Well on the old engine, gong back to that jsut to keep track f everything we went through, the cam belt needed a change, or, at elast, we said let's change it anwyay, meaning we had to source a new water pump, having 4 different guys try and crack this one out, using a big bar, a hammer, everything in avail.. it eventually fell out with a o-ring rusted in for good measure:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00472.jpg)
New pump went in, and obviously will be translated to the newblock with new alt belt soon :)
Sunroof was one of the first bit's of damage I sorted.. oe side already had the chrome arms, the only oens VAG seem to do now, so the other might as well have gone the same way.. after the drivers side one ahd fallen to pieces and was swimming in its own grime:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00473.jpg)
The usual pikey aerial snapping.. then my kepy for my Beru security arial broke so its sitting jsut up a few mm now, constantly, which is annoying :rolleyes:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00474.jpg)
The old, degraded head gasket..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00475.jpg)
Combined with some rather messy sparks that were replaced..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00476.jpg)
Destoryed exhaust, inlet, and oil gaskets..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00477.jpg)
Anyone notice the trend of how this car really wasn't looked after, and obviously jsut used as a run around :sad:
Obviously because the other couple were "away and he was selling it for them" (another crap story from a private seller) they couldn't care less!
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Pleased with todays trip to the breakers..
A nice pile of various VAG booklets, to make a nice big collection, and really only to add an instruction manual that ahd gone awol from mine :laugh:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00483.jpg)
Ooh and replaced drivers rear side winder, whoever had a dog in there prior had chewed the bloody thing to bits.. Pair of armour door plates went on as well, for peace of mind, really..
Oh and it went for a tune up on the PB which proved worthless.. The story of the PB that came with the engine was the usual, voer revving, sticking open etc.. and i idn't have time to see how far it went or the money to, I'm sure the suto choke spring is sticking, holding it opewn, it would start fine, thenstart to rev and stick at around 2k.. ended up with a weber, i was told was for a 1.3, came with a 1.3 manifold anyrate, looks a bit like a 1.6 or 1.8 one to the eye though, got that in for a tune up and it flys now, prior to that it would stall everytime you put the clutch down, on the PB. Keeping the both tohugh, worth a recondition I reckon, if jsut for a bit of fun..
Got a nice manual choke lead with the old N shape on, from a morris minor place in bath :laugh:
Pics to come
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Well, recently we discovered there was no servo assistance, a change of master cylinder as bleeding the brakes with the old method seemed to have killed the seals, all went swimmingly, pressure bleeding kit, all done and dusted, oh and this comes after needing to change a rear cyliunder on the apssenger side as it was pouring brake fluid everywhere!
So, that goes in fine, but braking still required a fair bit of pressure, take the pipe form the servo, and blow test works both ways (in the sense that it only went one way through, so it was ok) check the manifold, looks riveted, there was no suction at all. The manfiold, as far as i knew had been swapped, but the state of the gasket that came of didn't look as though, so check the other manifold, the one the weber came on, or might not have come on, who knows, ahd the same problem, riveted. so was the polo mk2 1.3 a non servo model? Well we managed to drill one out, and then checking the original golf engine, there was a gaping hole for vacuum, uhoh. Car was working fine anyrate, everything ran smooth, was jsut the braking was a bit inefficient, but they stopped me so that was ok for now, till the problem was source and i had time to swap the manifold. Get up wednesday morning, live on a slight hill, try to pull away, foot on brake, stright to floor, was free playing like nobodys business.. Look round the fornt and the metal retaining ring holding the plunger inside the servo had fallen out completly, it was laying in the bototm of the servo, the ring had bent out of shape, somehow. So, new servo it is. Sourced one forma 1.3 on ebay being broken, for £10.95 including postage, wahey! But then needing it ASAP and wanting it by saturday had to pay the uprated postage of bloody royal mail and their special delivery theft..
Was suprised by the ease of removign the servo really, apart form the nuts being a bit nippy to the thred, overall not too bad. Just looking forward to getitng it in their with a vacuum on it and get an early MOT sorted soon after the cambelt/waterpump/alternator switch over.
Riveted shut
(http://i89.photobucket.com/albums/k234/mattneck/DSC00610.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00611.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00619.jpg)
Weber, removed for manifold swap due to rivet also being on this manfiold, swapped to original golf manifold and preheater with plug from golf as polo had differing plug. Just need my inlet gasket form the old engine which was brand new to come across now :smiley:
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Original golf manifold, the wonky look of the hole and the polished tip makes me think they may have been all blanked from factory, and then changed according to car?
(http://i89.photobucket.com/albums/k234/mattneck/DSC00623.jpg)
My busted servo, look through the middle and note the..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00624.jpg)
..missing pin and retaining ring
(http://i89.photobucket.com/albums/k234/mattneck/DSC00625.jpg)
Shame, as it's in such nice cosmetic condition, and the new one coming I have recieved a close up of, looks quite rusty.. will need ome treatment without doubt..
(http://i89.photobucket.com/albums/k234/mattneck/P1010228.jpg)
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woo the new servo arrived, in a state!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00628.jpg)
gave it a good old scrub, and a lick of grey primer and it looked a bit more beastly!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00630.jpg)
and voila the finished article, whilst looking a lil oily due to the flash, came out nice, will have to take one of it mounted :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00633.jpg)
and the rocker cover is coming along, needs a final sand and coat!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00641.jpg)
till tomorrow :laugh:
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All together now! :wink:
A Nicely done rocker cover if i do say so myself, air filter touched back up for final replacement, all i need now is something to polish hat damn warm air shield!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00642.jpg)
After getitng it up and running though, a lap around the block shows the servo to be working.. by locing the rear wheels and screeching like a banshee :rolleyes:
But then when heading to show my mate who guest stars in the pictures and helped me do all of this, Bruce if you read it none of this would have bene possible without you mate, you're a star :wink: it decided it was going to kangaroo a treat, and cut out. Fuel pump maybe? Well, went and got the one of the old block and still no luck.. Had to leave it were it was 10 minutes from the house overnight, get it towed to the garage the next day only to ind out the carb was full of crap, apparently lots of black crap, probably due to having it off, and form when it was in the breakers for god knows how long, but the fine particles in the air from my spray job channeling into the house and floating in. All sorted now but apparently the fuel pump is backing up a little.. Really need to do my GB oil as well, as th 5th gear isn't very nice at the moment due to previous leak! My dad hadn't done up the bototm drain plug properly :rolleyes:
Once thats done and it's had a wash, i'll put up some pictures of it cosmetics and all that jazz!
:smiley:
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Jsut a little update, part 1, around and aobut the outside :laugh:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00755.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00757.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00763.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00765.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00753.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00764.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00762.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00752.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00754.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00766.jpg)
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a bit of damage to be fixed, off to get a quote off a friend of friend on tuesday, hope it doesn't make my jaw drop to the floor :grin:
rear driverside wheel arch
(http://i89.photobucket.com/albums/k234/mattneck/DSC00759.jpg)
wiper recess
(http://i89.photobucket.com/albums/k234/mattneck/DSC00758.jpg)
confusing as all hell as to how it happened.. passenger front wing
(http://i89.photobucket.com/albums/k234/mattneck/DSC00756.jpg)
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removed all me door handles today, decided to remove the grime surrounding thema fter ahving done the rubbing strips and side repeaters prior.. they all ahd the usual ring of grime around them like so..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00747.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00748.jpg)
so after removal, to eliminate those horrible faint scratch lines that the recess was riddled with a nice dose of tcut colour fast all around the dish and handle, taking away the cack..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00750.jpg)
leaving me with a very nice looking handle and suround, admittedly this one is with the armour plate, but you get the idea!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00746.jpg)
:laugh:
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Well, bodywork didn't get done as soon as hope, the guys boss is paying them all £60 extra a week to do every saturday till christmas due to having a lot of work on, but he really want's to do mine and promised he would come January.. I tried to pick out all the bits I could jsut to keep a record of all the little nicks and bits across the body so here goes..
(pics to insert)
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decided also to try and touch up my pinstriping, around the petrol cap and a little bit on the drivers rear door has come away, 20 2 metres for £1.50 and the works yet to come..
even managed to get the exact double line pattern :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00816.jpg)
and how it looks currently
(http://i89.photobucket.com/albums/k234/mattneck/DSC00815.jpg)
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"i cant apss that looking like that, it looks like its jsut bieng held on by string"
(http://i89.photobucket.com/albums/k234/mattneck/DSC00820.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00826.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00835.jpg)
had to do it in the pouring rain, so it's a bit messy :laugh:
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Ok, so some condensation in my headlights? no problem, get some kitchen towel, wipe it out, hairdryer, get the damp out, jobs a good un.. youd think..
the heat managed to make what was left of the seal around the glass go, as it was so dry anyway i dont know how it was holding the glass in even (see picture down below).. a dose of no more nails around the outside and voila shes back on the car now, clearer than ever :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00822.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00823.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00825.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00837.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00836.jpg)
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Pinstripe: Pt. 1: Petrol Cap area..
Pretty pelase with how it went, first time I ahve ever done something like this, this evening..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00838.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00839.jpg)
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its been a long time coming but finally an update!
mot passed, so happy with that, a few advisorys to clear up, main one atm is the fact my exhaust is blowing down underneath where the gearstick is, can hear it quite a lot and really want to get that sealed up! pretty sure its due to the toruble we had getting it together after the engine swap.. went for two new tyres at the front, so deep tread all round now, a pair of uniroyals for the wet weather for just shy of 60 quid all in was pleasing.. and a new dizzy cap and rotor went in for just under 9quid as well..
recently have been working on the dash lights getitng them all up to scratch, putting some brightness back in and making them all even, spurred on by the entire st of lights in my £15 cd palyer being dead, and my heater control bulb packing up to.. i decided to attempt the swaps and re-illumination of the lot..
so to bits it came
(http://i89.photobucket.com/albums/k234/mattneck/DSC00901.jpg)
and removing the bulb proved tricky
(http://i89.photobucket.com/albums/k234/mattneck/DSC00904.jpg)
as i ahd two sets of controls i decided to transplant the two together, as each had their positives, the noe in the car when i got it was full of moisture, anyway removing the display cracked it in two spots, a dap of brush on super glue did the trick..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00905.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00906.jpg)
and attmpting to remove the moisture from my original set washed away the display
(http://i89.photobucket.com/albums/k234/mattneck/DSC00909.jpg)
eventually after making a bodge job from a defunct rocker switch for my foglights, taking the bulb and feeding it through, i realised how to remove the pins, and the joy of a 99p bulb from maplin with..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00910.jpg)
so next came the radio display..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00911.jpg)
stripped back as you can see the new bubls and the orange filters from the radio in the bag.. all to be soldered on and fitted back together again..
to give a much better looking central dash
(http://i89.photobucket.com/albums/k234/mattneck/DSC00917.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00918.jpg)
next job replace the rear shelves with the ones i bought from ebay, my right hand has the shelf support snapped off, a direct swap will be easy and they came ready cut for a bootlight, something i found on a trip to the scrappy the other day.. so that can go in aswell..
they came to me in a state, heres the semi clean contrast..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00922.jpg)
scrappy haul was grand though..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00842.jpg)
with more besides :wink:
next jobs, replace fanbelt, complete pinstripe on rear drivers door and install shelves and bootlight properly..
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Well.. what a week, I park up on the road, for 10, 15 minutes.. Pop into my old school to see my old music teacher tell her what I'm up to nowadays (music tech at uni) and come out and find this sat next to my car..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00924.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00923.jpg)
Wether they drove into it, kicked it, went intro it trying to park or what I don't know, but when I found it the first tohught was wing damage, which there was nothing, no-one around, no note left.. no cars nearby.. nothing..
Lucky I have a vw breaker near my house and it was en route home.. so swung by there straight away.. shame he's extremely expensive doh..
the new bumper, perfect condition missing noe indicator luckily salvagable form the other bumper..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00929.jpg)
and the old bumpers damage..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00930.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00931.jpg)
I counted myself lucky the bumper is easily removable and easy to swap, compared to modern cars where everything is blended in, it could have been much worse I guess!
new bumper went on nicely though..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00933.jpg)
:smiley:
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have a gaping hole in my mid-box to..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00935.jpg)
and apparently a small split in the back box, both came up on the MOT, the one above as a minor leak advisory :grin:
checked the local Trade-It jsut as I generally do.. and have been noticing
"VW GOLF MK2 1300/1600 EXHAUST BITS £30 THE LOT"
for quite a while, located only aobut 20-25 minutes from my place I decided to get in touch and have a look.. was told it was the "Downpipe, midbox and backbox" so I thought fair enough, thats still bloody good, jsut have to pick up all the connectors and maybe a new corrugated so it was new all the way through..
Got there only to find that I was getting a lot more for my money..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00940.jpg)
tailpipe got the Autosol treatment, standardly :laugh:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00942.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00943.jpg)
So, a complete system, brand new and unused, all rubber fixings on, brand new, 3 brand new brackets for connecting the pipes, a brand new manifold to downpipe bracket, and brand new rubbers for backbox support..
All for £30..
Chuffed? I am indeed :laugh:
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An extension to the last post, thanks to rubjohnny for provoking me into having a second look, i was missing a new intermediate pipe to go between the corrugated and silencer :tongue:
South western exhausts, a new intermediate pipe of the same design with the flared end, plus an extra clamp that i would be needing.. £4.71.. still, I've only pid £40ish including my firegum, even more chuffed!
Hoping o mkae a trip to the scrappy to use the ramp there to lift it up and put it on, as axle stands just arent gonna cut it in this current weather :grin:
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just a small update for the moment.. till i ge the pictures uploaded.. after changing the lights in my radio etc, it spurred me on to overhaul every switch with new bulbs, brightening them all up, for only around 69p from maplin per bulb i couldnt say no :grin:
when fitting the exhaust i also realised a lot of the part which holds up the downpipe was mssing, so a trip to dealer or scrappy to source them all i think is in order.. current bodge: exhaust clamp through and around holding it up :rolleyes:
the exhaust went on easy enough though done on the side of the rpoad, after claling many garages who wouldnt let me use a ramp.. the one i had visited befire, couldnt find the number of, and popped to after, said i didnt call him.. :huh: would have saved some effort.. but tis made i a hell of a lot quieter now, no rattles or blows :smiley:
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So after a full morning of phoning around every small garage I could find who I thought would possibly be able to help me and rent me a ramp for an hour so I can fit the exhaust onto my car that I bought.. to no avail, so I decide to go it alone on the side of the road, only to find out alter when passing by a garage I had visited to see if he could weld the hole in my front silencer, he said to me "you didn't ring me did you" no, cause i couldn't find you in the yellow pages or anything, grr!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00944.jpg)
so these were the clamps sat on the pipes, they were unbelievably easy to remove, kind of loose infact, and i think it must have been leaking form everywhere, as there wasnt very much assembly paste if any in there, it literally slid off easy..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00945.jpg)
added to the dodgy rubber mounts that were on there, same as the previous one these were again originals, and didnt come away easy, i had to remove the entire metal mount and then unthread that from the rubber, refitting is a reversal of removal heh heh
(http://i89.photobucket.com/albums/k234/mattneck/DSC00946.jpg)
admittedly once i got into installing it, as i was on my bike under the car with about a foot of working space, the pictures just didn't happen, dirty hands and covered in paste, i didn't dare touch the camera but this was how it was looking on the day, one nicely polished tailpipe sticking out the rear..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00947.jpg)
and just a quick shot taken form the rear end looking under at the new system, looks odd, brand new, compared to the rusty brown colour of the old which matched the rest of the bits!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00948.jpg)
a random shot of the bits left over, i literally had to cut through the rubber mounts to remove them, last time using a saw in a pen knife, this time a stanley which was nowhere near as easy, but easier than trying to remove the bloody things at least..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00949.jpg)
the old exhaust system, luckily easy to remove by only splitting 2 joints, at first i couldnt remove the corrugated/intermediate/box from the downpipe, so had to stick 2 feet on the box and push hard, and bang it popped out, on top of me admittedly but at least it was done..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00950.jpg)
another shot of the hole in the midbox, where it was blowing form majorly, and cause hell of a noise, not in the way of an exhaust made for noise either ;)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00951.jpg)
currently i'm missing, form somewhere down the line the parts for the downpipe brace, I can't remember if they were there when we changed the engine or if it was done in this way prior, but at least it works temporarily, am currently toying with the idea of using a pipe clip, putting the silverish brace through the pipe clip then the bolt through pipeclip-silverbit-pipeclip-nut.. this should hold everything up above the steering rack successfully.
(http://i89.photobucket.com/albums/k234/mattneck/DSC00952.jpg)
and again from another angle, i'm sure it's not right at all..
also what with the winter weather and the cold and damp we are currently experiencing i thought it was best to finally swap the dizzy cap and rotor that ws left on the engine we bought from the breakers.. as this also seemed to be a common plan of attack when people buy a car.. i think it's lucky that i did considering the state that it was in..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00954.jpg)
old rotor arm wear..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00955.jpg)
old dizzy cap wear..
runs a lot nicer now as well!
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next job, which has been due admittedly since me and my dad changed the servo, has been to sort out why the brake pedal has to sit so high.. the pedal had to be adjusted, and lifted, due to the fact that the pedal was otherwise pulled too far down, onto the switch and an always on brake light, and now, its tempermental in staying on at times, a slight dab of the pedal and it will stick, or a full push and it will stick, but not always, and usually a slight touch will turn it out..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00956.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00958.jpg)
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another job as well is to work out why I currently have so much play in my gear lever, i've been told to test for 2mm of movement pulling upwards, and it seems to not go anywhere, but when moved to other points, it will lift, so wether the ball or cup is worn or not at all i am unsure, but for £12 for the complete repair kit, i'm overwhelmingly tempted to go for it in the hope it may do something. currently the ball atop the shift finger i am thinking is where the play may be, but i am unsure as to if the ball has worn, or not, and the part number atop this is an obsolete part but the shift finger which is on etka, seems to show the entire item complete with the ball atop.. so wether this will be worth buying, i am unsure, as i don't want to waste £11 buying it on special order from vw and then finding it makes no difference! the other things currently missing from it which i have spotted on etka seem to be the bearing ring, again another possibility, yet something which is not visible in the haynes, and does not define as being for 4 or 5 speed exclusively, which the shift fingers do.
(http://i89.photobucket.com/albums/k234/mattneck/DSC00959.jpg)
shift ball atop finger
(http://i89.photobucket.com/albums/k234/mattneck/DSC00976.jpg)
bracket with loop around ball atop shift finger, and shift finger
(http://i89.photobucket.com/albums/k234/mattneck/DSC00977.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00978.jpg)
the same visible from further behind showing the pipe clip holding the shift pole in place to the bracket, where according to etka there should feature a bearing, and a top down view of the same clip where there is nothing else inside
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Managed to remove the brake light switch today, get to the local factors to see if they ahve another one, only to be told "they do extend, you just pull it out, look.." cue the guy pulling the switch out to a good length, rather than it being pushed all the way in, must have got knocked during servo swap, grr.. at leas ti've got flat pedals now, will edit this post with some pictures..
Also found tonight, as I have been wondering as my MPG seemd to drop a fair amount.. Turned out the Vac from dizzy advance to carb had split at the end, so underneath the airbox, on the side of the carb, I had a bare open vacuume connection, I forgot to get a photo of it but it was about 2cm of the pipe just opened wide.. cut the end of and have stretched it a little to hopefully fit, will bae to be attempting at that tomorrow now.. hoping the return of the vacuume will help the fuelling/consumption out!
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Big thanks to rubjohnny for putting me up with tea and parts and a trip to the scrappy, Legend! :smiley:
Managed to pick up a few good bits but the white 5dr had gone awol unfortunately :sad: and by the time we got back from the ayrd, I started to realise the things I wanted, always the way :laugh:
Saturday morning I finally got rid of the annoying piece of foam stuck to the rear passenger window, the only peice of non original glass on the car, and the oiginal glass was everywhere in the car, when we bought it :rolleyes:
£2 for a scraper at the local cheapy store
(http://i89.photobucket.com/albums/k234/mattneck/DSC01026.jpg)
and the before and after, from mess to cleanli-ness
(http://i89.photobucket.com/albums/k234/mattneck/DSC01027.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01028.jpg)
oh and I found my old fan belt, replaced due to fer of snapping, admittedly it was only through the outer layer but still..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01029.jpg)
scrappy/johns garage haulage..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01034.jpg)
another thanks goes for doing all the ends of my vacuume pipes and stuff, and making my airbox sit lower, quality idea with putting it underneath the threads isntead, and emans it's not rubbing my bonent anymore :laugh:
as my fullbeam switch ahd worn right out, found a stalk sat in a rado.. and stole the end from it
(http://i89.photobucket.com/albums/k234/mattneck/DSC01035.jpg)
as my old oe was worn the new one went on..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01038.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01039.jpg)
next job, seals, hacksaw these down and get them on hopefully..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01036.jpg)
oh and a new dipstick guide, It looks like i've got more oil than I thought atm :embarassed:
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Nothing much but a little something I thought I would add..
As far as tidying up the engine bay goes I am extremely tempted to get some plastic tubing to put around all of my wiring to make it look that extra bit neater.. but first things first I changed the coolant overflow cover for a less faded nicer looking one..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01042.jpg)
And also finally changed the earth strap which was hanging loose when I bought the car, as a temporary fix I managed to cut through it with the bolt that held it in, but after finding a new one on Sunday, I've swapped it for the tidier one.
(http://i89.photobucket.com/albums/k234/mattneck/DSC01044.jpg)
Also finally managed to get a shot of the brake light switch and how it was fixed, the length of the switch which can be seen was actually minimal, turns out that all that needs doing is pulling it as far out as can go, with the pedal adjusted to the right height, hen push the pedal down and release and the switch will lock into place at the correct length, voila..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01048.jpg)
Also have been introduced to the joy of relay number 99.. For those of you who drive regularly in the rain etc, and the intermittent wipers are too slow and the constant first speed too fast, this lets you set your speed by turning on, waiting till you cannot see again then turning them off and on again, to set the delay time.. thanks to rubjonny for that!
(http://i89.photobucket.com/albums/k234/mattneck/DSC01049.jpg)
Relay 99, replace in same location as number 19..
Also had a random call form my friends in the bodyshop who said the uni 2 doors down that does scrap metal just had a golf roll in, it as being depolluted and was going to be gone within minutes as per usual.. managed to get there quick enough to grab the seals as it was a 5 door.. now, on this car the seals were long enough to fit in underneath the seal by the half window on the rear doors, yet, as soon as I put them on my car the same thing happens as they were with the originals, they arent long enough to fit.. is this possibly due to my car being post 90? Anyway this was the state of the old seal which I wanted to replace mainly for cosmetics..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01054.jpg)
Also got a nice little haul off the thing, such as a mint condition non faded rear vw emblem, a leather golf ball gear knob.. with a slight bit of damage, where a hole has been picked out but its not overwhelming, and a heater control panel which on closer inspection when I arrive home, are newer than expected, hopefully meaning theyve got some good lighting left in them yet..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01055.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01056.jpg)
Not bad for a fiver!
Oh and a new ryder badge for the rear, in a better state than the almost scuffed to black on Ive got... need a new front one at the moment though, as thats scuffed to, could be another tin of humbrol for that one though..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01146.jpg)
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Went to my local factor this morning, with one aim.. 2 new heater hoses to eliminate my smashed and broken vavles, and to avoid the bodge copper pipe job, and a new acceslerator cabe of the right elngth so it doesnt do a loop the size of my mainfold before it clips into place..
all 3 were 9.75+vat each, so around £30 in all, which wasn't bad at all.. and it will finally mean I get some heat.
(http://i89.photobucket.com/albums/k234/mattneck/DSC01107.jpg)
this was the first pipe off, which i took first away from the valve, and then drained as much of the coolant off as possible to save too much loss.. altohugh I did run out in the end and had to evert to pure water until I can get some more coolant tuesday evening
(http://i89.photobucket.com/albums/k234/mattneck/DSC01108.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01109.jpg)
removed the feed from the thermostat housing end, and then also removed from the matrix pipes at the bulkhead..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01110.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01111.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01112.jpg)
although i forgot to put the return pipe into a nother bottle, so, laws of gravity say, i'm going to spray you and soak you and lose most of your coolant.. bugger.
(http://i89.photobucket.com/albums/k234/mattneck/DSC01113.jpg)
the valve removed with traces of the pipes left on it..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01114.jpg)
and the rather odd damage I found the other day when I flushed my matrix!
(http://i89.photobucket.com/albums/k234/mattneck/DSC01115.jpg)
so on went the two new pipes, i decided to mess about with jubilees rather than attempt to replace the spring clips in such an awkward location
(http://i89.photobucket.com/albums/k234/mattneck/DSC01116.jpg)
so with my bodged coolant resevoir i created, I realised the top half would make a great funnel and I proceeded to fill up the system again, a little too much oops, forgetitng there would be a huge airlock up in the matrix pipes..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01117.jpg)
cue some major boiling over, spraying everywhere and general mentality, as you can see, a fair bit went awol at this point..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01118.jpg)
took it for a good drive up the keynsham bypass doing 60ish, got it to warm up and work it's way through, had some good heat, but it did drop at times, so, gonig to go on jonnys advice as to "burp" the system and retopup, and here's hoping it will :smiley:
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next job, stop the bloody screenwash gonig all the way back from the tailgate, one small part form halfords, total cost, £2.29.. and it was done..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01120.jpg)
for some unknown reason I didn;t think to cut the rubber pipe where it would so obviously stretch to fit the valve, no, I cut the main plastic pipe like a pillock :huh:
luckily my mate had brought me home some rubber vac hose the other day, which came in useful, as it had just enough spare on the end that I was planning to cut off, to cut in half and put on either end of the valve, and the plastic pipes.
this is the area you should cut, i recommend after experience now, cutting the rubber pipe between pump and the main line..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01133.jpg)
then ifd you buy the same halfords one as me, it's black side to the bottle, and now you have instant wash each time
(http://i89.photobucket.com/albums/k234/mattneck/DSC01137.jpg)
:cool:
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Accelerator cable, the next job, having heard it constantly grinding and it being very tight for a long time it had to be done..
So, in underneath the dash i unearth the accelerator cable hooked into the pedal, and attempt to extract it..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01144.jpg)
but don't do too good getting it out tidy..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01167.jpg)
now my old cable had been cable tied to my fuel line, went in a large loop then went onto the carb, probably one of the factors making it grind and horrible.. comparison of old and new..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01168.jpg)
After pulling it out, finding how to get it back through at first didnt occur to me that it was going under the scuttle tray, so after lifting it up it made threading it a lot easier
(http://i89.photobucket.com/albums/k234/mattneck/DSC01172.jpg)
this also meant the cable could be routed a lot tidier, and after filling it with 3 in 1 to keep it smooth, it bolted in perfect, note having cut off the small bell shape that is found on the end of a carb accelerator pedal which isn't of any use to me, trimming it to the crimp which fits meant it was a lot better than my frayed old one, and frayed choke cable..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01173.jpg)
Also realised after that the hook was in the wrong side, this was due to me having to insert it after getting the weber installed, and the choke cable hanging down, catching the accelerator and pulling the cable right out..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01176.jpg)
next job get to repainting the accelerator pedal jsut to tidy it all up a bit, and put on the new brake pedal rubber, to match the new clutch rubber. Nice.
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Finally, I get around to checking out aobut healdight looms,. within 24 hours of researching it I had it built.. within 32 hours it was finished and mounted in the car.. :grin:
On the shopping list, 4 colours of 2mm2 17amp rated cable, here ive got 5 colours, but halfords had .75mm blue on the shelf in palce of the 17, i didnt notice till i got home that t was wrong as i didnt think and i wasnt the ne measuring :laugh:
went fr the professional approach of 2 brand new H4 plugs.. a proper ABS box, 3relay blocks, a proper mini fusebox, and a load of connector bits.. and relays from VAG cars, jsut to keep it all close to home :rolleyes:
(http://i89.photobucket.com/albums/k234/mattneck/DSC01187.jpg)
first job was to chekc behind my headlamps how the wiring went..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01183.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01184.jpg)
as can be seen on both sides due to me having spots, the brown is ground, the white is live to the mainbeam/spot and the yellow is the dip.
first job, 2 connector leads to go from loomcase to battery, need 6.35mm rings iirc.
(http://i89.photobucket.com/albums/k234/mattneck/DSC01188.jpg)
I then connected the fuseholder up swith some leads, and then into the relay blocks..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01189.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01190.jpg)
this was the positive connection gonig in on pin 30. next i added the ground to pin 85..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01191.jpg)
and bulb and blade connections to that, the blades will be hanging outside the bx to connct the original loom H4, the in from the main loom on pin 86 and out to the new h4 on pin 87
(http://i89.photobucket.com/albums/k234/mattneck/DSC01192.jpg)
then added the H4s and the loom was complete
(http://i89.photobucket.com/albums/k234/mattneck/DSC01193.jpg)
due to the ruts in the box for the scres to go in the relay blocks were minimally too wide for it, so i "fabricated" a board form some card and ducktape, to which I taped the relay blocks..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01194.jpg)
then proceeded to drill and mount all the connections, and yes i plan on swapping the ducktape on the fusebox for somehting a little more professional :laugh:
(http://i89.photobucket.com/albums/k234/mattneck/DSC01195.jpg)
and a closeup inside the box, one relay to cover mainbeams, one runnign dipleft and one dipright..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01196.jpg)
wahey, the meter reading for the original loom was around 7.87 reading with new loom, after haivng lghts on sa while and not engine, 11.73 coming out direct, wether extra brightness will actually be visible i'm not sure yet, as I haven't had chance to test, but form within a few feet, I couldn't tell :tongue:
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Just a short one for now, as I have had my first semester of uni work going in this week, yay!
Managed to get a new front grille as mine had all but one clip missing, and was smashed around one of the spots, £15, just need to swap the lower trim over, but keeping it off atm, as it has a black one so can wait till the bodywork gets done. Must also get pictures of all the little blips and stuff that I'm going to get painted, although after asking about getting it blown over, the guy doing it had apparently said it might be worth while doing the full body instead as it will turn up a lot better :smile:
Next jobs that are currently sat in the boot, turret carpets, need to find the lining to bridge between as my boots a bit of a state inside, and as I transport PA it will only get damaged again. Oh and tempted to get the bay tidied up on the sides, running up to the turrets.
fitted my new handbrake surround with intact t piece below, so no more movement, if only the bloody thing stood straight now (the actual lever) I’d be happier! also found a number 20 relay, needs testing for rear wiper non intermittent, im sure I’m not the only one who gets annoyed at the turn on then have to turn off annoyance of it. :grin:
engine steam clean and a full valet, post bodywork, so the cars full fresh, cause then the door cards will get done at least, and once its done properly once, I wont keep chasing the dirt that comes up out the carpets, also did get some VW logo rubber mats from a scrappy mk2.. Fiver for the lot on them, not VAG I don’t think but quality looking all the same, can protect my carpet form the mats I’ve got sliding around on them at times.
Got the remaining under seat leg linings I needed to cover all the legs, a non visible piece of trim really, but it'll look tidier. and after seeing Lewy selling "cold air feed pipe" and noticing I had the same pipe as my warm air feed, I was worried I would be losing heat as it moved through the pipe, as thought it may transfer away with no insulation, so a OE heater pipe cut down to size with this material insulation should help out in the cold weather and it looks tidier to
major picture update to come :cool:
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It's been a funny few weeks, with everything going in to uni, and discovering 3 or 4 new yards for bits... My favourite find at the moment has to be an original factory blanking plate for the radio, possibly useful, most likely not, if I ever park somewhere a bit dodgy and don't want to leave the stereo. Got to love the fact that you have to sue genuine stuff to avoid rattles..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01198.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01199.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01200.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01202.jpg)
Finally got round to swapping the air feed, got worried after reading about the metal pipe being cold air, and pondered on the insulation on the warm air feeds, stopping the heat dissipating, theres been a noticeable bit of difference in the carb warming up as well..
Old pipe
(http://i89.photobucket.com/albums/k234/mattneck/DSC01204.jpg)
New pipe, a bit tidier too..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01205.jpg)
Next job I decided to go with a steam clean, get all the crap off the underside of the bonnet and some of the winter gubbins off the block and that.. £10 for an engine steam wasnt too bad, but it did blow paint off my rocker, oops
(http://i89.photobucket.com/albums/k234/mattneck/DSC01212.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01214.jpg)
Next tried to stop the rocking driver window Ive got, it's not too bad, but rocks when you got your hands on it, doesnt do it itself, first had to trace the 2 bolts going through, and removed
(http://i89.photobucket.com/albums/k234/mattneck/DSC01216.jpg)
Then managed to move from 315mm to 310mm, the length between the edge of the grasp and the edge of the glass, with a few knocks of a hammer; first downward then inwards.
(http://i89.photobucket.com/albums/k234/mattneck/DSC01217.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01218.jpg)
Oh, and in the end, no difference, the window STILL rocks back and forth :laugh: bit more to come soon.. if only i can get out the house to take pictures in this cold!
-
due to my damaged grille, in this case, only noe clip remaining holding it to the headlamp at one end, the plastic around one of my spots split right the way round ready to fall off at any point, and the fact it was held on by 1 screw wasnt very good.. a nice new grille, with a black trim on the bottom, whcih will get swapped to my white one when i get round to sanding/priming/painting the bugger, may jsut throw it in with my soon come body job.
in the end it took a junior hcksaw to rmeove the spots, as every screw was seized in, so i couldnt turn the wings..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01203.jpg)
next the final bulb in the dash that eneded replacing, apart form my right ahnd clcoks bulb which is tempermental, remove the console, get round the back and pull the bulb off..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01219.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01221.jpg)
tiny thing, not even wroth £2.62 surely?
(http://i89.photobucket.com/albums/k234/mattneck/DSC01242.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01243.jpg)
new one arrives, different design, how the hell does it ffit? turns out ive left a piece of plastic behind, a quick fiddle with the pliers and a flat blade and everything is removed, its not as bright as the one i nnoticed in a scrapped golf, but itll do..
bonnet catch, during engine change, RIP.. my mate manages toc rank up the engine crane catching the catch and bending it, so now it doesnt spring, usually catching when closing the bonnet like this:
(http://i89.photobucket.com/albums/k234/mattneck/DSC01250.jpg)
£5 for a very dirty noe form the scrap, coul have done better i espexct but nevermind.
a good dose of engien degreaser ad a wire brush tidys everything up..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01230.jpg)1230
still cant find a working door speaker, ive boguht 2 within the past week, both with grilels which means i got soemthing out of it but again both were dead. the only remaining speaker for a complete OEM collection..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01225.jpg)
also got round to picking up the 4 new seals for my interior light door switches, around about £1.60 each were a bit pricey but will look a lot tidier
(http://i89.photobucket.com/albums/k234/mattneck/DSC01244.jpg)
-
also managed to find a new scuttle panel, my old hard plastic one is scratched and discoloured and has a small (repairable) hole but i saw this and got it for a fiver.. gave it a soap up and showered it down as you can see here tis drying back to the manky grey they fade to..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01254.jpg)
only a small bit of damage on one off the drainage bits, but no biggie, bit of silicone on it..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01255.jpg)
a lick of paint, engine enamel black for high sheen, the difference is noticeable..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01257.jpg)
and the final article huzzah!
(http://i89.photobucket.com/albums/k234/mattneck/DSC01258.jpg)
its a sunday, and no, I've not got a lot to do today :grin:
also if anyone ever removes their scuttle, a top tip to not lose them bloody clips that are there..
bit of duck tape over the top, down the back and onto the boy, then a flat blade underneath one side, bring it up and they stay on at one end and then a small flick and its off, and stuck to the tape not lost forever :smiley:
and the obligatory shot of the old vs new scuttles on the car :grin:
(the photo I took has gone awol, so this is how the bay looked before the work, followed by a shot of the bay with the work, its a little scuffed and dirty again cause of the winter weather and the steam clean blowing paint off my rocker, oops.)
(http://thwackme.net/Golf/IM000588.JPG)
*new*
-
bootcarpet, chokecable, grillelowertrim
jsut a note to remind meself :grin:
-
Wow, it's been a while.. had a few thigns going on, sso ehre a small rundown of some of the main ones with the car for now!
Handbrake light, coming home from a night out DJing, mate in car, tlakign aobut getting combined HB and choke light for my new genuine choke cable, try to take it out and rip out the bulb :laugh:
I rememebr somene tlaking of changing theres and how to do it, proved very easy, and jsut the same 69p bulb from maplins i sued for my dash switches :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC01442.jpg)
Then I did some work for my mates misus, loads of work n the side fixing peoples decks etc so the car didn't get much done, altohugh the money set me up ready to get work done, but then it snowed..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01443.jpg)
:smug:
And also solved my oil filler cap leak, thatw as rolling down the front of the rocker, dodgy gaskt, it was cracked and perished beyone belief, lucky i had the spare from the old engine..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01445.jpg)
Also decided recently to refurb my steels, in time for when the bodyshop work comes around the start f april, when i head off to Barcelona :cool:
Decide for a chuckle to get soem cheap spare whels to put on while the steels get done.. slapped vw bbs on google, and oddly, out of all teh sites that could have coem up, a set of bbs style wheels are for sale, 2 roads away from me, the first find on google!? so 4 bbs style 14s, not in great con, one trye got a nail in mid but all good tread.. not bad for £40!
(http://i89.photobucket.com/albums/k234/mattneck/DSC01451.jpg)
Started on the refurb last weekend, favour from my good mate neil, rubbing of trims, testing a few ideas, rubbed A wheel, just A wheel i said. bloody time consuming. Should all be done in the enxt cople of weeks, the rings are the worst..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01480.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01481.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01482.jpg)
tried this blue line to match my pinsripe but wasnt sure
(http://i89.photobucket.com/albums/k234/mattneck/DSC01483.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01484.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01485.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01486.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01487.jpg)
thena ttempted with a clsoer match blue humbrol paint brushed in, still, not too keen so gonan revert to the fully silver as seen above, should keep em looking nice..
the refurbed on:
(http://i89.photobucket.com/albums/k234/mattneck/DSC01488.jpg)
and with a blue attempt cap instead..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01489.jpg)
:smiley:
p.s. no feet or hands in these photos are mine :grin:
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Lights! New uns!
Bought these crystals from Ben Mew.. now thinking it was too much of an impulse by, with the rest of my car being so stock, i don't think it'll suit at all.. everything else is standard as.. maybe these will go up for sale soon!
(http://i89.photobucket.com/albums/k234/mattneck/DSC01492.jpg)
also a set of LHD lights from germny, bought with good reason..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01494.jpg)
they have motors!
(http://i89.photobucket.com/albums/k234/mattneck/DSC01493.jpg)
now these look easy enough t fit to a set of RHDs, the same screw is sued, the alttice piece is jsut remvoed and the motor installed..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01505.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01509.jpg)
adnd held with a seal between the 2
(http://i89.photobucket.com/albums/k234/mattneck/DSC01510.jpg)
inside the motor the setup is extremely basic.. jsut a switch and itll pull the screw in and out to adjust the height
(http://i89.photobucket.com/albums/k234/mattneck/DSC01511.jpg)
sourced 2 of the 3 plugs from vw needed for the loom, one i still cant get and is on backorder, so the standard bodge job has been commited.. spades.
(http://i89.photobucket.com/albums/k234/mattneck/DSC01512.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01513.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01514.jpg)
still need to make a wire fr illumination, 4 of 5 are there currently.. this jsut eneds fitting to the D plug for the ign live feed to get the babby going.
also hanks to rubjonny for the original loom pictures..
(http://i89.photobucket.com/albums/k234/mattneck/hladjustfusebox.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/hladjustswitch1.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/hladjustswitch2.jpg)
a very simple piece, heres hoping all goes to plan now :smiley:
-
Oh yeh almost forgot the little try i had with a bit of gloss black and a set of busted side repeaters today.. after watching my mate dust a pair to a strong black, instead of using smoke tint, i did these that wer ready to bin to see how they looked..
Light still shines through, with a clear bulb, not very intense but definately does it..
Plus I don't think i'll bother fititng them, maybe try them with an orange bulb to see if they are any better then but anyrate.. Heres a couple of shots form different angles showing ow solid they look, would match black trim perfectly I reckon, makes everything match, maybe smoked front bumper indicators to blend the lot, but not for me, standard baby!! :laugh:
(http://i89.photobucket.com/albums/k234/mattneck/DSC01515.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01517.jpg)
And just held up to a light in the room, shows light can still penetrate through..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01521.jpg)
They're broke ayrate so they'll msot likely be binned soon :rolleyes:
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There's too much I need to add here, new wishbones, new tie rods and ends, new bottom ball joints, new front hubs and bearings, new rear bearings, got a replacement front passenger wing due to the fornt end dmage on it, altohugh its got an arch so im a bit sketchy as to underneath, altohugh my mate said he can sort it.. mint condition ryder interior, well almost mint, £20 so i can make one complete mint interior from it all. mint condition not a single ding or dent or mark bonnet £5 in alpine white, although is covered in cack so will need to get the tcut out! its in the bodyshop while im on holiday which is good, finally it gets done.. cant think of much else ive done at the moment, havent had any time! oh flat boot carpet as well, which is so so much better.. photos and all that jazz soon :laugh:
-
Well it's been through the shop, it's not completed yet but theres a few key bits that did get done! :laugh: Before that though..
Finally got around to replacing my rocker cover gasket, I highly recommend doing it to anyone who's got oil seeping down around the head, a) it's messy b) it's a suprising amount over time, it's my fault for having the rocker off and not renewing it even though it was a couple of weeks old, it had already been compressed.. You can see where the oil was just passing by the rubber and out..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01894.jpg)
This gave me chance to redo my rocker with a bit more experience and idea of what the hell I was doing! It's all about the little things to, the finer details.. :laugh:
Such as repainting the rings and wire brushing the bolts off!
(http://i89.photobucket.com/albums/k234/mattneck/DSC01898.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01899.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01900.jpg)
Finally got round to giving the interior a fully good clean, admitted only with a can of upholstery cleaner but it still did good, the after math form one seat and looking around proved how dirty it really was.. so a full strip of the interior form the car to clean properly ensued, no seat cover strippage though, unfortunatly..
I've ben sat in that!!?
(http://i89.photobucket.com/albums/k234/mattneck/DSC01974.jpg)
Left is cleaned, right is manky.. :grin:
(http://i89.photobucket.com/albums/k234/mattneck/DSC01976.jpg)
Fresh, ahh ahh!!
(http://i89.photobucket.com/albums/k234/mattneck/DSC02105.jpg)
It then became an odd job week.. the light above my clock had gone so I thought i'd finally get round to doing it, open up the bulb holder and find out that its easy to do, pull the bulb out..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01977.jpg)
Open it up replace bulb in holder, no point, 69p at the local factor, so binned them :wink:
Trying to refit them I broke 5.. trying to get into this little hole, the only way to pivot them was long nose pliers.. got one in 45deg, left it 5 seconds and hear "tssh".. 5 times..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01983.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC01988.jpg)
Found the ebst way to be shove the speedo cable and grommet into the car to pull the clocks up and out, disconnect spedo and loom, do it in your kitchen, refit speedo cable, pull back through and poke into point around the edges :cool:
Someones beasted up my radio loom, maybe this needs tidying sometime.. noticed an extra plug back there as well, i think someones done some editing though to make it ISO?
(http://i89.photobucket.com/albums/k234/mattneck/DSC01979.jpg)
the main dings were done, the wing totally reshaped, an excellent job I feel
(http://i89.photobucket.com/albums/k234/mattneck/DSC00756.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02094.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00758.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02095.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/driverreararch1.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02097.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/rearabovebadge.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02098.jpg)
finally tidyed up the front end with a toweye cover that fits.. clips onto the actual eye rather than flipping up like the older ones
(http://i89.photobucket.com/albums/k234/mattneck/DSC02096.jpg)
Oh finally, my coupe rear wiper with a blade that doesn't foul at the top leaving a chunk of unwashed window, and a rather natty sticker :laugh:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02099.jpg)
Get. In. There...
(http://i89.photobucket.com/albums/k234/mattneck/DSC02101.jpg)
and also have gone with a little boot pop, jsut for the sake of doing it, me and my dad managed to get this in on sunday, lucky he's a sparkie so had a nice metal rope thing for pulling wires through, enough spades to shovel the sahara, and the expertise :rolleyes:
The current popper switch..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02100.jpg)
And where i've located the solonoid, although has since caused problems, fouling the bar inside the tailgate, I don't know if the bars twisted slightly, or shifted somehow, but, I've had to temporary remove it, going to remount and start again, the single screw holding it I don't think helps too much either, as it's causing it to pivot and not open the boot..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02103.jpg)
And earthed to the rear wiper motor :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02104.jpg)
That's about it at the moment, Some new 6x4's coming later this week for the rear, hopefully the UK pressed plates witohut GB band as replacement will be here thursday as well, got some nice genuine wolfsburg surrounds to wrap them babys in as well.. this ones been a long time coming but finally i've got round to something with pictures :cool:
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I don;t really know if these bear any relevance to being gone or not whe you look at them but, these are the old hubs and bearings that got pushed out my carriers.. they came in at around 25 and sounded like the car was gonig to take orf :laugh:
(http://i89.photobucket.com/albums/k234/mattneck/DSC01842.jpg)
Also found these a little while ago, was dead chuffed, still cannae decide if to fit them or not, admittedly..
(http://i89.photobucket.com/albums/k234/mattneck/DSC01523.jpg)
And my UK Pressed plates appeared finally, the right ones this time with no GB :cool:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02108.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02107.jpg)
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Current shortlist of things to do, not so short anymore, some bigger than others, some menial things i've tought of and oticed recently, some majorly needed at the moment!
All in good time, goin to get this done in the coming couple of months, want it finished by august tops, the cars birthday and 1 year of me owning it, be nice to reach a clean slate by then, of having done a lot of what had set out to and what was wrong initially, so I can stop worrying, start eenjoying it more, and put less money in, and start treating it to a few polishes and waxes more :grin:
So here we gooooo!
Work to be Done:
Engine
-Cambelt
-Camshaft Oil Seal (added 24/5/07)
-Waterpump
-PreHeater Gasket (added 30/05/07)
-Sump Gasket
-Breather T Hose (rocker to breather assembly to replace) (added 30/05/07)
-Oil Seperator (replace) (added 30/05/07)
-Oil Seperator to Airbox pipe (Replace) (added 30/05/07)
-Clean out breather assembly if gause intact, otherwise replace! (added 30/05/07)
-Sump Pan (think the edges have deteriorated, apparently the small engines sumps used to go like hotcakes) (added 24/5/07)
Drivers Window
-Guide Felt
Alternator
-Swap Mount to Golf Mount
-Clean Earth Points Around Bay
Sunroof
-Deflector Plate (Rub and Paint)
-Seal (added 05/06/07)
After Accident (to be done to return to previous state (added 24/5/07))
-Fit New Slam Panel
Doors
-Rip plates, aka Slimjim Plates (added 30/05/07)
Completed Work:
Exhaust
-Blow below Gearknob Area (Fixed Weds 9 May)
Alternator
-Brushes?(Not needed (added 24/5/07))
Rear Beam
-Bushes(Not needed, flew through todays MOT! (added 24/5/07))
Front Struts (Rebuild in full of car - 24/5/07) (finished 25/05/07)
-Top Mounts
-Shocks
-Boots
-Bump Stops
-Top Nuts
-Spring Caps and washer (added 24/5/07)
Rear Struts
-Upper and Lower Bearing (finished 25/05/07)
-Shocks
-Bump Stops
-Boot
-Upper Spring Disc
-Upper Base
-Snap Ring
Aerial
-Straighten Aerial Up With Wing (completed 02/06/07)
-Set To Angle Toward Windscreen (completed 02/06/07)
Accident Repair
-Fit New Wing (completed 02/06/07)
-Fit New Bumper (completed 02/06/07)
Tailgate
-Washer jet (old one looks tired and cracked) (completed 02/06/07)
Drivers Window
-Slot Seal (05/06/07)
Drivers Rear, Passenger Front
-Slot Seal (05/06/07)
Brakes
-Copper Brake Lines
-Flexi Brake Lines > Braided (Alright after all)
Passenger Rear Window
-Slot Seal (Done sometime..)
Tailgate (all done, somepoint..)
-Lock gasket
-Trim piece screws (if i can remove them to do gasket)
-Rear Light Foam Gaskets
Nice. :smug:
Exhaust fix didnt really need an extra post I didn't think, all it took was gentle persuasion over the rear beam, wasn't blowing where I thought it was after all. The midbox curve to the back box was where the blow was, it just didnt sit in straight :rolleyes:
And then yesterdays events..
-
Stolen from my oher post admittedly but it was the only way to sum it up, and it needs to be recorded
to quote the guy a tthe insurance today 'yeh it's fine to put them up, something along the lines of half way through the restoration and oops!' I quote :grin:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02187.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02188.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02189.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02190.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02191.jpg)
I was coming down a one way hill, when he pulled out in front of me, I had about a car lengths distance to react and stop as he started pulling out when i was literally a car and half away, AND that was clear view, the ony car was about 3 lengths away so i was in full view, and he was in an MPV so had the height advntage and only having to look one way..
had to chuck on my brakes at about 25mph on the bottom of hill skidded in wet and where he stuck it right out (furthest wheel back on his was on the junction lines, he came right out) and the newly repaired wign thats been damaged since i got the car took a beating.
he jumpwed out saying i wasdoing 90mph etc etc. until a woman told him he pulled out in front of me and she'd be a witness, at that point he wet extremely quiet and realised what eh ahd done, trying to pin it on me cause im young i expect :rolleyes:
he took full liablity and its in for repair.. should hear back by middle of next week :undecided:
Think I get a vauxhall tomorrow :grin:
-
Well car returns to me with a £508.25 cheque aswell :shocked: was valued at £535 first offer so didnt even bother messing around with a figure like that :cool:
Managed to pick up a new slam panel c/w headlights but, once took the car apart realised all i need to do was put my hand behind and push it forward, and the ehadlight wasnt broke at all nor the frame.. jsut the adjusting screws need replacing! also thanks to my mate dave for the all black grille with the spots on, perfect condition with all clips and that :cool:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02221.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02225.jpg)
luckily my indicators didnt break in the bumper either :shocked: im really quite shocked by the non breaking of so much stuff.. lucky they didnt eiether as the new bumper was pre 90 :wink:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02220.jpg)
replacement bumper is on atm, red stripe though, need to trace an all black hopefully in trade, and finally got a drivers side manual adjust mirror to swap or put on while i repair mine.. i tihnk one of my cables is broken, i know i can jsut use my hand but wheres the luxury in that, i aint opening no windows :grin:
so now its back ive beaten out the wing, although thats gonna be swapped as its got a tear in it.. from the bumper iron. once its off though itll give me the required access for the battery tray/chassis leg edge bend, at the moment the curve of the wing has limited the space and the inner wing needs flatting back out to anyway, but for the first time ive ever beaten a panel i feel i did alright..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02227.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02228.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02229.jpg)
managed to straighten up my grille trim as well.. needs rubbing right back and painting again..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02219.jpg)
have a current stockpile of parts as well for the 4 corners suspension rebuild, i think theyve been running on the spring in at elast one front corner, maybe both considering the boatyness of it, so i didnt want to rebuild it and find the springs were dead, and ended up getitng talked into a 40mm drop.. need to get my front shocks and new spring caps so i can build them ready for a straight awap up front but otherwise.. cam belt and waterpump to do as well..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02194.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02215.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02216.jpg)
cant wait for the new wing now so i can get the old off and rework the metal back into shape.. probably gonna remove the slam panel to make room to and fix it properly.. found whoever slotted it on when we rebuilt it didnt slot it in upfront properly.. the central bolt at the bottom doesnt exist and the panel is behind where it shoudl be screwed in, not ined up in front. doh. wont take long to strip and rebuild the front at least, bar the wing, and itll make life easier ey :smiley:
oh and ive forgotten to mention this, or have i? best £28 ebay win ever :grin:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02218.jpg)
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Well, looks like might have to add a couple of seals to that Job list now.. Think the cam oil seal is leaking and maybe crank at the timing belt end.. sump gaskets pretty definate now to :angry:
Wings on its way next weekend, thanks Mark H! Pics of that I recieved to follow..
Spent today sorting out getitng a new bumper and that that was plain black, found noe that was mossy and mouldy as hell, forgot any photos along the way, but gave it a good clean, the iron is very rusty but i cant remove it, which is a shame.. Sprayed engine enamel over it all just to protect it a little.. It'll have to do for now..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02238.jpg)
Saw fit to include my bumper and bonnet I picked up a while back, £5 bonent, £10 bumper.. would get rid of the tow bar weight on the back at least :rolleyes:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02239.jpg)
The old bumper up front, note the major bendage.
(http://i89.photobucket.com/albums/k234/mattneck/DSC02240.jpg)
The new bumper side clip had broke, as these are only plstic welded on.. decided to go for a little mission on these, by drilling one off, and drilling off the broken noe, taking an old broken seat leg liner and cutting a pair of rectangles from it..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02241.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02242.jpg)
these could be sued to cover the size of the holes, which can then have small holes drilled, and then screwed through with self tappers into palce, creating one nicely mounting bumper at the side..
currently forming with epoxy..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02243.jpg)
That's aobut it for now, until I get that fitted to the new bumper and get the blooming thing on, expect i'll leave it till after next weekend now once i got the new wing as well.. Finish uni on friday majority of the way then only one more hand in wednesday the 30th, then time to crack in and compelte all the put off jobs ready for a hopefully mostly trouble free summer :smug: I wont speak too soon though
Oh my batterys out as well, for full charge and drop test, somethigns draining it ever 3 or 4 days if not used.. Gonna ahve to check my uprated headlight loom for a sticky relay or somesuch now.. only other ting i can think is a ticking analogue clock as the test across the neg came back with fluctuating results.. itd mainly sit at 0.02A but then suddenly jmup to aobut 1, eevry 5-10 seconds and return quickly.. No time tot hink too much into that at the moment admittedly but it'll get done :smiley:
Oh and rear beam bushes to be done, £60+VAT at Vee W. Services in bristol, springs are getitng compressed onto fronts thursday afternoon hopefully then its a case of swapping them and swapping the trimmings at the rear :smiley:
Lovely jubbly, can't wait to get it bck to it's former glory+a bit more since the crash!
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Ok so.. a proper update is looming but before that.. (I thought this would be a case of just phoning the insurance company and it adding a small charge on for modifications, I couldn't find anyhting against this anyhwere in any of the documents I had such as my certificate and that..)
Lowered it 40mm, feels an immense amount safer to drive, its only a 1300 so the speed isn't the key.. Although now, it doesn't roll like it did throwing you everywhere at slow speeds round corners, any of that.. BUT... Direct Line then tell me I have to be 25 to even have a different set of wheels on the car.. So back to standard it is.
The old shocks I removed, I thought had knackered top mounts. They probably are now tohugh as at 70 the wheel used to shake car would rumble.. The slotted ntus werent even tightened right up, they were finger tightened and then when you couldt get your figners in any more they had stopped doing anymore. Same with the top nuts, nipped up, came fof easy with a spark socket and a spanner..
Going to have to get 2 fresh oil struts for up front now and revert to standard until August comes around when I can move insurers to gain soem freedom for one, and hopefully a better rate!
Shouldn't be too bad, one strut up front is leaking a fair bit, ones got bad corrosion to the casing.. And so the reason for swapping them. At least this time I can get the slotted nuts done up properly, and make sure its all secure, ill jsut set the camber to the same as it was prior, and then pay to get it setup properly once back on the Boge and springs.
Shame, because it wasn't too much of a job, and its made me feel safer driving it around, but I'm not sure they would take it that way, as I'm "unde 25, male, and have a Golf" Cause I'm bpound to race it around the streets aren't I.
I'll have to get some pictures ad that up regarding it soon..
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Well.. Oil breather system has given up the ghost it may seem.. I'm expecting to find the gauze down below in the breather assembly (spaceship thing) clogged right up. The pipes have sene better days to but they are only pence anyway. Theyre cracked and weatehred on the outside, and the bottle looks a bit knackered to. Not hard to replace, sump and gasket are being done anyway so a steamer through the breather assemblys is gonna be the step to clean it, hope sticking my fingers in fins the gauze intact!!
(http://i89.photobucket.com/albums/k234/mattneck/DSC02265.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02266.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02267.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02275.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02276.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02277.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02279.jpg)
It's all voer the top of the manifold and up the carby block to, so, pics of that to come (will edit this post with them)
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Did a bit of shopping in relation to the oil leak and the insurance payout, decided to clear out all the loose ends and that on the car i thought might as well be done after I’ve uhmmed and ahh'ed so long. :smiley:
So... New sump, sump gasket, cam oil seal, rear washer jet, and air hoses for oil breather were picked up today...
Ordered the oil separator bottle and right hand rear slot seal from GSF...
And from Volkswagen...
-gasket for preheater hedgehog thing.
-new gear shift finger (with bush atop), bearing bush and washer, to try and remove some slack from the gear knob I hope.
-to repair my wobbly drivers window the seal that holds bracket to the glass, the felt channel at the front and the guide channel it sits in (one of these is a backorder though, cant think which so have to wait and see, hope its the metal so I can find a good one in the scrap..
-window slot seals all round except the right hand rear which is deleted...
-tailgate lock gasket, rear light gaskets and the screws that hold the grab handle on as they’re probably destroyed on mine
-and last but not least rip plates, for anti slim jim protection :smiley:
picked up so far.. :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02314.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02315.jpg)
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been meaning to add.. fixed the bumper, the bodge works :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02250.jpg)
new slam panel may not be needed after all but, its looking tidy :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02254.jpg)
this was mikey, our micra for 10 days :laugh:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02251.jpg)
standard stance
(http://i89.photobucket.com/albums/k234/mattneck/DSC02257.jpg)
lowered 40, but has to be reverted back till august now, doh.
(http://i89.photobucket.com/albums/k234/mattneck/DSC02293.jpg)
my new wing wrapped up, only got a tiny bit of bubbling upfront, gonna get it remvoed even tho itll be hidden by the bumper :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02258.jpg)
should be getitng that fitted and the proper bumper and all that jazz on tomorrow.. cannae wait to be honest, want it looking nice for volksfest! :grin:
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Bit alte in the update but alas!
Ordered a big bag of bits last friday finally..
New sump, gasket, air hsoes for breather, cam oil seal and rear jet..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02314.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02315.jpg)
New rear light cluster and boot lock gaskets, and new screws for the grab handle..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02370.jpg)
New preheater hedgehog gasket
(http://i89.photobucket.com/albums/k234/mattneck/DSC02371.jpg)
New gear shift finger, bush and washer
(http://i89.photobucket.com/albums/k234/mattneck/DSC02372.jpg)
New rip plates/anti slim jim plates
(http://i89.photobucket.com/albums/k234/mattneck/DSC02373.jpg)
and new slot seals for the front doors, and enw window guide for the rocking divers window.. also got a slot seal for drivers rear window, need to go and get passenger soon, to :smiley:
Also picked up a pollen filter, a long time back, the filter which fits the seat toledo is the same that will fit a mk2 :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02369.jpg)
And gave my handles a flash over with some trim paint just to sharpen them up a bit, ill do them properly another time though :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02365.jpg)
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And the boyo went in the body shop last saturday, my mate's boss elt em come in to help, which was cool, mean't i could learn some and watch how it's done, and keep toasty early morning in the oven with my wing :grin:
Wing after first coat..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02316.jpg)
Mixed up paint
(http://i89.photobucket.com/albums/k234/mattneck/DSC02317.jpg)
Wing after final coat
(http://i89.photobucket.com/albums/k234/mattneck/DSC02319.jpg)
Neil, masking up the rear end where he had a dodgy blend gonig on, the blend now reduced but is hidden behind the rear wiper where it's still not come up too well :grin:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02320.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02321.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02322.jpg)
Neil removing the old wing
(http://i89.photobucket.com/albums/k234/mattneck/DSC02323.jpg)
Stripped off and looking sorry..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02324.jpg)
old, new, ready to go
(http://i89.photobucket.com/albums/k234/mattneck/DSC02325.jpg)
and back on, needs the blue pinstripe and original bumper refitting now :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02326.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02327.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02328.jpg)
Glad o have it back to it's former glory, only to find a deep scratch across teh roof :angry:
Dents need doing now, waiting for a call back on that, the rear apssenger door being the worst.. Bonnet a close second..
Roll on volksfest, it'll be sat in the car park, but who cares, it'll look good there in my opinion :laugh:
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So, a few little bit's recently..
Found a single light CL grille, really wanted the white trim below.. but the whole grille with all intact clips was £10.. so i'll stash that :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02468.jpg)
Got the new front end together, compelte with the bumper it should have, clear indicators with silvertecs.. pinstripe on the new wing, although you cannae actually see it due to it bleaching out in this photo :laugh:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02470.jpg)
Tried on the valver rears, and then becky did me some photo chops for comparisons of new lighting to the rear and sides..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02471.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02473.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/lights.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/indicator.jpg)
Fitted the new foams behind these as well, although back to standard buisness for now, till I find some white top red bottom ones :smiley:
Also fitted the new trim screws up the back to replace those that had rusted.. and my tailgate lock gasket, of which only the left hand lower quarter remained. easy job, plinth of, pop the lock out from behind on the 2 lugs, slap it over, clip it back in and clip the rod in, easy pickings :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02477.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02478.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02479.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02481.jpg)
Only a short one for now, but a fair few bits to come, got the slot seals and that on there to, gonna give the bay a good clean soon and get all my hoses looking tidy, get the oil water off the manifold from the leaky breather soon to, and refit the new hoses, bottle and sump at the same time, an excuse to clean the full oil system :cool:
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Just a small update for now.. Took the boyo in for a tune up the other week, came back needing a new rotor arm and vacuum pull down unit. The old pull down had no vac at all, when you suck or blew through the pipe a constant flow was, well, constantly present. The rotor arm could be turned on the shaft with a finger also.. very loose like. Tried stripping the dizzy myself but couldnt get one of the centre parts out, the actual rotor plate inside wouldnt shift from the spline, altohugh all circlips etc had been removed.. Ended up rebuilding it, driving to the garage and getting it done, they didnt need to take it apart, fitted it from the side instead. if only i knew prior i wouldn't have made this mess..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02508.jpg)
Next job is to do the gearshift as well as theres a lot of play, both around the knob and in the ball. Here its visual betwene the 2 pictures that the entire mech can be turnt, looks only slight by picture but feels a lot more, same as when it is in gear it flops a lot. Have been told where the shift finger is in the bay with the metal loop around it, to clamp it as his stretches over time, due to the primitive design it gradually pushes it out with gear changes.
(http://i89.photobucket.com/albums/k234/mattneck/DSC02510.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02511.jpg)
Also got a new bearing ring to replace the old in the shiftbox, to try and help the side to side play.
(http://i89.photobucket.com/albums/k234/mattneck/DSC02512.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02515.jpg)
Got my new cup and ball repair kit and everything, still the sump and breather need doing to, just waiting on workshop availability, and the new gearstick to come, hopefully thi will reduce the play between the eccentric adjuster and the shift rod, and generally renewing everything should in theory repair the rest of the play :smiley:
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Well, it's been an eventful month - I've been meaning to get around tot his but what with my lung going doolally - and my mate telling everyone I'd taken a bullet to the chest, I haven't had chance for much!
Took on a bit of a powder coating addiction since getting out the hospital...
Causing me to start with removing my fan cowling and air filter lid and taking them for blasting and coating, the pictures of the finished articles aren’t the best indoors, but one of the bay will show that they have come up extremely well. Also got the warm air deflector shot blasted to clean it up a bit... rocker cover and slam panel need doing next to match :laugh:
Fan:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02687.jpg)
Cowling previous state - and the sticker which I need to replace, this original one went obsolete in '92, so, the new one it'll have to be after all...
(http://i89.photobucket.com/albums/k234/mattneck/DSC02688.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02689.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02690.jpg)
Finally got a shot of the set of wheels I bought to, unfortunately now I don’t think I'm going to be able to put them to any use, due to the heavy steering I think that they'll cause in comparison to 13x5's with a manual rack :grin:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02703.jpg)
And also finally - a switch loom for the adjustable load leveller headlights. It took a long time but patience paid off, getting this setup for £40 from Germany, a complete kit of loom, from fuse box to front of car (LHD loom now for sale cheap if anyone is interested) including a pair of LHD lights, motors, switch and this small section.
The current loom has a 2 pin plug leading out to the motors... on this loom and mine it was a blue plug... which the switch loom fitted directly to. Using the spare dash illumination behind the fuse box to light it up after replacing the bulb, all was well, and the motors spin!
Switch loom:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02709.jpg)
Fuse box End:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02710.jpg)
Connected up:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02711.jpg)
Switch in situ:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02712.jpg)
Inside of the switch is just a variable dial which drives the motors to the desired spot, although the internal filter could make things tricky for converting to anything other than green illumination... witha bit of ffiddling due to the bulb location, the previously blown one was replaced, and refitted to the dash, stock location above the headlight switch..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02717.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02718.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02719.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02722.jpg)
After this, the sand blasters came back with my stuff, which came up trumps... fan cowling and air filter lid ready for powder...
(http://i89.photobucket.com/albums/k234/mattneck/DSC02730.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02731.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02732.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02733.jpg)
Next is to prep the lights for fitting motors, transplanting a RHD set onto motor control. I took apart the LHD only to realise the adjuster setup differs from the RHD although the backing plates are the same:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02739.jpg)
By unscrewing from, and removing the lattice adjuster in the bottom corner, the motor can be refitted to the original screw and mounted, the 2 top screws left alone.
Lattice piece to remove:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02740.jpg)
I'm currently waiting on some new adjuster screws due to the brittleness of the ones here. Once they arrive - then I'll be swapping to the motor controlled lights all being well. Also looking at getting the headlight backing plate’s powder coated combined with the slam panel for that extra fresh gloss approach to match the air/rocker/cowling combination. Relocation of my uprated headlight loom using 4mm2 wiring will put it in place on the other side of the bay so it's no longer sat atop my battery, this shouldn't see any loss in volts, if anything only minimal 0.1's.
The stuff also came back from the coaters..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02742.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02743.jpg)
An insitu photo is needed to really show these off, they look a lot better in the flesh than these photos...
Also have picked up a set of VDO gauges from an Audi 80 coupe, complete with oil pressure sender, have built a full loom for it including illumination, but am currently waiting on both my new centre console for chopping, my mounting plate for the ashtray area and my oil temperature sender for the sump before I mount them :smiley:
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Work to be Done:
Engine
-Cambelt
-Camshaft Oil Seal (added 24/5/07)
-Waterpump
-PreHeater Gasket (added 30/05/07)
-Sump Gasket
-Breather T Hose (rocker to breather assembly to replace) (added 30/05/07) (sorted august 07)
-Oil Seperator (replace) (added 30/05/07) (sorted august 07)
-Oil Seperator to Airbox pipe (Replace) (added 30/05/07) (sorted august 07)
-Clean out breather assembly if gause intact, otherwise replace! (added 30/05/07)
-Sump Pan (think the edges have deteriorated, apparently the small engines sumps used to go like hotcakes) (added 24/5/07)
Drivers Window
-Guide Felt (sorted august 07, but rocking is actually in the regulator)
Alternator
-Swap Mount to Golf Mount (swapped over thu 20th sept)
-Clean Earth Points Around Bay
-Replace regulator and Brushes.. (Possibly causing battery to drain at speed - 2/3days - output from alternator may not be all that..) (new huco one sourced for valeo alternator after bosch's stud and insulating block broke)
Sunroof
-Deflector Plate (Rub and Paint)
-Seal (added 05/06/07)
After Accident (to be done to return to previous state (added 24/5/07))
-Fit New Slam Panel
Doors
-Rip plates, aka Slimjim Plates (added 30/05/07)[/b]
This is what remains of the original list, but a few additions are going to be made..
-Powdercoating of a slam panel and rocker, (arb gone to coaters.. slam and rocker still to go)
-New exhaust manifold heat deflector, (tidyed up the bay)
-Fit the motors to headlights and fit them, (need extra adjusters for conversion still)
-Have been attempting to clean the grease from my spotlights, (washed out nicely)
-Fit VDOs in new centre console minus ashtray, (looomed up cut and fitted with m1 gauge schackles to retain the gauges and panel)
-Fit new drivers door trim without damaged seal, (cut off damaged part, and door tirm fits flush)
-Oil temp sender needs fitting (sump bolt replacement one) (fitted at last service in august)
-Oil pressure dual sender has gone in.. (all gauge parts fitted and working)
-Maybe a 5dr OEM central locking system as I've sourced one.. (sone mid august, 5dr to 5dr direct swap except the boot mech as i already have the solonoid pop)
Bloomin eck.. :grin:
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Just a short one today, did the cup and ball repair, it feels a bit tighter but i've got play in the box for one..
The looping frame which goes around the shift finger and bush on the 084/085 boxes also looks as though it suffers wear where the rubber bush rubs against it (this bushing had also gone flat down the sides and was loose, could be turnt freely where it was meant to be secure..) a replacement one of these is on the cards now, as everything else has been replaced anyrate, the bearing ring wasnt possible without dropping the exhaust (which ill need to do for my sump job anyway) to get the shift box out, so that will have to wait, hoping that will reduce a bit more of the play though, holding it tighter hopefully.
also managed to do my alternator brushes the other night, became important when i was getting 11.5amps under load out of the alternator, and the brushes were worn to about 3mm.. but then due to the rubbish design of the bosch alternator having the terminal insulation block not attatched to the alternator but flying loose, the thing broke causing the battery light to earth and recieve constant 12v, cue the alternator doing no charging at all, and the alternator having to be swapped for the old one from my original engine. the blue wire terminal also snapped, the rod snapping about half way down making it pretty useless.
heres the worn brushes..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02810.jpg)
and the busted alternator..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02815.jpg)
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Well, it's been a busy few weeks, so I need to update this properly sometime soon admittedly but..
The drivers window felt, I've replaced but it's proved to be the actual regulator featuring the play so a new one is due to be fitted I think.
I have realised now that, after knowing one of my quarter lights had been done in quite close to the time I bought the car due to the shattered glass etc, the pilkington window will hopefully be replaced by gen VW for that extra little touch but, I have since realised, whilst fitting central locking (yes, OEM and the full system!) that the window on the drivers side is green tint, and from the wrong side!? the inscription lettering is actually outside currently, and backwards. whoever fitted it must have been just as backwards..
So theres a few small pieces which need sorting which have arisen, I have finally mounted my VDOs to my centre console and am currently in the throws of making a small adapter loom to run both those, and my newly fitted sunroof motor also! Ive now discovered though it ould probably be quicker to crank the sunroof by hand, although, maybe its the lack of effort using a motor thats good about it? Also fitted the audi 80 chrome back winders as a tester, they code well with the outer door handles which is looking good.
Also delocked the passenger door now i've got the central locking, jsut for an added element of security. also currently tempted by one of the plastic mans smoothed OEM texture boot plinths to tidy the rear a little and also add that extra bit of security, as the solonoid popper is present behind.
Small current idea to be toyed with is blue pinstriping my grille to match the blue pinstripe decal along the side of the car, also needing tog et the thing tracked, although a seized driver side end to rod is proving a bugger. the tyre guys at work are telling me, let them heat it up copper slip it, heat it copper slip it, etc, to get it fully moving once again, it had a new end byut not rod, where as the passenger side was refurbished, so this tmepted me to go the wohle hog and just refresh it to save the labour of tkaing it off and having that done. But i shall see what they say tomorrow!
I'll get on the case of pictures and a better write up regarding the pictures soon, and have had the joy of an impact wrench this past couple of days making my life immensely easy, finally i can swap my alternator bracket to the original golf one to rid of the overhang of the polo one, should make it look a lot more tidy at least, and give me chance to fit the new voltage regulator to the now fitted alternator!
All fun and games, but I'll get there in the end, or not as the case probably will be, there will always be soemthing to play with, heh!
Oh, got an ARB arriving to, to bolt up front, just o make it feel a bit more level.. Cheers to ben Mew for that one! :smiley:
Oh also managed to clean the grease form inside of my spotlights, a photo of that to come, and fixed my drivers door trim by cutting the offending bit of rubber at the edges where it had fallen from, and it now retains to the body perfectly.. Time to get on the case and get it all out the way before I head back to Uni! :smiley:
-
Right, finally time to catch up with all my updates.. this post, VDO gauges!
So I bough these complete with the oil pressure sender from my local audi specialist.. came complete straight out of a Coupe that had just come in for breaking!
(http://i89.photobucket.com/albums/k234/mattneck/DSC02749.jpg)
On the back of these came a small piece of loom which would have fitted to the original audi loom, i removed this and remade my own loom semi based on it..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02753.jpg)
i coupled the earthing on the gauges and bulbs inot one loo, the live across the gauges were piggybacked across and same again for the illumination. using 3 core power cable gave the the possiblity to keep it tidy across from console to fusebox.
(http://i89.photobucket.com/albums/k234/mattneck/DSC02750.jpg)
also a close up of the forming of the looms..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02751.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02752.jpg)
these are then hooked up with some small 2 to 1 looms i made so i could use the ign live and illumination for both the gauges and the motorised headlamps switch.
and then the oil temperature is taken from a genuine VDO sump sender :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC02754.jpg)
a few more to come - ive been polishing and cold galvanising a couple of things, havent got round to ding much more though due to weather and time restrictions.. oh also how to swap youre original milometer between clocks (useful for small engine or driver people, can go to a digi clock and rev counter combo or even an mfa rigged set of clocks with the production of some extra loom) :smiley:
elsewhere, tried on my new wheels, but with baloon tyres in the pictures!! got my arb sorted and fitted, swapped the alternator mount for a golf one, relocated my uprated headlight loom.. and done a few other little things besides! :smiley:
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So.. the cold galvanise.. something I've been having a bit of fun with recently. fully sanded back and polished the cap cover by hand. one coat fo the cold galv went on amazingly well. it just seems to disperse and settle well at its own accord.
pics..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02756.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02760.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02761.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02762.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02763.jpg)
also had a pop at the petrol pump and engine lift bracket..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02764.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02766.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02767.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02769.jpg)
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Right, so boredom setting by not being at work due to illness.. I decided to get a set of GL clocks with a rev counter in, perfect for transplantation.. :cool: also gives a useful function at least!
So these are the original clocks that I removed from my 1.3, note the analogue clock and the petrol gauge in the center..
(http://i89.photobucket.com/albums/k234/mattneck/DSC02816.jpg)
I ahd wished to combine my original milometer to retain the original milage. On checking the speedometer the gearigns also proved to be different, 1505 vs 1540. Proving the new speedo was no use as the reading will be wrong.
(http://i89.photobucket.com/albums/k234/mattneck/DSC02817.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02818.jpg)
Next to open and seperate the clocks the 8 bolt head screws around the back border of the clocks must be removed.
(http://i89.photobucket.com/albums/k234/mattneck/DSC02819.jpg)
Next the oil pressure circuit ribbon had to be pulled and the transistor lifted to release the clocks internals.
(http://i89.photobucket.com/albums/k234/mattneck/DSC02820.jpg)
Then the one plug connection to the clocks must be slid back to unclip and lifted off.
(http://i89.photobucket.com/albums/k234/mattneck/DSC02821.jpg)
From here the clocks can be dropped out of the back of the cluster and seperated into electronics and speedometer.
(http://i89.photobucket.com/albums/k234/mattneck/DSC02822.jpg)
The different clocks (one set VDO, one set Motometer) meant the oil pressure connection differed. The ribbon still fitted and connected.
(http://i89.photobucket.com/albums/k234/mattneck/DSC02823.jpg)
The speedo is then swapped into place of the revcounters original speedometer, bolted back together in a reversal of removal then fitted to the car as seen in the next picture below.
(http://i89.photobucket.com/albums/k234/mattneck/DSC02824.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02826.jpg)
Thus you have a rev counter and retained your original milage and speedometer with correct gearing :smiley:
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Next thing wasto FINALLY get round to checking out my new wheels on the car, a good chance when I had a 14.4v impact gun. TSW Omegas with a polished lip and black facing, am hoping to get 4 flat silver centre caps machines to fit them to, oh and downgrade from 205/55 baloons to 195/50 tyres. :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC03079.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03081.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03082.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03083.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03084.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03085.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03086.jpg)
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A couple of other jobs also completed recently, a GTI front ARB fitted just to reduce the roll and make the car feel a lot safer and stable.
Bought for £10 from Ben Mew, blasted for £10, powdercoated gloss black for another £10 then rigged up with brand new eyelets, bushes, bolts and pipe clips.
It's fair to say the whole thing really does feel a lot more stable and tight. Drives like you would expect a normal car to now!
(http://i89.photobucket.com/albums/k234/mattneck/DSC03125.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03126.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03128.jpg)
Finally also got round to swapping my cambelt and water pump. Also while everything was apart swapped the cam oil seal and tappets as they had been getitng quite tappy, even after a day of non-driving. One problem encountered, wrong design of cambelt. I had a round tooth profile belt and pump when I actually needed a square one, so had to push the car out of the lockup plot onto the road, rush to work on my bike to swap it come back and bash the lot back together. Doh!
Remembered I needed to soak the tappets upside down in oil overnight. So that got done in Quantum using TQ OE Tappets.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03129.jpg)
Also finally got round after fitting my VDOs to the car, have picked up a 4-door electric window setup. Got a console cheap off a mate and proceeded to ahve a go at grafting the spare gauge panel into the console. Firs tI cut the gap and placed it on, this show there to be a lip which was causing the switches to jam in place when pushed down.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03131.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03132.jpg)
Instead I decided to drop some more plastic out from behind the console, which meant I could mount it further forward bringing it inline with the electric winow section above.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03133.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03134.jpg)
I then proceeded to test fit 2 random switches I had lying around combined with my set of gauges. The weight and pull of the gauges currently is too much. Admitted I only used bathroom silicone seal to locate the panel, so now i can remove a bit at a time and use plastic weld paste in place, which is both black and able to take the pressure.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03133.jpg)
:smiley:
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Thought Id bring this forward in the thread.. and update it with a few things and that!
Anytihng completes striked out as ive forgot dates ETC lol. although needto photo a fair few things.
Work to be Done:
Engine
-Cambelt
-Camshaft Oil Seal (added 24/5/07)
-Waterpump
-PreHeater Gasket (added 30/05/07)
-Sump Gasket
-Breather T Hose (rocker to breather assembly to replace) (added 30/05/07) (sorted august 07)
-Oil Seperator (replace) (added 30/05/07) (sorted august 07)
-Oil Seperator to Airbox pipe (Replace) (added 30/05/07) (sorted august 07)
-Clean out breather assembly if gause intact, otherwise replace! (added 30/05/07)
-Sump Pan (think the edges have deteriorated, apparently the small engines sumps used to go like hotcakes) (added 24/5/07)
Drivers Window
-Guide Felt (sorted august 07, but rocking is actually in the regulator)
Alternator
-Swap Mount to Golf Mount (swapped over thu 20th sept)
-Clean Earth Points Around Bay
-Replace regulator and Brushes.. (Possibly causing battery to drain at speed - 2/3days - output from alternator may not be all that..) (new huco one sourced for valeo alternator after bosch's stud and insulating block broke) (lights on dash and headlights now when idle is hunting, are visually flashing and dipping!?)
Sunroof
-Deflector Plate (Rub and Paint)
-Seal (added 05/06/07)
After Accident (to be done to return to previous state (added 24/5/07))
-Fit New Slam Panel
Doors
-Rip plates, aka Slimjim Plates (added 30/05/07)[/b]
This is what remains of the original list, but a few additions are going to be made..
-Powdercoating of a slam panel and rocker, (arb gone to coaters.. slam and rocker still to go)
-New exhaust manifold heat deflector, (tidyed up the bay)
-Fit the motors to headlights and fit them, (need extra adjusters for conversion still)
-Have been attempting to clean the grease from my spotlights, (washed out nicely)
-Fit VDOs in new centre console minus ashtray, (looomed up cut and fitted with m1 gauge schackles to retain the gauges and panel)
-Fit new drivers door trim without damaged seal, (cut off damaged part, and door tirm fits flush)
-Oil temp sender needs fitting (sump bolt replacement one) (fitted at last service in august)
-Oil pressure dual sender has gone in.. (all gauge parts fitted and working)
-Maybe a 5dr OEM central locking system as I've sourced one.. (sone mid august, 5dr to 5dr direct swap except the boot mech as i already have the solonoid pop)
So got through a fair bit so far.. Now for the new list with a pile of additions I've come up with.. :grin:
-
Work to be Done:
Engine
-Sump Gasket
-Sump Pan (think the edges have deteriorated, apparently the small engines sumps used to go like hotcakes) (added 24/5/07)
Sunroof
-Deflector Plate (Rub and Paint)
-Seal (added 05/06/07)
After Accident (to be done to return to previous state (added 24/5/07))
-Fit New Slam Panel (have to see if this is really worth it after all.. All jobs once I get my garage back!)
Random list..
-Is the front passenger side leaning down lower? Hit a large bump a while ago and have wondered ever since, spring shifted maybe? Going to have to get the tape measure out.
-Fit the motors to headlights and fit them, (need extra adjusters for conversion still)
-Fit rear inside door handles to front, cleaner less scratched
-Front door check straps may be worn, swap for rears as less used doors
-Radiator bottom hose has wear to the outside atm, bit roughed up, don't want it splitting, replace.
-Expansion tank - needs a clean so I can actually see the level through it for one, and the braided hose needs replacing as it's tatty.
-Petrol flap central locking to fit
-Carpet the back of the rear seat, to match the boot and tidy it up? Maybe follow suit across the boot and lock lip?
-A possible cross hairing of the standard headlights?
-Sunvisor with vanity light to adapt and wire in (LHD one needs adapting to RHD)
-Relocate cig lighter onto passenger side of centre console.
-Braided brake hoses?
-Get dents sorted, mainly passenger side rear door
-Get a VW1300 badge form a beetle - forgot to buy one at Bristol Volksfest till after, want to add this to my battery cover as a little bit of detailing..
-Oh almost forgot to.. Scirocco sunroof for Tilt & Slide. Needs stripping down cleaning and fully regreasing. Panel also requires stripping and repainting (currently red) and inside panel requires retrimming as it's a state and also doesn't match, doh!
-Heated seat pads to fit when arrive, combine with machine washing all seat cloth (fitted Nov 9, didn't wash the seats, everything went too well witohut stripping it right down so kept it that way!
-Fit Sunroof loom to switch and FB (all fitted oct 4)
-Fit VDO wiring back in, after finishing console adaptation. (Refitted, and now running Sunroof switch illumination on same loom. Need to high build primer and matt black the consoles panel now though to level it up and look tidy.)
-Swap rear bumper but leave wiring in for tow bar if ever needed, have a non tow bar bumper sat out back. (Done the night before Oxford Edition ready for the show!)
-Fit new sunroof cover over motor. (fitted oct 5th, a huge thanks to bomp for that, still requires some slight editing inside to sit flush but itll get there!)
-Buy a white rear pressed plate to match the car's black and white monotone theme (not to run daily though - too paranoid of £30 fine lol) (Bought one at Oxford Edition - total impulse buy in the end as I was really unsure.. But it looked top draw when it was on there!)
EDIT: Fit mint condition bonnet that has been sat in back garden for way too long now, and put old one in garage till I work out a plan of attack. It's got a few punched in dents on that arent pullable and someones splodged touch up in.. The new ones mint and cos a fiver so hey ho :cool: (Fitted this the wednesday before Oxford Edition ready to look a bit shiny and spankers on the club 'stand'!)
-Check the under carpet lining? Maybe replace, as it holds moisture I don't want corrosion.. Replace with something more durable and less worn. (It's all good..)
-Electric/heated mirrors - install. (Finally fitted! Looming to the passenger door was a bugger such a small gap to fit through..! Good fun they are now fitted though)
-Sort drivers side mirror - check if door skin is damaged after somebody kicked underside of mirror bending it up (was actually the mirror damaged, doh)
-Create a bracket or adapt fuel vapouriser/swirl pot bracket from pierburg to fit for return line not featured on Weber (currently fitted with cable ties holding it to the fuel pump! Has improved the running and made the whole flow a lot smoother)
-GK Inlet manifold for larger/matching bore to head? (Has arrived, is being cleaned by my mate at work in the parts cleaner and will then be fitted most likely with a shaved hedgehog for improved flow..)
-Electric windows to install now they have arrived and are now all fitted
-Rear quarter windows - one is on the wrong side, and is green tint, one is a pilkington window. Have one to replace the green glass so far, will replace the seals at the same time. (Have replaced the green one, but not the pilkington, that one will wait! It doesn't look as odd!)
Alternator
-Replace regulator and Brushes.. (Possibly causing battery to drain at speed - 2/3days - output from alternator may not be all that..) (new huco one sourced for valeo alternator after bosch's stud and insulating block broke) (also now have a problem where all the lights on dash and headlights etc are flickering and dipping etc in tune with the res flying up and down when cold-ish..!?) (Rebuilt the original bosch one now, see page 9!)
-Colour code armour door plates alpine white to make them blend in a bit more, subtle touch. (tried with rattle can, really didn't work out!)
-PreHeater Gasket fitted when inlet and everything was apart
-Find a new top plate for the carb and fit it with studs so I can spin nuts onto them instead of cutting into the alloy of the carb each time, and losing the thread again. cost me £85 but I rebuilt the whole thing heheh
-Powdercoating of a rocker Looks wicked.
-Going to get the headlight frames blasted and powdered just for that extra little neat touch, then rig them up with the motors TYip thats done
-Blast and powder the air cleaner lid once again - the top of the carb had lost it's thread so it's been rubbing on the underside of the bonnet. (Turns out the bonnets sunk at the back, brackets possibly loose?)
That's it for now.. Time to stop thinking and start working!
:grin:
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So Bomp hasmade me a flush sunroof motor cover. which is much appreciated and I owe him one (now its in writing, officially.. lol)
Its require a bit of sanding out to make the farthest back microswitch fit inside, luckily te resins thick enough.. a tiny bit more rubbing out and itll be there flush.
Heres the cover, in place over the motor..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03342.jpg)
And heres the switch lit up in the centre console, the window switches arent wired in yet admittedly though so they arentilluminated. but i created the loom for this from scratch and managed to hook in illumination to my VDO gauge loom :smiley: Excuse the shakes, it was a slow shutter!
(http://i89.photobucket.com/albums/k234/mattneck/DSC03340.jpg)
Also completely by chance withoutt hinking about it noticed my door was out of line, drivers rear,its always been horrible to open. New handles new lock blocks, notihng has sorted it, the alignmenet never really came to mine, till i noticed the top corner to be completely off, the top of the door next to front door is small and flares out to the bottom being quite large and stepped out.. Bet have a look at the hinges asap..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03343.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03344.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03345.jpg)
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It's been an eventful week. In a nutshell first regarding the TSW Omegas.. The fitment, and the aftermath..
Saturday: Get 195/50's fitted. Rubs in certain spots on all 4 corners. Visible dodgy Toe up front both sides, visible dodgy camber both sides, and an odd angle to the drivers rear wheel. This being the corner that previously took damage before I owned it. The drivers side tyre also sitting 10mm or so closer to the arch, turns out to be with fixed stub still the same, hinting towards rear beam bushes being done and beam replaced off key (becomes only corner to rub with 195/50s once proper camber is taken into consideration)..
Monday: 4 wheel alignment check. Rear toe on driver’s side, toe-in like crazy. Verdict - bent stub axle. Rest of the work couldn't be sorted though, they had broke 2 wobbly sockets in the past couple of days, and have lost out on the business all week.. Hopefully should have it in this week though. Source new stub axle, attempt to remove old one. One bolt remains. Go home annoyed with it. Attempt again, that evening, all comes off, all goes back together. Drum goes on, outer bearing goes o..No it doesn’t. The stubs been machined wrong. Revert back to old. Finished more annoyed.
Tuesday: get a letter saying we have to pay £40 to get my and rubjonnys combined parcel from Canada. Great. Return the stub axle, find out its been returned before. I did wonder why there were traces of grease in the end of it, to. Get a new one; try a brand new bearing on each one, fits replacement, wont fit originally given one. Our survey says Errerr. Get home Tuesday, undo everything in 10 minutes, get to bolt No. 4 on the back plate and spend 30minutes on it. Eventually get it out new one goes in, old one visibly warped on the base, and stub standing wonky. Get bolts back on, drum kind of goes on, gets stuck, bearing goes on wonky, oil seal has to be ripped out to refit drum, new oil seal now needed but bearing eventually got straightened up.
Dodgy Stub:
(http://i89.photobucket.com/albums/k234/mattneck/DSC03372.jpg)
Wednesday: go and get another check done, this time rear is perfect. Front proves to be cambering to the positive massively, and toe all over the place. Highly recommend to anyone in Bristol or nearby Pro-Tyre in Lawrence Hill.. Top bunch of lads there, let me have my check free as still no tool sourced, but the boss said to me I know you'll be back for it, and we'll ring you to get in first when the tool arrives. Bolted on the fresh bonnet, that had no dips or anything detrimental on it. Few deep chips out of it unfortunately but very small, look like flakes of dirt lol. Neil mops/glazes car, comes back covered in res but shines showing
Report:
(http://i89.photobucket.com/albums/k234/mattneck/DSC03360.jpg)
Thursday: Getting ready for OE show. Wash and wax car, comes up nice.. Remove blue pinstripe around grille that was colour coded to the side stripes.. Looks loads better. AutoGlym Super resin polish - polish whole car, whilst that’s going off black front bumper, grille, and tow eye cover, then buff off polish. Coat once again with hand glaze.. Horrible to buff off, very greasy and hard to work out completely but well worth it.. Farecla stuff, recommended. Shine shows nicely but condensation starts setting in so fighting a losing battle, Kiwi all side strips off car, refit once dry, and give exhaust tip a little bit of autosol polishing.. Looking sharp. Parcel arrives finally to! After waiting in all day for it! Still to go - Kiwi and replace rear OEM tow bar iron bumper with non tow, leave wring installed for possible revert. Kiwi boot grab handle. Clean up drivers seat (couple of splodged on stains) get tyres shined in black, have refitted all Ryder standard trimmings, looks a lot better for it! Clean glass and vac and she'll be ready to roll..
Nothing to really report on the parcel, some nice items though, a full heated seat setup (Pads, loom, relays, Passat switch but the guy has promised me a Mk2 on which I believe he has just found! and a LHD Mk2 Sunvisor with vanity light, a possible bodge into another visor to be thought through..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03367.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03368.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03369.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03370.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03366.jpg)
That's it for now, no exterior valet shots yet.. Not till it’s completed! :grin:
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Bit backwards in the order now.. But fitted the heated seats this week - was suprised by hoe easy everything worked out and went together!
This is what it all comes to visually, admittedly the wrong one and sitting proud ATM but that's due to me getitng it stuck as one of the metal locating clips on the back had bent and caused me to have to remove the dash surround to remove it!
(http://i89.photobucket.com/albums/k234/mattneck/DSC03442.jpg)
So the fun starts!
Job 1: Fit Loom.
So this is the loom which needed to go in, at one end is an earth, a 4 pin plug which goes onto the switch, a single white plug with a 12v line and another 12v line (this is a loom from a Mk3 so has junction box plugs. To run this in, I took off the sill trim, lifted the carpet, removed the front seats, undid the screws for bonnet release, dropped the fusebox from its bracket, pulled back the door seal and flicked off the plastic holding the carpet up, making it possible to lay the length of the loom into place. Refitting is a reversal of removal. Along the loom then I had 2 conenction,s one to pull out below drivers seat, one below passenger, this was fed directly across, and the 2 flying leads put through the cuts in carpet and holes where the seat runner guides through.
Loom:
(http://i89.photobucket.com/albums/k234/mattneck/DSC03369.jpg)
Junction Boxes fitted (made some extra little adapters so I could run my gauge feed and sunroof motor feed etc off of these, making it both tidyer and more sensible.. and OEM+ :grin:
(http://i89.photobucket.com/albums/k234/mattneck/DSC03433.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03434.jpg)
Job 2: Fit pads to seats.
So for this follow the standard procedure to strip a seat. Turn the seat upside down, undid the wire at each end, lifted the 2 tabs in the middle, pulled the ins pout, lifted the foam base and rolled the cover back. Undid the crossbar in the seat to give more flexibility and room to get my wrist through with the pad. Slid the pad into place and pulled the wire out through the back corner so it was hanging free. Refitting is a reversal of removal.
Again this follows the same trend with the backrest, lifting the 4 clips along the base, then rolling the cover up the seat, sliding the pad in, cable down below and wrapping the cover back, down around. This left the 2 bare wires hanging ready to be connected to the relay plugs. To do this I used bullet connectors between the 2 after stripping the ends, then hid the relays and loom up in the underside of the seats.
Pads and Plugs:
(http://i89.photobucket.com/albums/k234/mattneck/DSC03370.jpg)
Job 3: Fit Relays and complete plumbing in of switch loom.
To do this I used bullet connectors between the 2 after stripping the ends, then hid the relays and loom up in the underside of the seats. the relays have a 6 pin and a 4 pin plug hanging from their bases and sue a relay number 59.
Relays:
(http://i89.photobucket.com/albums/k234/mattneck/DSC03367.jpg)
To plumb i the switch loom, I routed itbelow the dash across below the clocks to the factory dash location, currently using a passat switch which will soon be replaced with an OEM Mk2 double dial switch.
Switch Loom, with dash illumination, link to 12V line on main loom, earth, 7 pin plug to dash switch and 4 pin plug onto main loom.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03368.jpg)
One all fitted, I realised whilst driving to work I had turned on the heat for the left hand seat (apparently) Yyet I was getting nothing, than gave it a moments tohught, touched the passenger seat and realised, It's a LHD loom. So the far end plug was classed as left.. passenger, and everything was in reverse to the switch.
Graphic representation:
(http://i89.photobucket.com/albums/k234/mattneck/SeatSetup.jpg)
Bentley Loom diagram shows where everything is routed, proving swapping of just 4 wires will make it possible to make the dials work as if it were a RHD loom.. Which it basically is with the swap.
(http://i89.photobucket.com/albums/k234/mattneck/SeatLoom.jpg)
These are the wires at the plug which when swapped, will put the signals to the correct sides.
1 is Dash illumination, 2 is Earth, 3 is 12v, 4 and 5 are one side, 6 and 7 the other. These are the ones to be swapped around (4 and 7, 5 and 6) whilst remaining the same at the other end as to send the correct signal and keep the wiring continuity, changing at the switch is the best point.
Switch plug:
(http://i89.photobucket.com/albums/k234/mattneck/DSC03431.jpg)
Joining main loom:
(http://i89.photobucket.com/albums/k234/mattneck/DSC03428.jpg)
Until I ge tthe tool form VW for doing these plugs, I've given up, a needle and watchmakers screwdrivers have been attempted and I've not managed with both, even tohugh I have previously! Buying the tool (VAS1978-4A) will make it a 2 minute job and I can keep it for the future :smiley:
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Just a brief update to bring my photo collection up to date on here..
Have ended up with a new steering wheel lying around, from a polo..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03436.jpg)
Picked up the white palte for the rear for shows at oxford edition..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03401.jpg)
At which i also had my my genuine motorsport gearknob fitted for that extra show piece..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03414.jpg)
Artsy photos on the way home..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03411.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03416.jpg)
finally started working on the sunvisor, stripped it down, flipped the mirror so it will be on the correct side, now jsut to work on a trimming idea.. possibly using the chunkier vinyl headlining that came in some golfs.. cut a alrge enough piece to fold it all over and together?
(http://i89.photobucket.com/albums/k234/mattneck/DSC03424.jpg)
Finally got a nice new oil breather fitted, got this done by the workshop linked with the parts place i work for, should aid the engine and reduce some crankcase pressure, stop oil pushing out all the seals it can..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03463.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03464.jpg)
Also finally got on the case of a fuel vapour seperator, so the carby has a return line back to the tank etc.
Blank return, carb doesnt have one standardly..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03469.jpg)
Fuel vapour seperator, fresh from pierburg keping it OE haha..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03466.jpg)
Also got my electric window setup through, so far have alid the loom out to check how it all goes together and that, found that some of the wiring at the fusebox end was missing and the fuse was gone to, managed to source them from an ibiza at the scrapper for £10 and have wired it all up together, ready to fit now, but just have to find the time aongst the miserable weather!
(http://i89.photobucket.com/albums/k234/mattneck/DSC03472.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03473.jpg)
My Ml2 heated seat switch also arrived, but the bulb in it is extremely dim, maplins do one the same, a green one, which is a tiny bit larger but should still be workable as currently it looks like it doesnt even come on, although it does, extremely dim! Nothing else to report until the mirrors and windows go in.. mirrors likely to go in first though considering the looms :grin:
:smiley:
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Well, nothing really in the way of pictures right now but they'll be added..
So the heated seat pads went in, these turned out to be pretty easy to do, literally a case of pulling the wire at each end lifting the cover and releasing one of the crossbars, and sliding the pad in and through. Didn't take long at all, just need a way to keep relay and loom safe under seat now! Wiring loom was also pretty easy and pretty basic.. so that got plumbed in pretty fast.
Next up my Mk2 switch arrived which looks even better in my dash now :cool:
Heated and electric mirrors have been fitted.. Still not had a chance to use the heating, one evening I'm asked if I've fited them, next morning theres frost.. sod's law i fit them that night and ever since there's been nothing. Have also devised a second loom to run the heated mirrors independent of the rear screen, so as not to waste energy running both when not needed. :smiley: This jsut needs pieceing together still but once done should work wel. Did ahve the aim of getitng a Transporter T3 Switch form the early 90s which had the heated mirror image on, stood the right way for a mk2 dash but was a corrado style texture unfortunately. Ordered hta totld it would be here the enxt day, only to have to clal anda sk where it had disapeered and then be called back 10 minutes later to be told it's back porder. Grr. Got a volvo switch the the mirror graphic on reay to chop and graft into a mk2 one :smiley:
Fitted the Olo steering wheel for a test run, very strange as it's slightly smaller. But does look quite sporty.
Also manage to get the electric windows in, on 3 doors so far. The drivers rear is still remaining as I ahve a replacement piece of glas for the rear quarter I'm going to fit, so no longer will I have a single piece of greeen tint glass, on the wrong side, with the etching on the outside. And I'll ahve all 4 doors electric :smiley: Not tat I ever really have people in the back.. Piced up an OE window switch new today from work as well, so now all 4 not jsut 3 of the window switches match the sunroofs switches full illumination, looks 100x better :smiley:
Couple more ideas being toyed with - the definate: colour code armour door plates.. the possible: paint GK inlet manifold silver before fitting and maybe fit 3 orange LEDs below my VDO gauges as if the orange behind them is dissapating downward, but also this will have use.. Lighting up my Fischer CD box so I can see what CD i'm pulling in the dark :grin:
Time to get on with it then :smiley:
-
Right then, as my old alternator ahd been lying around for so long I decided to have a crack at rebuilding it.. And this is what it entailed!
So this is the alternator as it was. mounted in the car, before attempting to change the regulator due to slack charging, and even slacker power on idle.. dipping lights etc. The regulator was ruined so out it came and the other one in, cue a lot of hassle getting it back together though, and the insulating part broke so it kept earthing out. Lucky I had my old alternator here so that went on.
(http://i89.photobucket.com/albums/k234/mattneck/DSC02774.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02810.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC02815.jpg)
first out were the through screws, the condensor came off, the voltage regulator out and the fan wheel off.. I took it to the garage below my work and got the nut buzzed off with an air gun, the easiest way.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03591.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03592.jpg)
After getting the 4th screw drilled out due to it being bent after the alternator had been dropped, I split the casign and ended up being presented with this, the rotor in the drive end casing and the NDE casing split from this.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03577.jpg)
To remove the rotos, removal of the woofruff key is required first. Then the rotor can be pressed from the bearing, the thrust washer removed, then the plate holdign the bearing in removed by the 2 scres, and the bearing pushed out from the casing. As can be seen you can only access the plate screws after the rotor is removed.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03578.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03585.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03590.jpg)
At the other end the diode pack and coil can be removed by removing the 2 screws holding it into the casing, on this is where the stud had broken, I've since found some fibre washers I'll use as insulation do didn't remove the stud and replace it, also a pole to plug repair kit is available I'm looking at trying out.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03579.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03581.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03582.jpg)
Next up I removed the bearing from the end of the rotor from the NDE, and drifted a new one back on using the old bearing as a drift. the bearings have nubmers marked on around the outside denoting what they are and these seem to vary depending on size of alternator. 6201xx xx denoting a lettercode seems to be a general rule of thumb to the style they are.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03598.jpg)
I then proceeded as I could do nothing more at this point, to wire brush all the casings, the fan wheel and the edge of the coil. And paint the lot, silver alt, colourcoded fan and coil strip.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03595.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03596.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03597.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03599.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03600.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03602.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03603.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03604.jpg)
Then, put everything back together and voila. 4 new through screws are going to be ordered, as the rust ones don;t look the greatest. Oh and it's back tgoether correctly now, in the picture it's currently 90degrees out after it span on the bearing when clamping it down.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03605.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03606.jpg)
So that'll be fitted soon, when I can stop the leak from the oil gallery coming slowly through my headgasket, common on small blocks so I'm told! Just don't want this one getting too mucky though :smiley:
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not a masssive update, more a preliminary one of things to come..
So this week, I'm finally going to fix the carburettor up, trial the new inlet, fit the new alternaotr and some new powdercoated bits.. and sort out that weeping head gasket!
So the slam panels been blasted, the headlight frames and the air filter lid have been done, waiting for the rocker to be done along with the euro inlet manifold..
So the ehadgasket, apparently causes a common leak on the small blocks, this relates back to the age odl problem of the breather system blocking up. In this case, it has gone that oens tep further that it can, and started seeping past the gasket. now this doesnt mean tis in anyway gone or detrimental to the running, or that the heads warped as if tis been overheated, its just the seals shot on the gasket for the main oil gallery as pictured..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03656.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03658.jpg)
So, it's from ehre that it's been seeping out, which also means oil could have got through to the dizzy, so a new seal on that, out the end of the cam seal, new seal, any place where oil is, and it could find a way out could have done.. a new head set should fix that. As I'm takign the ehad off this is what I'vve bought, an Elring TQ OE one.. and am going to get the stem seals done, the head flatness checked, the head dipped and cleaned and the valves and seats re ground and lapped :smiley:
Here's the other seals I got, randomly theres an extra green distributor seal that makes no sense?
(http://i89.photobucket.com/albums/k234/mattneck/DSC03651.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03653.jpg)
Brand new set of head bolts
(http://i89.photobucket.com/albums/k234/mattneck/DSC03655.jpg)
and an oil pump block gasket. I'm tempted to replace this one and whip the sump off to clean up the oil pump and change the crank seal with a little more ease. Seems sensible while everything esle is apart, and I have got a new sump that's ready to be refitted.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03659.jpg)
Also decided while I'm at it I'd need fresh water and coolant so stocked up, a new oil filter seems sensible and new pedal covers as mine are wearing a bit thin now..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03660.jpg)
On thursday I also decided I would open up my carburettor just quickly - at least, remove the jet assemblies and chekc the numbers on them to confirm what was there. Turned out that the second stage was missing it's main jet, now I know why the car bogs down a bit after 50 and takes ages to mvoe around speeds sometimes, due to its non calibrated fuelling!
So I ordered everything from weber which arrived yesterday, I was hoping i could use the one new main jet to test the car to see what response difference it made, and altohugh the new jet i was in need of most, was on the invoice, it wasnt ni the box! Coincidental, doh!
So, new bits for the carb include a new top plate, webers own retaining palte which actually lines up with the carb, rather than the rear screw being offset.. and a load of other bits and pieces..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03662.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03664.jpg)
The new top plate now has studs in instead, so I'm not bolting into the soft cast ally which is used and ruining the threads, causing it to be held in by only one bolt very insecurely, as it is now.. also matched here with the new retainer which should help tighten up the vacuum required.
Also picked up all new jets and everything, was gonig to go the whoel hog with the emulsion tubes but at around £10 a piece and jets noly being around £2, and being told tubes dont really wear at all, i decided against those. but instead went with an uprated pump jet going from 40 to 45 to help with the fuelling on the larger manifold.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03663.jpg)
also bought a proper weber service kit complete with sandwich plate, main gasket, needle valve and seat, vac diaphraghm and all the other gubbins like mixture screw and seals to recondition the lot
(http://i89.photobucket.com/albums/k234/mattneck/DSC03665.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03667.jpg)
And then organised everything ready to fit..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03668.jpg)
Thought it would make lfie easier anyway! bought 4 new screws for the alternator as well to swap out the rusty ones, and also have 4 instead of 3 holding the thing together. Also need to touch in the bit of sivler where some of the very thin casing snapped off. Other jobs now include tidying up the wiring giving it all tis best routing, have the bushings to redo the starter with, waiting no the actual repair kit at the moment though hopefully thatll come monday or tuesday.. if not im a bit stuffed as to doing that that i aimed to do. Got myself a new water pump seal as well as thatll be needed to release the cam belt tension.. can't really think of anything else at the moment, gonig to give the bay a good scrubbing and clean as it's in dire need. maybe clean up some of the block and GB but might wait on that for now.. as long as the most visible stuff is tidy ill be happy..
Just gotta wait till wednesday and get started now :cool:
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just a little placeholder..
Fitted alst electric window along with the correct colour quarterlight glass on the drivers rear.
have found ym tmep sender for ambient temp for the MFA clocks ill soon fit.
put everything back tgoether had the ehadwork done and that. pics to follow and a report on that oh so much of a bugger of a job it became.
fixed the drivers side heater blowing.. little fix which may help some people.
cant really think of anything else i've actually done right now. oh the cars going for paint as well, so there will be a writeup on that one :laugh:
-
first off then.
scraped the arch, on the metal reinforcing the garage door frame bloody lockups..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03650-1.jpg)
and then used all my bits to finally rebuild the carby (sucha time ago, as you cna tlel this is gonna be a bit of a slack writeup)
so i got the top off, within the top plate the threads ahd stripped out, usually they have studs in, but i had bene ahving to put bolts in, and the soft ally was bored out by this and the airbox was sitting loose
(http://i89.photobucket.com/albums/k234/mattneck/DSC03669.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03671.jpg)
so split the carb in half to its top and bottom chambers and sections
(http://i89.photobucket.com/albums/k234/mattneck/DSC03672.jpg)
cleane dit all up replaced the jets, needle valve, all the related gubbins and gaskets.. the fuel filter was a state..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03673.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03674.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03675.jpg)
next up, headgasket, it has the usual seepage of oil from the front left corner where the oil gallery seal gets pushed past when the oil breather blocks up
(http://i89.photobucket.com/albums/k234/mattneck/DSC03676.jpg)
so whipped everything off, and went to fit my gk manifold which had a different network of pipes. this pipe coming off went down to the waterpump channel on the bakc of the blocik but the enw manifold had an extra outlet. from this i put a new pipe down to the main channel, and replacing the following pipe i put a single straight pipe, non t-piece from a polo.
(pic to follow)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03677.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03678.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03679.jpg)
took the ehad to get the valve seats reground, and everything checked, started out as cam seal, dizzy seal and valve stem seals, prevailed the guides were worn so far, he wouldnt do the work without replacing them, an extra £80 :cry:
means ive got a top condition head now though.. still a shame, msut have bene the 'lady owner' that did ahrdly any miles in the thing, with low oil and funny pressure killing the thing off, seals were bone dry and guides worn, no wonder it rattled :laugh:
so it all came back
(http://i89.photobucket.com/albums/k234/mattneck/DSC03685.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03686.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03687.jpg)
ncie and clean with a light skim
on refitting, my torque wrench proved to have a few troubles.. got to the second go around with the bolts, number 9 and doof..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03688.jpg)
borrowed a snap on wrench after, and all was well :grin:
(http://i89.photobucket.com/albums/k234/mattneck/DSC03689.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03690.jpg)
got it all back together and its run sweet ever since.. few more bits to go in this update :smiley:
-
still digging up photos! pc has been out of action for around 2 months and ive jsut got it back up and running finally..
took a few bits to be blasted and powered when I did the head.. need to get round to fititng them up :smiley:
did get the air filter lid reblasted after it was rubbing, my bonnet has dropped at the back corners and needs looking at, its really messed up the lid and a seocnd blast left it really mottled.. time to get a new one i think :sad:
(http://i89.photobucket.com/albums/k234/mattneck/DSC03681.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03683.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03684.jpg)
also somebody attempted to crack my boot open but must have got scared off or something..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03706.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03707.jpg)
time to delock the back :angry:
-
So a few wiring troubles (again really im just catching up here.. lately havent had time to take photos with some of the jobs due to getting too involved and dirty :grin: )
So my radio..
Symptoms?
Hit a bump, cuts out, smack it, it'll come back on. Passenger rear speaker doesn't have 'proper' signal, all mechanical and electrical whirrings and signals can be ehard through this one speaker. Wires behind radio have been bodged before.. Doh.
So, here.. the power block. Standard wires..
Positive, Negative, Memory, Elec Aerial. So why the blue wire?
(http://i89.photobucket.com/albums/k234/mattneck/DSC03833.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03832.jpg)
Massive Belm.
With the effort it takes to remove the wires from the blocks, I don't see what posessed somebody to do this??
Crimped on a brand new power block, put the left wire into where it should be and alls been well, apart form the angry radio cashing has made the screen not always light properly.. doh!!
Boot popper took a bit of damage when fitting the clocks, in this instance a short on one of the dash mounts..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03843.jpg)
And also my oil pressure spades broke..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03840.jpg)
But my replacements were too small!
(http://i89.photobucket.com/albums/k234/mattneck/DSC03837.jpg)
So I got inventive :smug:
(http://i89.photobucket.com/albums/k234/mattneck/DSC03839.jpg)
Now my gauge works, my light works on the dash, and my oil tempt was reconnected, strapped up to buggery toprotect from the road where it had got frayed up before :rolleyes:
And finally fitted my scirocco roof, which brought with it a lot of hijinks. A particular starting problem was the major ripple in one runner.. slightl smoothed here but the remenants show..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03847.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03846.jpg)
That roof could have a writeup of its own :grin:
That alost catches me up with the recent tidbits.. Though some are a lot larger than tidbits all things considered :grin:
Next update, paint :cool:
-
So, massive delay in posting.. but finally an update! Only 6 months later..!
So it went in for paint finally.. This was due to the drivers rear arch.. middle of the rear door.. the new front wing from the time i got drove into and a few other bits being a bit ick. a few highspots in the metal. scratches and all manner of annoying crap. A huge shout goes to my amte neil for taking this on with me. In one weekend we stripped the car back (this is an entry level blow over basically) Had everything filled primed flatted you name it it was done and then rebuilt ready for monday - So the car was taken away on a break to oxford in this state.
(http://i89.photobucket.com/albums/k234/mattneck/DSC03743.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03744.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03745.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03749.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03750.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03751.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03746.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03747.jpg)
Also the same time we had the decorator in at the house so i took advantage of some of the strong glue stuff he ahd and the fact I found some polo trim clips at work. these with a bit of cutting amde perfect retainers to finally get my motor cover fitted properly..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03834.jpg)
At the same time I aslo amnaged to drag my boot release cable through live. causing a short..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03843.jpg)
Oops :embarassed:
Since this happened The best picture I've ahd of the car after paint was taken by Nick Horney at Santa Pod. compelte with scirocco roof open. Though that things become such a pain i think it'll soon be time to remove it as I just haven't got the patience :sad:
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So I went back to uni and put everything on hold for a while. On the last hand in day I got home and decided to fill a void. both in somethign to do and having fiddled with the golf.
Out come every last piece of interior. Even the dash at one point. i decided I wanted to tdiy underneath the carpets remvoing any manky sound deadening, reroute the cabling ftto factory locations for all i had added, get everything working again and clean everything up. and so it begun.
Initially I took everything from the rear out elaving the front, until oen day i forgot to replace my scuttle panel. It poured. HARD. Ad It flooded my passenger footwell so out came everything after all.. Joy.
Leading to a discovery..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03912.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03910.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03909.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03908.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03907.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03898.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03903.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03899.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03900.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03902.jpg)
Crap had bene collecting in the void above the fuel tank and ahd eventually come through unkowing to me due to the turret carpets I had fitted :sad:
Oh the dash came out to..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00044.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00056.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00057.jpg)
It was at this point I figured that It would have been rude.. Just plain rude. Not to swap in a new heater matrix. Going for a MK3 one instead. Ive now never known such wonderful heat. The inital month feeling as though my face was going to melt along with me getting gassed by the protective coating burning off :grin:
Also at this point found an MFA stalk to FB piece of loom. This meant the stalk was finally wired in. Only clock to FB loom now to go! :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00054-1.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03862.jpg)
And then, finally.. The holes were welded over, jsut require filler skim.. paint blow over and then the boot can be fully refitted with its gubbins :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00146.jpg)
Also a new interior was introduced..
(http://i89.photobucket.com/albums/k234/mattneck/DSC03863.jpg)
:smug:
-
Work in progress soon to be blasted, powder coated, new brake lines including flexis fitted.. mk3 calipers with new discs apds and bearings will be going on.. rebuilt calipers at that using a genuine vag seal kit, giving me the added luxury of rear disc braking and also a rear ARB.. call it futureproofing to a degree.. and the aprts were available cheap.. everythign currently bolted to the beam coming free.. and the calipers setting me back an initial £10 :cool:
(http://i89.photobucket.com/albums/k234/mattneck/DSC03906.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03904.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03905.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04858.jpg)
Beam arrived bare.. but is now at this stage..
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Hi jacking!!!
What an astonishing amount of work you have done to keep the old girl afloat. Nice one pal. Looking good. I like. :wink:
Keep it up!!
-
So a trip to mr Rubjonny.. the result? 2.0 power soon come..
Much of a picture update for the moment.. Everythings been resealed no the bottom end.. nothing spares. Heads gone in also for a full rebuild with twin cut seats, new valve guides, stem seals, other seals fitted. No expense is being spare really in making everything mechanical fresh and enw with the hope of fiinally making the old girl fully reliable.. and enjoyable for a few years to come :smiley:
Lots of rounding botls were encountered along the wayand various like that but eventually got up to speed and up to scratch and ehres the results..
(http://i89.photobucket.com/albums/k234/mattneck/DSC04222.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04223.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04224.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04225.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04226.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04227.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04228.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04229.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04230.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04232.jpg)
Then it got mvoed fianlyl and now resides in my lockup :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00046.jpg)
Rear engined golf? :grin:
during this time another alternator was stripped and rebuilt..
(http://i89.photobucket.com/albums/k234/mattneck/DSC04234.jpg)
Head stripped
(http://i89.photobucket.com/albums/k234/mattneck/DSC00044-1.jpg)
Accelerator cable that notchy repaired.. worn bush.. and a genuine cable now fitted.. though this needs a spring clip to stop it popping out and the pedal currently dropping to the floor at random intervals :huh:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00025.jpg)
modification to cable to fit to weber carb linkage :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00026.jpg)
Onwards..!
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Couple of details inbetween.. These crossovers now reside behind the doors, and the cig lighter is finally fitted!
(http://i89.photobucket.com/albums/k234/mattneck/DSC03913.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC03914.jpg)
Genuine first aid kit, original! added to the collection..
(http://i89.photobucket.com/albums/k234/mattneck/DSC04239.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04240.jpg)
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Engine stand has been borrowed from mr diamond Hell.. A lot of help from both DH and Danny P has been takne on whislt harring around the 2 track syncros -which comes wholly appreciated it has to be said :smiley:
More painting ensued..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00020.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00021.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00029.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00033.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00076.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00040.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00051.jpg)
Then duly fitted up!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00054.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00055.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00077.jpg)
And then my gearlinkage kit arrived!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00142.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00143.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00144.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00145.jpg)
:smiley:
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Then an investement in the most solid OEM mounting possible appeared.
(http://i89.photobucket.com/albums/k234/mattneck/DSC00088.jpg)
G60 rear engine.
1.3 gearbox.
1.3 front engine.
These have been fitted to Danny P's motor and now the ABF in there is standing very very firm :smiley:
with these mounts ill be building up a fresh subframe. powdercoated with poly wishbone and ARB bushes. fully rebuilt 256 or even 280 braking assemblys to the sides and a PAS setup between :smiley:
rear axle will also be compelted and then all the solid lines throughout the car from MC which will be 9" servo 22mm mc combination swapped whislt everything is out and open, before the 2.0 is dropped in with the clutch kit ive picked up cheap, and the 2Y box i will be fitting to it. This will be compelte with a 0.80 instead of 0.91 ratio 5th gear from a CHE mk3 8v gti box for 3k at 70 in 50th rather than 3.5k RPM :smiley:
Head will be fitted with a kent GS1H cam. sump has a 1.9diesel windage tray fitted, throttle body has been shoved through ultrasonic cleaning along with the head, ECU has a Digifast chip from the states fitted and ready to roll.. gearbox has all new seals on the outboard of it.. cant think of much more off the top of my head currently! :laugh:
I'm hoping by fiddlign with everything in such a way ill know roughly enough to be able to look after the car in any situation, and also know enoguh to fiddle with any others that come my way to a degre.. and finalyl be able to enjoy the car without fear of reliability issues.. though theory doesnt always become practice! :grin:
More updates to come soon. Holiday has sapped my cash and I'm waiting on various extra bits to come into my hands before any more work commences.. :smiley:
Other than all of this various little jobs ahve been fixed.. boot popper fixed. new radio fitted as old one ddecided to give up. 2 yeas for £15 of scrapyard cd palyer wasnt bad though! all the door cards and seats are now fitted along with the electric window gubbins. all itnerior screws fixings and parts are back in..
Im at a point now where i guess I could say im roughly happy with where im at, but theres still a lot of plans running through my head as ever :grin:
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Yes lad What A Fookin project page, makes mine look pooh credit is due and detail is second 2 none, keep it up it won't be long. :grin: :grin:
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Thanks darnpiston and seiko.. both those comments put a smile on my face once again :smiley:
Though wait until you see what happened middle of last month :shocked:
On a lighter note.. ooh ooh!! Fresh headings!!
(http://i89.photobucket.com/albums/k234/mattneck/DSC04861.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04860.jpg)
:cool:
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Wet and greasy roads.
Large vat of sitting water as you cross this large junction.
Civic stops in front of me half way around the junction, unsure why.
I brake, doing 20, fair way behind him.
Railings? No. Civic? That'll hurt proportionally less!
*swerveatlastmomentandcatchhimunfortunate*
Unfortunately I hit the sitting water cut straight through it and continued to slide.. :cry:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00099.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00100.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00101.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00102.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00103.jpg)
It's the wrong colour but it was all fxied within 5 hours of it happening.. so do I really care right now :rolleyes:
Just an excuse to get the wing repainted now. Sunroof panel painted jsut incase the original goes back in.. and the wheels done finally..
Cars. :rolleyes:
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Coming along nicely apart from the slight whoopsie!
Good work mate, you coming to players this weekend?
Nick
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unlucky about the crash mate, but the engine is looking sweet.
Did i say id by a weight shift rod from you? think it was during that server swap and lost the pm's
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oh and also, what did you do for the gasket for the crank case breather?
cheers
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Yo nick - It is a shame but makes me want to bounce back again better than ever.. and also a good excuse to get a few other tidbits sorted whilst the guns laoded with L90E :wink: Didnt make palyers. on account of being a poor ass student lam-o! :grin:
Phil - I did have one, may still ahve one laying around ive used one now but ill see what ive got.. Gasket for breather also? Its came in a block set.. you mean the funny shaped one that goes around the outside of the box sect?
New addition.. The missing link! :cool:
(http://i89.photobucket.com/albums/k234/mattneck/DSC04866.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04867.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04868.jpg)
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Build me up Buttercup..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00153.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00154.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00155.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00156.jpg)
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write yourself a feckin contents page at the start lad.
trim this comment out later
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Not been well since friday so no real pics or progress..
This is sort of how i left it friday arvo..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00158.jpg)
I've got the conenction for the breather to inlet boot from a mk3 coming from VW on tuesday. Hopefulyl this will be swappable and a bigger bore than the snapped off ISV elbow currently in palce. thus a snugger more secure fit. :smiley:
Oh.. also fiddling a bit with a gearbox and 5th gear, or 2..
(http://i89.photobucket.com/albums/k234/mattneck/gearratios.jpg)
That' s a 5th in a 2Y vs CHE vs diesel's.
Have recieved a CHE box for free courtesy of Diamond Hell, with a dodgy reverse so it's currently being liberated of its taller 5th to go in the 2Y I'll invest in to hook up to the engine for better motorway cruising. The costs and machining to make the .75 or .71 work will outweigh the effort as its only an extra 200 or 350 rpm drop. Getting the 0.80 for free is what swayed me to bother in the end! Plus that almost 500rpm drop will see better MPG and elss nosie cruising at 70 on the M-way :smiley:
:wink:
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Details, details..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00167.jpg)
Silver will be dropped into the engraved sections to bring everything out.. kind of reverse of the polished with black detail way :cool:
Oh and 5th gear was liberated today..
(http://i89.photobucket.com/albums/k234/mattneck/3059.jpg)
VW Tool 3059 - £29+VAT
Circlip pliers which fit down in the two notches? - £00 (Dad's toolbox)
Guess which I used in the end :grin: This is basically the tool which turns the selector rod, so that the selector fork gradually moves up and lifts off the shaft. :smiley: (visible on the right hand side of the last pic below)
Had to lock the flanges as I hadn't opened the selector shaft to lock it in to 2 gears. Using a VERY strong high torque impact gun still resulted in it taking a lot of force and eventual chkchkchkchkchking for the bolt to release its locked thread. It's fair to say it was boiling hot when it go pinched out with me fingertips. Oh and a screwdriver sorted the locking the box problem.. :grin:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00172.jpg)
This is what i was left with, 5th liberated..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00169.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00171.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00170.jpg)
That's my 0.80 set ready to be refitted to a new home now :smiley:
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Bish, bash.. BOSH!
So the TDC window and selector shaft cover have a 27MM recess on.. not a socket job.. no allen key that large.. Bodgery time..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00183.jpg)
Looks a bit like the VW tool in the previous post at the right angle :grin:
This meant the box was split and many bits removed from it..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00182.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00173.jpg)
Revealing a very ddogy reverse idler.. no wonder this box was a whiner!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00181.jpg)
Next was to attempt to put together the mk2 ISV elbow bit and the Mk3 breather.. size here became an issue.. but some jiggerypokery seemed possible..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00174.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00175.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00177.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00179.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00180.jpg)
So the plan was cut off the Mk3 one, plastiweld/glue it to the smaller Mk2 item and have a big to small adapter.. Dremel time..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00186.jpg)
Biggie smalls is ressurected! :grin:
Now it fits the boot perfectly. This will now sit no troubles on the throttlebody and couple up to the Mk3 rocker breather :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00188.jpg)
Not bad for a couple of hours!
Next jobs: Powdercoating wheels, subframe, rear beam, rocker.. maybe a couple of other bits. Get the 5th into the new box and new seals all over it, get clutch on, and bolt up box.. before stashing it and uni taking its priority..? :wink:
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Phil - I did have one, may still ahve one laying around ive used one now but ill see what ive got.. Gasket for breather also? Its came in a block set.. you mean the funny shaped one that goes around the outside of the box sect?
no problem about the shift rod, gonna mission round some scrappy when im bak for christmas.
yeah thats the one, i cant find one anywhere, think im just gonna make on myself out of some gasket material. it will be a whole load cheaper than going to the stealers.
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Phil - I did have one, may still ahve one laying around ive used one now but ill see what ive got.. Gasket for breather also? Its came in a block set.. you mean the funny shaped one that goes around the outside of the box sect?
no problem about the shift rod, gonna mission round some scrappy when im bak for christmas.
yeah thats the one, i cant find one anywhere, think im just gonna make on myself out of some gasket material. it will be a whole load cheaper than going to the stealers.
dont know how optimal that would be, mine was amde out of a kind of tinware thing! 026, or 028-115-441A is what you need. depends on chassis/year though.. 026 is about a pound. 028 about 2 or 3.. :wink:
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Wheel weight time.. Just to check I'm not outweighing the odds with the other rims :wink:
(http://i89.photobucket.com/albums/k234/mattneck/13x5Steel_Wheel.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/13x5Steel.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/ATS-Wheel.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/ATS-Weight.jpg)
All seems well enough to me :cool:
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So a few bits today! The misus was round to paint canvas' and that so I sat and fiddle with the new downpipe and manifold whilst we were round there..
Split the 2 rather easily, suprisingly everything just undid in no time! Gasket faces were covered with crap so have been scraped down with a screwdriver and then emeryed, awaiting new gasket! Can't decide if it's worth upping to a 16v DP or not atm, will the extra .25" actually be worth the extra cost, when the possibility of it being mated to a 2.25, or even 2.5" system is there.. hmm? Anyone care to suggest? :wink:
Manifold and downpipe pre and post cleanliness..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00202.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00201.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00203.jpg)
Fuel pump seal, old and new. The old one was seeping slightly so was replaced, it had gone quite soft and was covered in dirt as was the inside of the housing aroudn the mating faces. After a good clean up and scrub out, the new seals in and a new filter bolted onto the side..
Old vs New
(http://i89.photobucket.com/albums/k234/mattneck/DSC00206.jpg)
Reassembled..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00207.jpg)
Have also got my gearbox finally, with starter to follow.. It's a late 8V box afterall, not the 16V 2Y but an AUG. No second crunch, very clean looking, though it will get seals and whatnot as a matter of course with me..
Using this box still means I can use the CHE 0.80 gear I had waiting to fit but will not be using the locking clip to fit the grooved face of the gear, but will need to use an 8V shaft circlip instead.. BrokeVW.com details the swap and has this bit of information regarding such swaps:
16V codes and MK3 codes up to June 1st, 1997 will only accept the 0.80 and 0.91 5th gear sets. Those gears are the ones that use a deep groove in the top face of the gear for the output shaft, which secures the special locking clip. The locking clip has a tab that fits into the groove to stop it from sliding off. If you get a gear and machine a groove into the face for the special clip to lock in, it'll work just fine.
For 8V shafts, they use the circlip, because the groove is 16.5mm OD. The 16V gears fit the 8V shafts no problem, as the circlip can secure the 16V gear just fine. So, why not use a circlip with the 8V gear in your 16V? Because the circlip is too big to fit the 15.5mm OD groove in the 16V shafts. If you find a suitable circlip for the 15.5mm groove, the correct thickness, and hardness, then you'll be able to rig something up. Until then, you're forced to use the 15.5mm locking clip on the 16V shaft, and that forces the use of a deep groove gear set.
So now I require a new circlip as wlel as the 5th bolt I've already purchased which luckily isn't too much of a hassle! Have also tried revving around 3.5k, 3.0k and 2.8k on the current 1.3/085box combo in 5th. The difference in noise and revving from 3.5k to 3k is very significant to my ears so should make things more comfortable. Wether the 0.80->0.75 rev drop (200 or so more rpm) makes any more difference is not really noticable if at all though.
So next will to be to get the 5th housing off, clean up, swap gears, reassemble with the new gasket, seals, circlip and bolt on top of the 0.80 pair. Then bolt up to engine with clutch and fly! As I previously had a 16V clutch kit to take advantage of the pressure plate, the friction disc then became irrelevant due tot he fact I needed an 8V one, 24 down to 22mm input shaft size being the changing factor. So a quick call picks me up a fresh friction disc for £13, swapped into the kit for the 16V one means everything is ready to go on with new pressure plate bolts et flywheel bolts :smiley:
Then it cna be shoved into the corner out the ay whilst I wait for bits to come in from Germany.. oh and of course Uni will now take prime seat! :smiley:
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Oooh ah just a little bit..
So the 2Y route wasn't followed.. Ended up with an AUG box instead from a Mk2 8v, no crunches, no leaks though it's getting seals anyway.. and now.. no 5th! :grin:
From this:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00204.jpg)
To this!:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00233.jpg)
So the 0.80 gear off the CHE box is going in. Just need to put 150Nm through the bolt and get the spring clip on somehow.. Joy of joys that will be attempting to fit..
Bunged the clutch on, with new bolts.. note the factory threadlocking
(http://i89.photobucket.com/albums/k234/mattneck/DSC00216.jpg)
And the bodge locking to torque them up! :grin:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00217.jpg)
New metal cambelt cover:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00223.jpg)
And this is kind of where it got left..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00229.jpg)
I've since taken the cambelt end pulleys ETC off. checked the vernier and the cam for wether or not tis TDC markings were true which luckily they were, checked everything on the bottom lines up for TDC correctly including crank int. shaft and rotor arm - check. need the tappets to go in to bolt the cam down and get the cambelt on properly now though :smiley:
Couple of other bolts need finding and fitting such as those holding alternator and whatnot. Exhaust has had a new manifold->downpipe gasket and I've sourced a pair of driveshafts and a starter for it! :smiley:
Also being over-preparing inclined the shafts will all be recieving a good clean, new grease, and new boots.. Before being bolted up :wink:
So this should see box mated to block soon! Then only a couple of tiny bits on the main engine and box setup need completing before it can be filed under 'complete'!
Next thing will be to get it in and improve on my currently quite odd 25MPG from the weber on the 1300.. It's never been like this.. :shocked:
More pics to follow in the next couple of days :smiley:
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Progression! Has been made.. :grin:
So, circlip was off and needed replacing..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00239.jpg)
As you can see the width it reached stretched, jsut through removal was significantly losoer and larger than it's new counterpart. A nice pair of circlip pleirs side on soon opened the enw one enough to slip it on and drift it down with a suitable socket. Job done :smiley:
Thus gear was refitted fully, 5th bolt still to fit (box needs to be locked in both 5th and reverse to be able to torque the bolt up to the req'd 150Nm!) but the selector fork was fitted with tis 5mm of protrusion and the lockpalte had to be reused - oddly these are now obsolete from VW :huh:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00251.jpg)
Next was to refurb and check over the 5th housing. So, remvoed was; green cap, release bearing, clip, pushrod finger, spring, clutch arm and finally the seal. Everything was cleaned up and check, the figner was found to be perfectly fine to reuse so was then refitted, along with a new clutch arm seal :smiley:
Bits & pieces..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00247.jpg)
Housing sat in place..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00253.jpg)
I have also released the clutch arm retainer clip so as can be seen ehre the release bearing finger can be lifted, the 5th bolt torqued and the release bearing fitted, along with pushrod and green end cap. Pushrod bush, seal and input shaft seal require attention and the selector shaft seal will also be replace, then box bolted up to block! :smiley:
Also picked up a second airbox bottom as mine came with no hot air feed and vacuum flap - later to find the one I had was a diesel one and the vacuum hot/cold one was a proper digifant model. The diesel one seems less restrictive, not only with the removal of the cold air trumpet but the missing vaccum system and sealed over rear meaning all air coming in has only one route to follow.. Wether this will be an advantage or not I'm unsure! Maybe fitting the digibox with no trumpet could be the way.. at elast it'll help it warm up nicer! :grin:
Inside digi box..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00254.jpg)
In and out on the diesel..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00255.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00256.jpg)
Much more to do.. but getting there slowly! next key item on the lsit is recieving my tappets, fitting the cam with the new oil seal and bolting that down, along with fitting cambelt, covers and outer pulleys at long last.. Always more to be done! :smiley:
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(http://i89.photobucket.com/albums/k234/mattneck/DSC00257.jpg)
Green end cap on and release bearing, that means 5th swap is complete! :laugh:
Almsot gave me dad a hernia trying to do this earlier.. 150Nm of torque is A LOT!
We ahd to stick the box down on the floor, upright, with a piece of box section jsut underneath the 5th end of the casing to hold it off the floor.. My dad holding the gearbox mount bracket bolted to the diff housing and also holding the starter apature left me free to line up the torque wrench, stick a foot on the box, stand on wrench and support ymself on him.. about 1 full 260 turn eventually got it to click after a bit of effort upright before that, but it got there, and clicked bloody loudly! no arguing with it there :grin:
So this leaves me with the hybrid box of 2..
#1 #2 #3 #4 #5 FD
AUG - 3.45 1.94 1.44 1.13 0.89 3.67
CHE - 3.45 1.94 1.28 0.97 0.80 3.67
Now reads as..
#1 #2 #3 #4 #5 FD
AUG - 3.45 1.94 1.44 1.13 0.80 3.67
Thus giving me my better cruising 5th :smiley:
All this was further spurred on also by a PM recieved from Mk2Kezza earleir this week:
Hi Mattneck,
Just to let you know that i've got a 0.75 5th gear cog (out of a 4T box) in my AUG box. Motorway cruising is immense as it ticks over about 2750 rpm at 70 mph. This of course means I get a return of around 42 mpg @ 70 mph - much better than the 0.89 cog that is standard in the AUG, as that gave me around 34 mpg @ 70 mph.
I did the conversion as I was travelling 450 miles a week and I didn't want to get a diesel!
What I would say though is that if I did the conversion again I would probably go for the 0.80 cog out of the CHE as this would give the best compromise between economy and acceleration. Surprisingly, she still pulls well with the 0.75 particulary when your up to about 4000 rpm, of course at this point your doing about 90pmh!
Anyway, good luck with the rest of the modding and i'll be watching with interest.
Keri.
P.s Mines a 1.8 EZ i think (out of a sirocco) digifant golf II.
P.p.s My record is 430 miles from one tank, this was averaging 70 mph - at 60 mph I may even get up to about 450????
some useful advice, and also defiantely swayed me from looking at 0.75 or 0.71 gearsets! :smiley:
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Gearbox nearing completion.. last few bits are now on order and will be arriving in a combination of genuine and bits from my works..
Pushrod Bush
Pushrod Seal
Input Shaft Seal
Selector Shaft Seal
Starter Bush (in GB)
Once these are all fitted and the box given a damn good clean and degrease as the bellhousing is full of cack, It will be promptly offered up, and bolted up to the block this week :smiley:
Next on the agenda drive shaft refurb! :smiley:
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Box seals complete!
(http://i89.photobucket.com/albums/k234/mattneck/DSC00268.jpg)
Pushrod Bush
Pushrod Seal
Input Shaft Seal
Selector Shaft Seal
all done now.. Starter bushing needs to be looked at still.. tapping into that is required.. :smiley:
280s have become and addition to the collection
(http://i89.photobucket.com/albums/k234/mattneck/DSC00264.jpg)
along with a £1 stealth shelf, what is gonig to happen with that is of course, anyones guess :grin:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00265.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00266.jpg)
Now have an extensiv elsit of small things I need to source and attach and parts from germany are on their way somewhere, until then I'm stuck for any more doing! Doh.
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Driveshafts stripped and cleaned, gear stick housing and rods and that, stripped and cleaned, parts from germany arrived.. Things ar elooking ready to be put togetherish once again :smiley:
Did have an issue finding TDC the other night. the green plug had been loctited into the box, it required hammer screwdriver and some brutish behavious to get it out but it came free.. :grin:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00293.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00291.jpg)
but the other one refitted fine even with the thread chaffed.
Starter and front mount bracket fitted up nicely and confirmed box was aligned perfect and bolted up no trouble. jsut requries lower clutch cover palte and rear little one by the flange to be fitted now :smiley:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00289.jpg)
Also managed to get a pair of marks on the pulleys for use when timing up the cambelt when the tappets finally get slotted in..
(http://i89.photobucket.com/albums/k234/mattneck/DSC00295.jpg)
So not far off ahving it all bolted together and pushed out to one side to fester, while eveything else that needs done gets built! :cool:
Current ponders: Powerflex, Eibach Springs and stick with Boge Turbo's..
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Well, powerflex thought amounted in me buying rally design polysport all round instead.. read up many reviews pointing to these and saying no increase in noise, or reduction in comfort, just optimal steering and handling :grin:
So here they all are:
ARB Eylet, ARB Bolt, ARB Inner, Wishbone Rear, Wishbone Front, Rear Beam :cool:
(http://i89.photobucket.com/albums/k234/mattneck/DSC00304.jpg)
And of course these got fitted up into the new bits ready to assemble the subframe..
(http://i89.photobucket.com/albums/k234/mattneck/DSC04959.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00309.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC04961.jpg)
(http://i89.photobucket.com/albums/k234/mattneck/DSC00311.jpg)
So as stated, should see more positive and truer steering, and a more predictable solid ride and handling. Still in 2 minds regarding the rear beam bushes but have heard so much positive for them, it would almost now be rude not to try them at least!
Also read up on the Boge's I currently have fitted and they are applicable for most Mk2 applications.. 1.0, 1.3 and 16v carry the same, so with Eibach springs I'm sure will suit me just fine both in ride and handling :smiley:
Also now thinking of mating the fronts with Mk3 VR6 (PR code 2E1) top mount setup combined with Mk4 sports type bump stops, though I hear this raises the front a little, the comfort and solidity of it is a gaining factor - oh and they are much easier to change than the evil slotted nut etc of a mk2! - Though thats one that still requires thought currently.
The engine will finally be sealed up soon also.. new tappets are here!
(http://i89.photobucket.com/albums/k234/mattneck/DSC04962.jpg)
And the brake calipers will get a rebuild also, including the sliders etc upfront and the entire rear assembly's..
(http://i89.photobucket.com/albums/k234/mattneck/DSC04960.jpg)
Have also picked up the front hub assembly's, which will be receiving new bearings as the old were dry even when turned by hand, and onto these the 280's will be fitted up.. Plus the PAS setup has arrived for which I have new boots, clips and tie rod ends, and am now pondering getting this professionally reconditioned by a local firm who my work use for all steering related stuff.. this includes a full seal/bush etc swap internal and externally in/on the rack..
Though it's freezing at the moment so I ain't doing hardly anything on it :grin: