Author Topic: SoundillusioN - the re-united mk1!  (Read 130566 times)

Offline SoundillusioN

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Re: SoundillusioN - the re-united mk1!
« Reply #80 on: 05 February 2011, 04:06 »
A friend at work told me he has a Gas anyliser, I have borrowed it off him to see if i can set the engine up myself.


At the momement she's running a bit rich and wont settle below 1200-1300 RPM.  Also keen to see what the CO2 is like before the MOT.

Offline SoundillusioN

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Re: SoundillusioN - the re-united mk1!
« Reply #81 on: 05 February 2011, 04:08 »
This weekend has been about MOT tweaks and some tidying up. 
Re-bled the brakes
Got a gas tester on it, read 4% CO2, not bad. Tuning Plaque on the slam panel demands 1.8% at 1000 RPM which is what it's at now!.. whoop!

Tidied up some wiring, got my number plate holders and plates made up. 

Rebuilt the kamei fog light units with the Bosch parts from a Vauxhall Frontera... Just need to clean them up.





All my MK1 GTI's have never had the red Grille surround.  I wanted one on this and being a Cabby Grille my only option appeared to be painting it on...  Masking it was a b1tch! I had no idea how it was going to turn out...



Got carried away and did the badge spacer, not sure about it, might make it black again.  Need to get hold of a front GTI badge.  :sad:





Offline SoundillusioN

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Re: SoundillusioN - the re-united mk1!
« Reply #82 on: 05 February 2011, 04:09 »
So... bit of a cr@p update...

Thanks to Chris I now have a headlight bulb retaining clip in the lens that didn't have one.  I didn't have any side light bulb holders either and was struggling to find any, again Chris came to rescue, they fit but wrong connections!..  Only beer money wasted but i'm still annoyed as I've had to bodge them in now with some universal rubber holders that don't fit properly!

Dear VW,

what was the fecking need to change them when everything else is the same
:angry:

Front is now reassembled for the last time for now and everything works lights wise.  Red oval around Grille badge is now gone too.

Cannot for the life of me find the wiring for the brake fluid level sensor! I swear they were in the bay somewhere.  :angry:

Handbrake/Fluid level light on all the time. MOT Fail? I think so.

Need to get the tyres done tomorrow.  And after the above gremlins are sorted she's ready for an MOT (I Think)... down side is I'm broke!

Been doing some insurance quotes... Chris Knott wins hands down at the moment at £153 fully comp on classic!  :shocked:

Offline SoundillusioN

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Re: SoundillusioN - the re-united mk1!
« Reply #83 on: 05 February 2011, 04:10 »
Sounds like you have been a busy man mate. Looking forward to seeing this at a few shows this year! :cool:

Spending more time on stupid little faults now than I have with anything else!

Pictureless update

Had trouble trying to use the exisiting horn wiring as I cannot get a positve test through the wires under the engine bay.  Tested the steering wheel switch, that's fine, tested the sender wire to the fuse box with earh on the boss, passed. But when I put the testers earth on the car body and the positive to the horn switch sender wire, nothing.  After lots of head scratching it turns out the steering column and rack is not earthed so will not close a circuit.  Had a peek down the back of engine bay and I spotted that earth point 16 (rack to body) is broken.. Hope to sort this at the weekend!

After a few moments with the engine running, the Handbrake/Fluid Warning Light would come on and stay on.... I have now found the plug for the brake fluid level sensor (was wedged under the airbox),   I had to chop the plug off the loom and make new individual connections to use it. The cap is not the orginal as the car has a mk2 16v servo etc.. However the cap isn't off a MK2 and have no idea what it's from!
 
I have tested the fluid cap sensor and it appears to be switched on all the time, so will need to see if I can fix or replace. 

My other problem is that I cannot for the life of me find where the handbrake switch wire is supposed to go.  Having a connector at the end of the wire suggests that it shares a connection with a low fluid level sensor wire away from the fuse box, I cannot see any spare connections. I checked the following pin locations at the back of the fuse box to try and trace somewhere to stick it.

C/12 - brake fluid switch
B/1 and A/15 - brake fluid/handbrake warning switch
E/13 - handbrake warning switch

In my new looms there are no wires in the above pin locations!  WTF!? Looks like there never was.

Resorted to plan b, removed instrument panels and located plug for the warning light, found the correct earth wire and spliced the handbrake switch to the plug, did a continuity test and lifted the handbrake, result.  however, when I put the battery back on, I heard a fuse pop.. now obviously the switch does nothing again.

 :huh:
« Last Edit: 05 February 2011, 04:45 by SoundillusioN »

Offline SoundillusioN

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Re: SoundillusioN - the re-united mk1!
« Reply #84 on: 08 February 2011, 20:08 »
Well it looks like the growing list is finally slowing down for now, updated this to plan my last weekend bash at it!... (please don't fecking rain!)

To Source

Air Filter
All wiring looms (Engine, Interior/Dash, Lights)
Rear Light cluster
Bonnet
Front Bumper
N/S Wing
Front Indicators
Front side light bulb holders (bodged for now)
Headlight bulb retaining clip Thanks Chris :afro:
Rear Lights
Front Seats
Gear Linkage Kit
MK2 16v 256mm Vented Grooved/Drilled Discs
MK2 16v Front Brake Pads
New rear drums & Shoes
New Handbrake cables
Wheel bearings x4
Exhaust Hangers
15" BBS RA (Sportlines) x4
Late MK1 cabby Twin light Grille
Battery
Coil
Coilovers
Front Suspension Top Mounts
Rear Suspension Top Mounts
New Fuel Filter
Door Lock Pin
Headlight Bulbs
Spotlight Bulbs
Rear Twin Filament Bulbs
Windscreen Scuttle Repair Panel
Windscreen Seal
Windscreen Wipers
Window Winders
Twin Tone Horns
Front Wipers
2x 195/45/r15 tyres
Shift Weight
Windscreen Washer Jet
Washer Jet pipes
Heater Matrix Valve
Upgraded headlight wiring and relays
New Alarm System  :lipsrsealed:
New Numberplates and Dealer Holders


To Do

Strip out interior
Remove all wiring
Paint engine bay
Strip and paint cam cover and cam belt cover
Fit Air Filter
Remove BBS body kit
Full Rust Hunt and repair
Strip inner wings, paint/waxoyl
Strip Sills and Seams Paint/Waxoyl
Rewire car
Make and fit high power headlight/spots loom with relays
Fix Fuel gauge sender
Fault find MFA and fix if possible
No instrument cluster lights, fix
Remove and replace all gear linkages
Fit shift weight
Replace radiator
Clean out cooling system, fill with X Stream G30
Multiple engine flushes, new oil filter and fill with semi-synthetic
Fit later style cabby grille
Fit new bumper
Fit new 10 LED front indicators
Fit horns In progress
Refurb wheels
Fit new tyres
Fit new wheels
Replace rear drums pads and wheel bearings Bearings done, brakes postponed
Service Corrado Front Callipers
Replace front discs vented drilled/grooved 256mm and pads
Fix boot leak
Replace rear lights
Fit coilovers
Fit rear lights
Sound proof interior
Wash carpets and refit
Fit Seats
Fit window winders
Fit Front Wipers
Remove windscreen
Repair leak behind window rubber with new scuttle panel and seal
Prep and paint interior
Refurbish new wing
Prep and paint BBS body kit (Satin Black)
Prep and paint body and panels (Satin Black) In Progress
Refit BBS body kit
Seal Exhaust and replace hangers
New Numberplates and Dealer Holders
Fix Brake Fluid/Handbrake Warning Issue
Fit Alarm System
Camber and wheel alignment etc
Tune Engine!!!!  :evil:

MOT  :shocked:

Offline SoundillusioN

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Re: SoundillusioN - the re-united mk1!
« Reply #85 on: 12 February 2011, 22:39 »
The weather pretty much behaved itself so I got stuck in.

My dub is still not horny and I thought I'd discovered why, the earth from the body to the steering rack was perished, today I put a new strap on.  (not often you get horny and strap on in the same sentence on this site)  :grin:

Whilst still under the car I did a continuity test on the rack and bingo, rack is earthed, tested the horn wiring and nothing, test for continuity on the steering shaft and still nothing!  WTF!?  Posted the problem HERE, If anyone can help, please do.  I spent ages fecking about with it all and I was loosing light so gave up.  If I can't solve it soon then it's going to have to be a button on the dash and separate wiring and rely etc!  :sad:

Fitted the horns, shiny wing bolts, my heavily cleaned washer bottle, new jets and overkill silicone piping. (the beginning of the red theme)  :wink:





This side of the bay is still a bit messy.  Will tidy up when everything is sorted.  Got a better radiator cowling to refub and put on at a later date.



A mate popped over as he was bored and gave me hand with the timing... It's not been running right since it's been running.  :grin:

Turns out cam pulley was way out.  :shocked: Took cambelt off, lined it all up, cambelt back on, strobed it, got CO2 meter on it and after tinkering with mixture and idle to meet the engines spec of 1.8% CO2 at 1000 rpm she seems very eager now! (shame it's so tappety when revved, another job for another day).



No it hasn't got HID's in it before you ask, side lights have LEDs in for now, A long exposure has made them look a lot brighter than they are.

Offline SoundillusioN

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Re: SoundillusioN - the re-united mk1!
« Reply #86 on: 23 February 2011, 12:44 »
So not a great update but there's pictures to keep you going!  It's great for me as I think i'm about done as far as roadworthiness sh*t goes.

After wasting a lot of time on my steering shaft earth issues I gave up. I was advised by rubjohnny I should have a spring and circlip making contact further up the shaft to provide earth to the horn, mine was missing so it was GO for plan B.

Dash mounted horn.  The best place to mount a button was already taken by the controller for the engine hot start.  This is no longer in use so was removed, the hole was made bigger to take a Halfrauds Push Button Start switch.





Because I'd replaced all the wiring after finding Hell beind the dash, I wanted to keep things neat. note the wrap, used with everything I have added. (rescued from old alarm/stereo installs etc.)





Horns may not live here but was easy access for now.  Wired via a soon to be boxed 5 pin relay



No pictures but gave up on the handbrake and low fluid level light issues. Created my own wiring for them and fitted that instead.  Now works fine. Grille kind of sorted too.

Just put the dash backtogether, fit the tyres and........................................






Offline SoundillusioN

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Re: SoundillusioN - the re-united mk1!
« Reply #87 on: 10 March 2011, 18:19 »
Car now insured with Chris Knott.  Awesome deal!

Got next week off work with a few days spare for the car.. watch this space.

 :undecided:   :undecided:


Offline SoundillusioN

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Re: SoundillusioN - the re-united mk1!
« Reply #88 on: 16 March 2011, 01:01 »
MOT Today at 11:30!! 

:shocked:  :lipsrsealed:



Offline SoundillusioN

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Re: SoundillusioN - the re-united mk1!
« Reply #89 on: 17 March 2011, 08:42 »
MOT Failed..........  :sad:


..... But not badly  :smiley: and was expected after 7 years off the road and rebuilding it on a driveway!  Sorry for late update but have had a lot of other stuff to do and am back out again in 10 minutes...

It's silly bits I've missed or forgotten about.  The list is as follows:

Offside side light not working (popped this morning)

Nearside headlamp aim too low

Offside headlight aim too high

Offside brake hose ferrule excessively corroded

Nearside front track rod end nut split pin missing

Advisory:

Handbrake performance, nearside 50% less efficient than offside.

So not that bad really.

The funny thing about this morning was 10 minutes before I left she refused to turn over!...  I quite literally shat bricks!  The trigger wire for the starter had come off but took me a while to spot as I was in a panic by this point!