Shockingly, an update
Its been a bit unloved over the winter, engine bay is looking worse for wear to be honest (looking back at the time spent on it makes you realise why people trailer their show cars around!). Particularly irritating was the sticky rear calipers (couldn't use the handbrake) and squeeking front brakes. Decided to take it off the road for a couple of weeks while I did a few jobs, namely rebuilding the 'charger, fitting new intercooler and radiator, rebuilding rear calipers and replacing front brakes...
Now, the rear calipers were 'problem free' Mk4 items, but I had some Mk3 ones that were in ok condition, so stripped them down, got some new seals of Biggred, painted them up and put them on with some new pads;
Old;
New;
I'm running S2 twin pot (Girling G60) calipers, which when used with 280mm discs results in the pads sweeping close to the hub and creating a lip on the pads. After having a look at what others had done to solve this I ordered some *cough* vauxhall *cough* 280mm discs. These are vented differently so have a 'full face' as it were, eliminating the uneven wear. They are also 25mm thick (same as stock S2) as opposed to 22mm, but do require the centre bore opening up a little (5quid at local engineering shop). Bought some new Pagid pads too.
As usual, a quick job became anything but .. on both sides the 40mm piston was leaking fluid into the dust boot, so ordered new inner seals and pistons off biggred (good service and helpful on the phone, highly recommended). Anyway, got there in the end;
Old;
New;
Sooooo, onto the 'charger rebuild, lots of pics;
Stripped all the paint off;
Some light porting;
Bearing out and exhaust half cleaned;
Inlet half cleaned up with bearing removed;
Painted silver;
Scroll bearing out and cleaned up;
New bearings going back in (oven mit because it had just been cooking
)
Seals going in;
Shaft in;
Going back together;
Almost done
With 'charger rebuilt, it was time to refit with new intercooler/radiator and u-bend. I'll let the pics do the talking;
Hello massive Wagner intercooler
This is how much you have to chop out of a mk2 to fit the rallye 'cooler;
Charger and u-bend fitted;
Nearly there;
All in, with factory Rallye boost pipes too;
Drove it about 20 miles and it broke down
Alternator had packed up so battery died
Luckily I had another alternator in the garage, so got dad to bring me a battery and soon had it back up and running
340 miles into the run-in, can't wait to boot it..