Dan's mk2 8v to ABF project **Build For Le Mans??**

[tech1889]

Just spent the first full day on the golf in as far back as i can remember..

I removed old pedal box which is a right pita... Fitted up the new hydro pedal box.. has anyone else done this as i was under impression it was straight fit which it is but not all the bolts line up the servo ones do and a couple of others but not all just wondered if this was normal..

Also i trimmed up my mk3 shifter box and fitted that so it can be bolted to gearbox..

Sorted out the front brake line clips so they all held in place correctly now which is much neater..

Removed engine again to assist with going hyrdo..

Went to fit new crank angle sensor and found euro car parts had sent me the wrong one  so on the hunt for another..

Attempted fitting power steering pump to engine and realised im missing a bracket which i may have snapped 

Need to order a few parts but other than that progress is going well at the moment.. Need to flat back bulkhead tomorrow and drill the three holes to fit master cylinder then im pretty much 100% done on the hyrdo front just missing the hose from master to slave..

Might actually get this done for Le Mans the race is on 

[tech1889]

Well today went good and bad.. I attempted to drill multiple holes for the master cylinder and it was a right ball ache so spent £15 on a step drill and it made the job a jot easier.. The bulk head is tough steel so got my friend to use a blow torch to heat it up and re-formed it with a hammer just needs a quick lick of paint now.. master cylinder fits great final bolting up tomorrow but very please so far.. 

[tech1889]

How car was looking half way through day one and having removed engine



Day 3 saw us have a bit of fun.. Jacks can only go so high..

Removed the rear bumper to find the back panel straight and relatively rot free except minor under left chassis hole and corners which im happy about..



Jack the rear this high made my car go quite compressed at the front.. spring compressor anyone ??

[tech1889]

Just ordered a few parts to help me along..

- Metal p clips that are rubber lined for my brake lines..
- 8mm Fuel hose to replace the two engine bay ones as too short 

[tech1889]

Well spent another half a day on it a couple of days ago and was pleased with my work..

Managed to finish of the rear brake lines which was a big hill to get over as been doing them for a while but finally fitted all new flexi pipes and solid pipes so much fresher now.. All the brakes are now finally done.. All i need to do is get new discs and pads all round and paint the callipers which will be done when its closer to being finished..

Also i managed to sort my drivers door handle which was just being a pain and you had to wiggle the door to get it to work and was annoying me so removed exterior handle and gave it all a nice clean and regreased..

Also the car had become a shed and was used as storage so i cleaned up some of the inside of the garage and removed more of the inside of the golf and put it in the garage which means i can finish off the inside of the golf without having to navigate around a dash ive removed etc 

The car is definitely on the way to being running soon... Hopefully 



To Do List -

-Crank Angle Sensor - ECP Sent me the wrong part so need another
-Clutch hydro line
-Check over engine bolts
-Coolant top pipe rubber seal
-Immob delete
-Power steering belt
-Alternator belt
-Inlet Gasket
-Exhaust Gasket
-1.3 Throttle cable
-Front bumper
-Sort front wings
-Fit Exhaust
-Buy various expensive bolts from VW
-Discs and Pads
-Fit my Mk4 Track rod ends..
-Fit Driveshafts with new CV's i have
-New headlight loom as i lost mine 


Thats roughly it it probably looks worse than it is but i dont think theres that much just waiting for some money to buy bits from various people 

[tech1889]

Just placed a nice little order in for hopefully the last bits needed for the engine just need to pop to VW for a couple of small bits..

On Route

Crank Angle Sensor
Inlet Gasket
PAS Belt
Alternator Belt

[Metallix]

Just a note on the crank sensor:

ABF crank sensor from VW is expensive ~£100
& no guarantee that they will last any longer than other brands,
had one fail after 1.5 years service

The ~£30 ones from ECP seem to work just fine.

 

[tech1889]

Bought mine from vwsonline.com which is recommended by rubjonny and its only £40.. The belts were only like £3 and £6 each.. And gasket like a fiver..

Need to get an exhaust gasket any ideas ?

Atleast someone looks at the thread lol 

[Metallix]

Ahh 
I read your post as that you were en route to collect those bits from VW


Which gasket?:
- 4x gasket for manifold to head
- 1x gasket for manifold to downpipe
- 1x gasket for downpipe to decat (if using Mk3 downpipe)

[tech1889]

All of the above gaskets I have none