MK3 Anni

[swainy]

Been on with a few bits and bobs the last week or so. Got some gas for the mig so have been smoothing off some of the unwanted holes.
My £0.99 ebay bargain turned up Tuesday, I really didn't think the seller would go through with the sale but he did. I had to arrange my own courier so got work to sort that so I didn't have to pay for it.  its a electric power steering pump from a 106 GTI, need to mount it out the way and have some lines made to suit.



Also my wishbone bushes turned up so can get the subframe built back up. Just in the process of painting it.

[swainy]

Started on the notch today, think I've cut it a bit big but sure it'll be fine. Started off with a holesaw but was taking forever so drilled a series of holes round the groove and chopped it with the grinder.



My 312mm discs turned up aswell so had a quick mock up with the calipers in one of my 17s. They clear with a few mm to spare.





The steel also turned up so have been making small plates to cover all the holes in the bay.

[thai-wronghorse]

The size of that notch concerns me somewhat.

[BISSONE]

The size of that notch concerns me somewhat.

Lol any chassis leg left? Possible serious weak point?!?!

[swainy]

I know it looks massive but i used the same size holesaw as I did on my bora and that didn't look as big. Ill get some thick wall steel tube tack it in and fill the holes in with the same thickness of steel to make it a bit smaller.

[jimmydub]

nice build thread here mate, hell of a lot going on! i know you did it a while ago but just wondering if you could go into a bit of detail about the fiberglass boot install?? its one of the next things on my list and i hadn't considered fibreglass untill reading this!

[swainy]

Thanks mate, yer there is a lot going on, hopefully soon it will all tie together.
The sub box was fairly easy, masked off an area of the boot, bought a fibreglass kit for about £30 off eBay, think mine was a 2kg kit but could have done with about double that for a couple of extra layers in some areas, made the front out of some Mdf I had laying about and fibreglassed it in place. Covered with some carpet and job done.
All in all took a couple of days and made the car stink for about a week 

[Wayne]

The size of that notch concerns me somewhat.

Agreed that is a lot of metal to remove from the crash structure, maybe worth asking your insurance companies view as that looks very weak.

[CJA321]

Yeah that notch is huge. Also, are you sure those defender calipers are going to work? This thread reminded me I forgot to reply, those part numbers didnt come up on our system at work but im certain they are from a defender. But in my opinion, they dont look like there going to fit the disc, from the pic you have put up the disc looks as far in as it will go to the caliper but still leaving quite a big part of the disc with no pad on it!!

Apart from that, good work so far 

[swainy]

I also agree there is too much metal removed, I should have measured twice cut once but its done now and I'm more than capable of adding strength back into it like any normal notch.