mattneck - mk2 ryder

[mattneck(Beavis)]

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 

Wing after first coat..



Mixed up paint



Wing after final coat



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 







Neil removing the old wing



Stripped off and looking sorry..



old, new, ready to go



and back on, needs the blue pinstripe and original bumper refitting now 







Glad o have it back to it's former glory, only to find a deep scratch across teh roof 

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 

[mattneck(Beavis)]

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 



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 



Tried on the valver rears, and then becky did me some photo chops for comparisons of new lighting to the rear and sides..









Fitted the new foams behind these as well, although back to standard buisness for now, till I find some white top red bottom ones 

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 









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 

[mattneck(Beavis)]

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..



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.





Also got a new bearing ring to replace the old in the shiftbox, to try and help the side to side play.





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

[mattneck(Beavis)]

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 

Fan:


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...







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



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:


Fuse box End:


Connected up:


Switch in situ:


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..









After this, the sand blasters came back with my stuff, which came up trumps... fan cowling and air filter lid ready for powder...









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:



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:


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..





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 

[mattneck(Beavis)]

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.. 

[mattneck(Beavis)]

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..



and the busted alternator..

[mattneck(Beavis)]

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! 

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! 

[mattneck(Beavis)]

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!



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..



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.



also a close up of the forming of the looms..





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 



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) 

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! 

[mattneck(Beavis)]

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..











also had a pop at the petrol pump and engine lift bracket..

[mattneck(Beavis)]

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..  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..



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.





Next to open and seperate the clocks the 8 bolt head screws around the back border of the clocks must be removed.



Next the oil pressure circuit ribbon had to be pulled and the transistor lifted to release the clocks internals.



Then the one plug connection to the clocks must be slid back to unclip and lifted off.



From here the clocks can be dropped out of the back of the cluster and seperated into electronics and speedometer.



The different clocks (one set VDO, one set Motometer) meant the oil pressure connection differed. The ribbon still fitted and connected.



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.





Thus you have a rev counter and retained your original milage and speedometer with correct gearing