Trying to do body work in this weather is very trying (see what I did there ). Far from my best welding but it is solid and once it's linished and coated it will be presentable. Painted with epoxy mastic. It takes forever to go off in this weather so it's a day at a time unfortunately. Today gave the inside a liberal coating of Dynax cavity protector stuff. Once the cavity protector and the epoxy are properly dry (it takes ages in this weather) I will seal it all and paint it red. I was also unhappy with this bend, it could only be detrimental to servo vacuum. It's the old Mk2 servo pipe. It is pretty much impossible to get to the connector on the servo with the master cylinder in place so I conjoined the Mk3 pipe with the Mk2. Took it for a test drive and guess what, not a blind bit of difference oh well, at least I tried. I think the only way the brakes will be perfect is to change the servo for a 9 incher. In other news we finished off the sound insulation. I added some more deadener here, both sides of the tunnel. And then stuck the 6mm foam insulation all over the areas where the deadener is. No photos I'm afraid but you get the idea. It has made a huge difference. Well worth doing. In further news, although I did say above that there was nothing that came out of the MOT, the guys mentioned that the cam belt was too tight. I had thought this may be the case as it whined on acceleration, a bit like a turbo charger but not as loud (or my wife when I drive "spiritedly" ). So when we got home we slackened it off a touch, took ten minutes, the hardest part was getting the cover off.
Good work there Phil, looks almost sunny, it's tipping it down here in Bristol and home in Yorkshire, so I'm probably not getting much done this week either. Was there much burn on the paintwork?
Well no, I had to strip off the outside of the arch anyway as there was a little surface rust. However, it will be covered by the GTi arches when they go on.
Yesterday Ralph set about the rear lights. 600, 1000, 1500 then polish. Before. After They look like new, he’s done a great job
So to rear brakes. As mentioned in other threads we are swapping to discs. After much deliberation and procrastination We ended up buying a rear beam from a 1.6/1.8 for the brake bias valve and associated gubbins. Before Dismantled. Didn’t take long, everything came undone relatively easily and I used the tried and tested method of drilling and cutting the beam bushes. They were well past their sell date! And some rubbish for the scrappy. What is this spring for. Let the stripping and painting begin
Yes please Sir, clean and shiny bits. Just the main beam to do. I also found a 3D print file for the NLA brake pipe retaining clips. They work but I’m not sure how robust they will be over time.
Yes, I phoned VW and they confirmed NLA. Any stock is now new old stock. They are still available from sellers in Europe. £1.10 each plus postage is a rip off when other types of brake pipe clips are pence. If the 3D prints don’t stand up I shall use a different type and drill mounting holes.
This evening we have pressed the axle bushes in. What a pig of a job!!!! I created some bits of metal that I thought would do the job - hopeless These looked like this…. The threaded kept threading and so this lot got the bush in about half an inch So we ended up with this, a hefty M12 bolt and bunch of bits of metal and sockets We have this. Does this look OK. Does it look like it wants to go in a couple more mm? It’s about as far as we could get it using a breaker bar.