dazzx10r

Rear beam has had 2 coats of red oxide primer and now ready for some gloss black enamel. [ATTACH=CONFIG]91138[/ATTACH] I decided to strip the calipers and see how bad they actually were, to my suprise they weren't seized so I tackled them with my wire wheel on the grinder to remove the worst of the rust and gave them a lick of silver paint before reassembling them. [ATTACH=CONFIG]91141[/ATTACH] [ATTACH=CONFIG]91144[/ATTACH] [ATTACH=CONFIG]91147[/ATTACH] That's all for this week due to being on 12hr days all week. I have bought a roll of copper brake pipe, so I will be remaking all of the brake lines next weekend then I'll move on to making up the intercooler pipe work. This is all going to be done in 2.5" stainless with as little silicone hose conections as possible.

I have stripped every thing off the rear beam ready to clean it up and repaint The brakes look like they've had it and the back plates are pretty much non existant. [ATTACH=CONFIG]91120[/ATTACH] [ATTACH=CONFIG]91123[/ATTACH] [ATTACH=CONFIG]91126[/ATTACH] [ATTACH=CONFIG]91129[/ATTACH] I went on a little shopping trip to Toolstation and bought these [ATTACH=CONFIG]91132[/ATTACH] They should rip through the rust in no time, probably the most lethal tool ever inveted by man :lol: All of the loose flakey rust removed from the beam and ready to paint [ATTACH=CONFIG]91135[/ATTACH]

The exhaust flange turned up in the post today so I could get on with making the decat pipe. [ATTACH=CONFIG]91054[/ATTACH] All done, I made an extended 02 boss, sorry I didn't get pics of making that. [ATTACH=CONFIG]91057[/ATTACH]

I removed all of the brake lines from the beam whilst I had it out on the floor, they were pretty much shot. [ATTACH=CONFIG]91042[/ATTACH] I also noticed that the little plastic wheel that goes inside the spring for the proportioning valve was broken. [ATTACH=CONFIG]91045[/ATTACH] [ATTACH=CONFIG]91048[/ATTACH] So I couldn't really leave that, time to fire up the lathe. [ATTACH=CONFIG]91051[/ATTACH] So new Floflex bushes on order, less than half the price of the Powerflex ones. ;) and that's about all I can do for now with the beam. I'll give it a clean up and paint before refitting.

I was going to fit my rear brake hoses today, but as I got under the rear of the car I noticed that the rear beam bushes looked a little tired [ATTACH=CONFIG]91027[/ATTACH] Now that I had seen this I just had to get the beam off and get those bushes out, not a job I had planned on. I used Ed China's trick of suing a bolt through a socket to pull the middle out of the bush, then using a 35mm hole saw I drilled the remaining rubber out. [ATTACH=CONFIG]91030[/ATTACH] [ATTACH=CONFIG]91033[/ATTACH] Then it was just a simple case of using the hacksaw to cut through the outer steel shell and knocking it out with a hammer and chisel. Whilst I was removing the beam I disconected the ABS sensor cable from inside the car and pushed it and the gromet though the boot floor, unforunately I also removed a little bit of rot at the same time :mad2: [ATTACH=CONFIG]91036[/ATTACH] So I cut a plate and repaired the hole, I'll dill it out for the gromet later and paint it all back up. [ATTACH=CONFIG]91039[/ATTACH]

Car is looking good mate, where did you get your 20v grille badge from?

I made a boss for my MAP sensor and got mt mate to weld it into my intercooler. [ATTACH=CONFIG]90958[/ATTACH] I then gave the intercooler a coat of high temp black paint, it's the only black spray I had to hand at the time :lol: [ATTACH=CONFIG]90961[/ATTACH] [ATTACH=CONFIG]90964[/ATTACH] As things were going so well I thought I'd get the front panel back on, which then led me to fitting the headlights and grille. [ATTACH=CONFIG]90967[/ATTACH] [ATTACH=CONFIG]90970[/ATTACH] I think I might need a new grille badge now? [ATTACH=CONFIG]90973[/ATTACH] It's all coming together now, won't be long before it's back on the road.

I found an 80mm Maf that I had from my old Focus ST, so I took the Ford sensor out of it and tried the VW one in it. I now have a choice of 70mm or 80mm maf. [ATTACH=CONFIG]90955[/ATTACH]

Got this intercooler donated to me from my son's old Polo GTI, it's a bit big but I reckon it will work ok. I do like freebies [ATTACH=CONFIG]90949[/ATTACH] [ATTACH=CONFIG]90952[/ATTACH]

A bit of an update from the weekend, Tried to start the car today after finaly finishing up the wiring. The fuel pump wirred into life, the throttle body buzzed away and the engine cranked over but would'nt fire. We spent an hour or so problem solving and checking over a few things and then realised that the crankshaft sensor wasn't plugged in. Doh! Tried the car again and it sprung straight into life. to say that I'm happy is an understatement. So I then went and refitted the fusebox and put the dash back together. [ATTACH=CONFIG]90940[/ATTACH] Posty came and left me this Temp sender. :) [ATTACH=CONFIG]90943[/ATTACH] Fitted [ATTACH=CONFIG]90946[/ATTACH]

That's going to look fantastic mate. Best colour too, but then I am biased. :thumbleft:

Got back in the garage and finished up a bit of the wiring and fitted the battery. Good news is............................................... the car run's :) The guide over on Club GTI forum is spot on. So I have moved on the making the downpipe. [ATTACH=CONFIG]90856[/ATTACH] [ATTACH=CONFIG]90859[/ATTACH] I'm still waiting on a few bits to turn up, but on a plus note I have had this intercooler given to me. It looks like it could work ok. [ATTACH=CONFIG]90862[/ATTACH] [ATTACH=CONFIG]90865[/ATTACH]

Oh dear, get well soon.

Plan B is to use these Lotus Elise (S2) discs. [ATTACH=CONFIG]90760[/ATTACH] They are 288mm but slightly thicker at 25mm and the center bore is smaller at 60mm. [ATTACH=CONFIG]90775[/ATTACH] So I popped one in the lathe and opened the centre bore out to 65mm and did a test fit. These are a few discs I have to hand, from the left; std Corrado disc, G60 280mm disc, Mk4 Golf disc, S2 Lotus Elise disc. [ATTACH=CONFIG]90763[/ATTACH] Elise disc at the side of a Golf 4 disc, note the thickness. [ATTACH=CONFIG]90766[/ATTACH] Elise disc fitted to the car, looks okay but those are worn pads so I'm not sure if they will work with brand new pads. I'll check back later when I have the new pads to hand. [ATTACH=CONFIG]90769[/ATTACH] [ATTACH=CONFIG]90772[/ATTACH]

Hmm, I didn't realise that. On to plan B then.

So that's about it for now, I'm waiting on a few parts to arrive, Exhaust bends & a MAF. I'm going to make my own turbo intake rather than spend £80 on a silicone intake pipe, so to make a start I spun this turbo intake nozzle up on the lathe [ATTACH=CONFIG]90751[/ATTACH] [ATTACH=CONFIG]90754[/ATTACH] It fits perfectly and blends into the throat of the turbo lovely. I had the idea from the old Badger5 one that I had on my Lotus. I will fit a 2.5" to 3" silicone bend onto this and the rest will be made up of aluminium pipe.

Looks like there might just be enough clearence for an engine cover. [ATTACH=CONFIG]90748[/ATTACH]

Got some new brake lines through the post today, really pleased with them. [ATTACH=CONFIG]90730[/ATTACH] Also got some new gearshift cable ends [ATTACH=CONFIG]90733[/ATTACH] So I thought I would get the brakes all bak together with the new lines fitted. [ATTACH=CONFIG]90736[/ATTACH] I fired up the compressor and gave the strut brace a coat of 2k black and got it fitted, this then gave me the opertunity to get the front suspension back on the car. [ATTACH=CONFIG]90739[/ATTACH] [ATTACH=CONFIG]90742[/ATTACH] [ATTACH=CONFIG]90745[/ATTACH]

I managed to bet bak on the lathe and turned the ends up for my strut brace, I then weled it all together and went for a test fit [ATTACH=CONFIG]90718[/ATTACH] Posty came and left a few parts, of which were my new driveshaft bolts. I have not gone with the standard VW bolts, instead I have used high tensile (10.9) M8 x 80 cap screws. These are about 5mm longer than the standard VW ones and just poke through the other side of the flange. Being 10.9 tensile I wasn't scared of really nipping them. [ATTACH=CONFIG]90721[/ATTACH] [ATTACH=CONFIG]90724[/ATTACH] [ATTACH=CONFIG]90727[/ATTACH]

Manageged to get a couple of days back in the garage, been quite busy [ATTACH=CONFIG]90706[/ATTACH] [ATTACH=CONFIG]90709[/ATTACH] I cut the flange fom the old mk4 golf downpipe and put it in the lathe to clean it up ready to make the downpipe when my bends arrive. That's the problem with ordering parts over the xmas period, postal delays and vendors closed for the xmas break. [ATTACH=CONFIG]90712[/ATTACH] [ATTACH=CONFIG]90715[/ATTACH] I stripped the old brake off and fitted my G60 discs that I already had. These mate up perfectly with the Mk4 Golf calipers, which I stripped and cleaned and then treated them to a coat of silver caliper paint. I went with silver because I did'nt want anything too ott, that and the fact that I already had the silver paint. :)

It sure does come in handy, it's an old Colchester Master made in 1960! I only paid £500 for it and it's already paid for itself.

The 2 strut mounting rings were made from a lump of 5mm plate that I had knocking around. I cut it into a sqoare and then mounted it into my lathe using the 4 jaw chuck, once I had it centered I bored a pilot hole and then opened this up with a 70mm hole saw. I could now use the lathe to bore the centre out to the diameter of the inner strut top. Once I had a perfectly round circle I swapped the chuck over to my 3 jaw and mounted the plate from the centre of the circle, I could now turn the outside diameter to suit. Which left me with a perfect circular ring [ATTACH=CONFIG]90694[/ATTACH] I 'borrowed' a bit of CDS tube from work, I think this will do the job 4.2mm wall thickness :) [ATTACH=CONFIG]90697[/ATTACH] That's about all for today, I can't see me getting much done for the next few day's, something called xmas has gotten in the way. [ATTACH=CONFIG]90700[/ATTACH] Test fit with the engine back in (again)

As things were going so well I thought I'd look at the strut brace that I've been working on. I cut the 2 m6 studs that hold the abs sensor cable from the strut tops and applied a bit of primer (i'll give it a proper paint at a later date). [ATTACH=CONFIG]90688[/ATTACH] [ATTACH=CONFIG]90691[/ATTACH]

[ATTACH=CONFIG]90682[/ATTACH] [ATTACH=CONFIG]90685[/ATTACH] I had a bit of a brain wave and thought I could maybe convert the old carbon canister into a catch tank, if it does'nt work then i'll get my mate to make me one and mount it in position of the carbon canister.

Got a bit more done on the car today after the mad supermarket run. I finished up wrapping the loom with Tessa tape and fixed it into place, i'm running the loom along the inside of the scuttle, asyou can see I have my ecu mounted up in there just as it was with the 16v. I then went on fitting my Focus master cylinder, getting the servo back in was a right pain it's such a tight fit against the strut tower. [ATTACH=CONFIG]90676[/ATTACH] [ATTACH=CONFIG]90679[/ATTACH]