She's back from hibernation........with about an inch of dust all over Now at least dust free Let the work begin!
Brake master cylinder removed, speedo-clutch-throttle cables removed. Got problem with the hydraulic pedal box - the metalwork to the right hand side clashes with the fusebox support bracket, and the top bracket is set to the right, whereas the original is set to the left. Is this a passat pedal box maybe? I can modify it no problem with grinder and welder but i'd prefer not to!
Usual problem that,move the top bracket if you can & just "" trim" the fuse box earth bracket "thingy" or move the whole fusebox as far as you can to the right.
AAh thanks for the reassurance. I will modify the pedal box I think, as this means the fusebox can stay "as-is".
Original pedal box on the left (with lug cut off) - hydraulic pedal box on the right. The difference here is obvious and this is why it clashes with the fusebox. The bit on the left is cut off the original pedal box......and you can see the hydraulic pedalbox has a wider section - plus the mounting lug is offset. Hydraulc box modified with a few cuts of the grinder (side plate trimmed to match original shape) and the original lug/switch mount plate welded into new frame. Now for a few coats of back paint Here's one I made earlier...........
Never seen a pedalbox modded like that,but i LIKE it! and it works welding looks great too. Onwards as they say,to the next challange........(plenty of them with these pmsl)
i like how you modded this but i would just add some metal in the open bit left now (what looks to be in front of pedal spring) to add some extra strengh and reduce flexing
Good idea but this replicates the shape of the original mk2 pedalbox. ill trial it and if it flexes excessively i'll strap it with plate
Bulkhead tapped flatter and holes drilled / dremelled for the clutch hydraulic master cylinder. Test fit for the F*rd brake master cylinder....I need the 3mm spacer. Which hydraulic reservoir will fit as the one I have on the original doesn't look like it will?
Great stuff!! I'm going to drill the plunger out to lose the 3mm......and I have a mk3 TDi reservoir which has the clutch outlet so will modify the MC and fit earlier seals
Looking to improve the PCV system and I found this custom adapter in my parts bin. Looks to have been turned out of nylon and fitted with silicone hose to connect to the rest of the system.
Bit more done today.........up on axle stands to access rear. Jobs to do...... Swap fuel tank, and lines for Mk3 golf 16v (pump in tank). Replace rear beam for one i've had powdercoated and polybushed. Typically the bracket at the fuel filler neck is rotten and i've spent time cutting out the rust and re-making one / welding.
the ford master cylinder just drill out the inside 3 mm it is solid alu so plenty in there and no need for a stupid spacer, i have it on my 20v and is fine!! although need the hell bleeding more!!! i lke the crankcase breather? where is it from ?
Yerr i've looked at drilling out the plunger and i've got some decent cobalt drills so should manage it ok. The crankcase breather is custom made I believe.
