My pearly dream of just popping in a diff bolt kit has been well and truely shattered, to be fair it was always on the cards. All the taper roller bearings need replacing and one synchronised ring looks like it's been fried to death!. On a plus side all the roller bearings, gears and shafts look in good order. Managed to pull the diff bearings off with my 250mm puller and a bit of make do and mend.. Need to buy a bearing splitter for the output shaft taper bearings. Taking diff into work tomorrow to use the drill press to drill out diff rivets.
Got a bit busy with other projects but my lad's been on about our Mk2 and he's been a great help today (hopefully he'll be driving it in a few years!). Engines out, subframe etc. Could do with brake lines all through really, mulling over using AN-3 Braided Teflon lines but we'll see. Had a great afternoon with my son, think he's a VW fan now!.
Motoring along now, my daughter "tool lady" has promoted herself to mechanic so she's been helping today too!. Subframes etc all cleaned/ prepped and painted in cold galvanising paint. The spare gearbox looks a goer for fitting after my lad gave it a good clean. Day off tomorrow so probably get all the engine bay cleaned up ready for doing the brake lines etc. Waiting for new Master Cylinder to turn up.. Ordered some Fine walnut shell and a media blaster to do my inlet manifold and engine parts, seems best least destructive option!.
Spent 3 hours cleaning the engine bay today. Apart from a little surface rust she's solid as a rock still!. Got a bit of painting to do then at least I can get brake lines/ steering rack/ subframe back in.
Had a bit of an issue with my Manual Steering conversion. I thought I could get away with just swapping the rack.. I've had to buy: New Steering UJ. New UJ boot (longer than PS). New tie rod ends (PS don't fit!). Did contemplate stripping and gutting the power steering rack (might still do that later if I get time).
Manual vs Power steering UJ's, brake calipers and gave my daughter a head torch!. She's helped out every night bless her, a mechanic in the making!. These pipes are a bit sketchy, wonder if anyone does aftermarket silicone jobbies?.
Just about done with subframe assy, had to make some Half Nuts as VW are NLA?. Calipers done. Patio's a war zone but getting there..
You have reverted from PAS? Why’s that? Or did my skin read fail me. Whoever I bought my PAS from gave me the wrong UJ I found out yesterday
My PAS Rack and pipes were in a right state, I've gone manual rack to neaten up the engine bay but I've kept the rack just in case. Ideally I'd like to go the electric steering column route. The PAS UJ is shorter and has a bigger end on the steering rack end. The PAS UJ boot is different as well.
Kong coilovers getting some needed attention yesterday. Had welder our to pull a snapped stud out of cylinder head and my daughter was having a practice while it was out!. She's got stuck in with everything.
PTFE brake lines this morning, 8 meters doesn't go far!. Having wheel well exit rear bulkhead fixings, two nice pipe entries in lhs of engine bay. Front wise going PTFE up to the original mounting points then normal wheel well hose. My rear Mk4 calipers appear to be M11 fine brake fitting?, not done me any favours today.. Got some Stainless P clips to secure it in the engine bay.
But of an update, made some frames and got Golf on Chassis Trollies. Rear beam and hangers of, measuring up for wheel stud conversion. My new sills arrived (should have used VW Heritage first time around!), was going to just use the bottom section but looking at the quality I'm doing the full sills, more work but better outcome hopefully!. Helix Autosport are refurbishing my paddle clutch for £76 + vat due to oil contamination which is a bloomin bargain really!.
A few more poc of progress. 3mm Angle Iron down both sides now, can easily jack car up from middle of sills!.
NS finally done and wheel wells sorted out. Rear 1/4 looked a bit iffy bur after welding the holes up without blowing it to bits I'm sure I can salvage it.
Managed to find a new MegaSquirt 1, bought as a spare!. Booted my old laptop up, not been turned on for at least 15 years and it booted straight up!. Managed to get my original code off the old laptop luckily. Got my original MS1 running from a Milwaukee M12 battery, took a while but I've got Megatune running on a Windows 10 laptop with FTDI USB to Serial adapter. Computer happily taking to MS1!.
Me and my lad have been beavering away and today we got it running again. AN-6 Teflon fuel lines, Sytec FPR, Mitsubishi GTO fuel pump and a lot of work!. Mechanically and chassis wise we are nearly done. Light at the end of the tunnel!. https://youtube.com/shorts/MkfbXA9kpr8?feature=share
