93 cabrio repairs...

[roccodingo]

wow, taking so long...

Getting back into this project, been crazy flat strap at work last 3 weeks and weekends..

managed to get some filling and sanding done to the front valence

...

Its amazing what stuff is hidden under the paintwork, If I knew this panel was as damaged as it is, i would have bought a replacement lower valence.... I got one for the GTI which has only just arrived...

Need to do a few things to the engine to tidy it up, Trans needs the 5th gear syncro checking out...



Starting with a good tub for both of em...

[Jarred]

Degreaser!

I have a feeling will come in handy!

Good work.

[roccodingo]

time flies...

After piddling about with the red Mk 1 salvage ( see golfballs thread..) managed to get some time on the Cabby today...

Transmission is all cleaned up, just need to get into the 5th gear syncro and check a few other items while its opened...( background 3rd pic )

Took the dash out of the car as i will be fitting a new audio unit,



the main reason was this though..



Cant believe VW made such a poor job of designing this glovebox, thin brittle ( with age) plastic, a bugger to replace as well...

Test fitted it to the dash after removing the old box, managing not to stuff the pressed cardboard these things are made of...



The plan is to reinforce the hinge area with plastic metal and adhesive, hopefully making the box itself last as long as the car... next task will be to bond it into the dash .. Any ideas greatfully accepted..????

The dash bezel had seen better days ...



broken thru in 2 places, and all but one fixing screw hole remained intact.. Have a few spares, so got the replacement for that already..

[roccodingo]

merry xmas..

Had some parts arrive from the states on Christmas eve, ( Big thanks to Brian at BrokeVW.com ) so it was time to open the tranny up...

Came apart very easy, someone had been into this before, evidence of silastic all over the leaking gaskets... Had to knock up a few specialised tools to do the job however persistance paid off...



Originally I was just going to do seals and gaskets, Have a look at 5th syncro as it was a bit crunchy in shifting... I think the shift fork could have been out of adjustment looking at the shift fork rod...



Will be replacing the diff rivets for a bolt kit while its apart, one of the must do's for the VW 020 trans...



More tomorrow with a bit o luck...

[Jarred]

cool fun.

How difficult would you rate "going over" the gearbox?? Ie replacing seals and syncro's?

[roccodingo]

How difficult would you rate "going over" the gearbox?? Ie replacing seals and syncro's?

Dont rate it difficult at all, more the point how much tooling you have to be able to do the job effectively. Had to make 2 pullers and a holding jig. Also have a hyd press handy, an industrial washing machine for parts, drill press etc.

To do a bearing change you would need a torque meter and a good selection of shims and ciclips + a good deal of nounce to do the job correctly ( bentley as a minimum reference book )

Go to www.brokevw.com you will learn loads if your serious about doing a trans.

Definately cheaper to get the parts offshore from what ive been quoted as well.

[roccodingo]

monday's effort..

Dragged all the bits over to the other workshop ( 25 min drive...) everything got a good wash in the robowash.



I could now see how mangled the 5th selector rod was, None available from VW in Oz or Singapore, quoted 4 weeks to supply from the dealer here.. looks like i may cannibalise an old 5 cogger here or try buying out of the US...price here was about $65...



Kinda pi**es me when dudes butcher stuff that would take 20 mins to make the right tool..

[roccodingo]

Monday ( cont...)

drilled out the diff rivets, fitted the bolts from the kit to the carrier...



Got back to my junk shop with a stop at the post office on the way...



Not bad considering they sent it the 23rd... maybe it was in santa's sack...

checked out to see if all was in there..



No casualties except this CV trying to pack itself with grease mid flight...



Hopefully get some of the trans back together tomorrow pending the decision to use the selector rod again. It will work, just needs tidying up first...

.

[GOLFBALLS]

HOORAY FOR FREDDO!!!

Thats some good work there Grant!

[Water Boy]

You dont muck around do you...

How are your son's Mk1's going? We're keen to see some pics!

[roccodingo]

HOORAY FOR FREDDO!!!

Thats some good work there Grant!

yeah, been getting into it, but not enough !!! needs to be running by end of Jan...

[roccodingo]

You dont muck around do you...

How are your son's Mk1's going? We're keen to see some pics!

Eldest has been driving his red banger into the ground, remarkably its only needed a trans swap when the clutch locked up...

Second son and the GTI rebuild has come to a stop. he worked out that removing hard enamel paint isnt his forte'.... so looks like i have recieved it back...He is due to get his license ina few weeks, so that will reduce the chances of him doing anything by another 1000%..

[roccodingo]

And so far....

K Just been chewing away at this project....

Have the dash out to fix the glove box hinges and sort some wiring shennanigans out... cant believe how rough these immobiliser fitting guy's are...thats what you get when its done to a price...

Stripped out the heater box and made new seals for all the flaps,places where the box seals against other section ( body etc) did the vents in the dash as well..


With the heater core out i found a localised bit of rot...



So new core on order from UK, should be here hopefully by Monday...

[roccodingo]

Well the box is all done bar the CV flanges, got a few things happening there...



Dont have time to send the mounts over to my electroplating guy to get the original finish re done



Although the bolts etc came out of the stockpile of stuff done previously..
So i just used gold paint to tidy it all up...



Doing the last of the sanding back and prepping for paint, plan on getting the primer down at least if not all the painting done by Monday . Still have the engine to give the once over, finish the glove box mods, complete a few wiring tasks, then start slammin it back together...

[roccodingo]

weekend madness

Got the car to the painting shed Sat morning, lost as few hours with all the trailering and moving stuff...

Primered the panel closures..



inside the engine bay and the closure on the tops of the guards.. did inside the hood also.



Then on with a few coats of colour and clear..



.