The Mk1 ABF Project

[Peter Jones]

I've got one.

I've had to weld these up in the past. Makes 'em stronger.

[cartertronic]

Great tip!

PM Sent..

[roccodingo]

Yeah, seen a few cracked versions mate..

[cartertronic]

Had a bucks night over the weekend, but managed to make a bit of progress...

Stripped down the front and rear calipers & gave them a good clean


Rub a dub-dub, big brakes in the tub


Sprayed red and hit with the heat gun, before baking in the oven for an hour.


Lunch of champions (cooked prior to brakes)


Fronts came out a treat. The clear coat gives them a great shine


Rears being fitted


Fitted poly bushes for rear beam mounts (with plenty of lithium grease to hopefully stop the squeaks)



+Mk1 braided lines .. will have to track down some Mk3 braided lines for the other piece of flexi-hose


Disconnected the old handbrake cables & brake lines, then dropped the old beam with sway bar and Cordoba drums.


A few things to be done while the back is in the air, watch this space

[cartertronic]

Bit more progress today..

Fitted new rear engine mount bracket (thanks Pete!)


Replaced the rear suspension. Out with the old, in with the new (+poly bushes)






Simple job, but stoked to fit these!

I know the world doesn't need another meme, but couldn't resist


---------- Post added 11-04-2012 at 01:53 PM ---------- Previous post was 10-04-2012 at 11:15 PM ----------

Rang a few places about getting braided lines made (via www.braidedhoses.com.au - Thanks Pete), seems to be approx. $70-80 per line. Seeing as Mk3 Goodridge kits go for about $100 on ebay, might give custom lines a miss.

One bloke I spoke to reckons buying pre-made brake lines from OS is a bad idea as they don't meet our safety standards!? Find this a bit hard to believe. Maybe no-name lines have suspect quality .. or maybe he's just trying to drum up some business

Interested in making them myself, but could be asking for trouble:
Making Braided Lines - Old Britts
How to make braided brake lines - Custom Fighters
How to make braided stainless steel brake lines - DoTheTon
Teflon hose assembly - Earls Speed

[mikinoz]

I use Goodridge lines and if they are good enough for Europe on European cars then they will meet my requirements. I have heard every reason for buying them in Australia. Most insulted when a bloke sold me some custom ones here that had GOODRIDGE on the side of the hose. Same thing just more expensive.



Looks like you and I are on about the same path based on this, when are you planning on getting it all finished?

[Peter Jones]

The issue is to do with ADR compliance. The lines need to have part numbers and the part numbers must be ADR approved.

Market here is too small for any manufacturer to bother with going through the process for every item in their inventory.

Realistically you'd think anything DOT or TUV approved would be OK but it's technically illegal.

Somehow the retailers represented by braided hoses.com.au have figured out a way to create paperwork that makes their lines legal.

[gldgti]

GAP sell a braided kit for mk1....they have a good rep so I dont see how they could be a problem. GAP's ones are DOT approved.

Thanks Pete), seems to be approx. $70-80 per line. Seeing as Mk3 Goodridge kits go for about $100 on ebay, might give custom lines a miss.

One bloke I spoke to reckons buying pre-made brake lines from OS is a bad idea as they don't meet our safety standards!? Find this a bit hard to believe. Maybe no-name lines have suspect quality .. or maybe he's just trying to drum up some business

Interested in making them myself, but could be asking for trouble:

[cartertronic]

Cheers, for the brake line info all. Well persist with Goodridge lines and swap them over if I hit any legal trouble (car is already rego'd, but will be getting engineers cert. at some stage).

Looks like you and I are on about the same path based on this, when are you planning on getting it all finished?

Seeing as I started this thread in 2009, if I set a deadline I'll probably be laughed off the forum

Seriously though, I'm deliberately not setting deadlines and actively taking my time. The more pressure I put on myself, the less I enjoy it and the more mistakes I make!

Looks like I do have similar plans to yourself:
Wheels - Ronal R10s (but not NOS, respect!)
Lower - Half way there!
16V - Keeps giving me the stink eye every time I walk in the garage
Exhaust - Pending
Black interior - Got some nice seats tucked away myself


BTW - Just read through you're thread, inspiring stuff! Your Mk1 is clean as a whistle! Love the Imp too Genius politicking with the Type 3, the ladies do love 'em!

A couple of personal highlights haha:
-I see it more like a slightly more mature lady who likes to take their time and show you their skills and give you the mindblowing experience.
-Mrs will get over it. Just use my line: "Well at least I don't spend the money on crack, booze and other minge."

Hahah! Been too long since I heard the word 'minge'

---------- Post added 12-04-2012 at 11:10 PM ---------- Previous post was 11-04-2012 at 11:19 PM ----------

While the back is up and brake lines disconnected, I'm going to fit a proper fuel pump bracket I picked up ages ago.



Had to remember how this fitted up, luckily I remembered I had some photos from back in 2010 when I was at the VW AutoStadt in Germany.. when the tour guide wasn't looking I shimmied under their Mk1 GTI and took some photos of the fuel pump setup

I fitted it up just now, then got some inspiration from Mike's thread and thought I'd clean them up, as some parts were a bit rusty.

Hit them with the drill/wire-brush and coated with rust killer/primer.. will spray them black and fit them up.

[mikinoz]

That is the way. If there is one thing that I am unwilling to do after seeing some proper builds is put **** on a car that is not rusty. Even if it is functional it deserves the time to wire brush and hit them with something. My current favourite coating is aluminium calliper paint - it looks great on everything (that you want to be silver) as it has the proper metallic finish and sprays really well.

You have now jumped ahead of me as I am replacing my whole front brake set up.

These brackets look a bit familiar, thought about using the ones I have but will probably go custom on mine I think. Keep motivated son!!

[roccodingo]

76 shell doesnt have the tabs for the fuel pump and accumalator brackets, I will dig out the measurements tomorrow if your wanting them Simon,
( tab position and size, also what size bolts to weld to the body )

I had to weld the tab's on Anton's car, the PO had the fuel pump cable tied up....

[cartertronic]

That is the way. If there is one thing that I am unwilling to do after seeing some proper builds is put **** on a car that is not rusty. Even if it is functional it deserves the time to wire brush and hit them with something. My current favourite coating is aluminium calliper paint - it looks great on everything (that you want to be silver) as it has the proper metallic finish and sprays really well.

You have now jumped ahead of me as I am replacing my whole front brake set up.

These brackets look a bit familiar, thought about using the ones I have but will probably go custom on mine I think. Keep motivated son!!

They're just Mk1 Kjet brackets, should be available off any Mk1 running a electric fuel pump and accumulator. The big rectangular part has soft foam to reduce pump noise, the pump does buzz occasionally so interesting to see if this makes it quieter.

If you're interested in tracking one down, Cabby's are probably the best bet.. otherwise there should be tons of these overseas.

76 shell doesnt have the tabs for the fuel pump and accumalator brackets, I will dig out the measurements tomorrow if your wanting them Simon,
( tab position and size, also what size bolts to weld to the body )

I had to weld the tab's on Anton's car, the PO had the fuel pump cable tied up....

I did a test fit before I sprayed the brackets and all the mounting bolts were there!? The fuel tank is from a later model Diesel so could explain why it has it's tab.. not sure why the chassis would have them though.

Hopefully get enough time to refit it tonight +pics

[Peter Jones]

Older Volvos are a good source of KJet bracketry too.

[cartertronic]

Older Volvos are a good source of KJet bracketry too.

80's Saabs, Mercs, BMWs would be good bet for Kjet gear as well. I pinched an auxiliary air valve from a BMW a couple of years ago

[roccodingo]

fuel pump mount and accumalator mount to the body underside, not the fuel tank. will post you some pics when I get home.