Yellow 4 Door Project...

[Rattle]

So, I’m having problems fitting the brakes. Apparently early ‘79 and late ‘79 have different thickness rotors and from the details I found on my car I have the right rotor thickness. But the pads don’t fit.

Here are a few pictures of the old and new pads which according to size is the exact same.

Anyone with info or help on this issue, please share I really can’t figure this out. My last resort is, overhaul kits for the callipers and just pulling it apart, cleaning it and then fresh seals etc.





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[guile]

I had the same issue and had to reorder pads for ones that were thinner. they looked identical and I thought my calliper wasn't all the way input I eventually found it was pad thickness that was the problem...

[Rattle]

I had the same issue and had to reorder pads for ones that were thinner. they looked identical and I thought my calliper wasn't all the way input I eventually found it was pad thickness that was the problem...

Went and double checked with the shop I bought from and there are two pads listed with the exact same thickness.

Worst case scenario, I buy overhaul kits for the callipers and maybe do the same and search for exact pad but slightly thinner. [emoji2371]


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[Shadow_Rusty]

I just machined off the extra thickness on a set of bike pads...
The material is the same on both types, just the thickness that’s different.

[sports racer]

You should upgrade to the MK1 GTI front brakes. Ventilated disks and the pads are twice the size. Gives you much better stopping power.

[Rattle]

You should upgrade to the MK1 GTI front brakes. Ventilated disks and the pads are twice the size. Gives you much better stopping power.

That is future plans for the car. At the moment my main focus is to get the car on the road, and start driving her.


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[Shadow_Rusty]

Late model cabriolets (ie clipper kit ones) came with gti brakes.
From memory, You just need the callipers and then get new disks + pads.

[Rattle]

Been away from the car for a short period due to work and other commitments.

Brief catch up on everything:

Put the old rotors and pads back in the front so I can get her on her wheels.
I have brackets being laser cut for the LED headlights. (Should have it on monday)
I have the air guides for the radiator being cut as well.(should have it on monday)

New water pump installed, and prepping new radiator for fitment during the next week. Gotta fabricate brackets to make the old fan shroud fit as the new radiator is GTi(will look for GTi shroud and fan a bit later)

Gotta get the mock up made today for the new expansion tank I have as well, so I can get that laser cut during the week.

And I realised that the timing belt tensioner I originally bought was to narrow, but luckily Repco could help when I was able to find the genuine part number. Also fitting that today and getting all the timing stuff sorted.

Will post pictures during the week with the lights and the air guides for the radiator etc.


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[genebaby]

Looking forward to the pics.

[Rattle]

New Timing belt[emoji736]
New Timing belt tensioner[emoji736]
Timing adjusted to have near perfect TDC[emoji736]
New Water Pump[emoji736]
New water pump/alternator belt[emoji736]
New front engine mount bush[emoji736]
Fuel pump timing set[emoji736]


Still to do:

New coolant hoses
Rubber grommets/feet for new radiator
Expansion tank bracket design
New thermostat
New coolant
Install new brackets for LED lights and then work on light placement

And I had my supervisor with me at all times to make sure I do things right and not miss anything.





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[genebaby]

Cool, ETA till she's back on the road?

Would be good to see this one day.

[Rattle]

Cool, ETA till she's back on the road?

Would be good to see this one day.

I’m hoping in a couple of weeks she’ll be on the road.


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[genebaby]

Cool! That will be a great day.

[Rattle]

So, I have a thermostat on the way for the old girl, but still searching around for the coolant hoses.

I have found a mob in the UK that sells kits and they say that it fits the 1.5 but I’m not sure it’ll fit the diesel. Have sent them an email and I’m waiting to hear back from them.

These hoses I have found are silicone and they have about 6 different colours you can choose from and I was thinking of going with these:


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[Rattle]

Received my laser cut pieces today and quite happy with the design we have come up with for the new LED headlights but also how the ar guides for the radiator turned out.

The first picture is the start of the LED headlight brackets which was made from a mock up I made with a cardboard box so they can see what I want and need. There might be some small mods needed here and there to have the brackets work and fit 100% as I still need to add a mounting point for the headlights on these brackets but also add the adjusting screw holes to be able to have the lights sit perfect and where they need to shine. The main part of the bracket will be bolted down with 3mm bolts and I’ll be using nylon nuts to help with extra security.

The second picture is the air guides for the radiator. And although they aren’t completely finished yet either, there are one or two methods of finishing them up to sit properly and work the way they should. At the moment as you can see in the picture, the very top part is not bent at a 90degree angle like the originals as I have a plan for securing them down even better, rather than using the self tapping screw and the clips to hold it in place. Once again, I’m thinking about doing 3mm bolts with nylon nuts but it all depends on whether the top part bends underneath or over. Cause I can also use rivnuts which help make things so much easier to remove but also assemble.

PS: Once I have the final products of these things, and anyone is interested in changing over to LED headlights or better and far more sturdy air guides to the radiator, please let me know once you see the final product if you want any as I could make packages of the lights with the brackets and also just the air guides by themselves.



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