My sort-of restoration

[Jarred]

My only concern is that if you have a polished gearbox and nothing else in the engine bay is polish. it'll look out of place.

[GeorgeMK1]

Yeah dude thats what i was worried about as well. I think i might just paint it. Other things are going to be painted the same colour so atleast it will mix and match.

What exactly do i have to do to get the box prepared for a paint? just a light sand and make sure there is no rust dirt or dust?

[Jarred]

key the surface (ie sand), wax and grease remover! (very important to make sure the box is extrememly clean and has no dirt/grime/grease on it!)and then I'd hit it with some etch primer, to make sure the top coat sticks to the gearbox!

[16v_kid]

key the surface (ie sand), wax and grease remover! (very important to make sure the box is extrememly clean and has no dirt/grime/grease on it!)and then I'd hit it with some etch primer, to make sure the top coat sticks to the gearbox!

yeah, if you don't clean it really good, your going to end up with render. The paint will react to the grease and it will look like render.

use some thinners or something to clean it too.

[Preen59]

What exactly do i have to do to get the box prepared for a paint? just a light sand and make sure there is no rust dirt or dust?

Sand blast it.

[GeorgeMK1]

I was originally worried that the paint wont stick on coz it wasnt heat proof, guess it doesnt matter. Ill have to look for a quote on sandblasting it as i dont have the paitence anymore to sand the tricky bits.

I made the mistake of painting it already (only a light coat) and thanks to the paint colour it came out extremely good. Although im a bit worried now as i dont think i cleaned it THAT well and if its gonna be painted might as well do it properly so it doesnt stuff up in the long run.

[Jarred]

... if its gonna be painted might as well do it properly so it doesnt stuff up in the long run.

exactly. Alot of this stuff is teedious. but I try and work by the motto "do it right, do it once!"

obviously you'll make mistakes with various things along the way, but by doing research and stuff (like you're doing) maximises your chances of doing it right!

[GeorgeMK1]

Hi everyone, looking for some help.

Everytime i looked at the brake booster n that, i kept thinking to myself something isnt right. Today it finally hit me that the brake booster on my orange mk1 is bigger than the swallow tail one. Could this one be from a mk3 as it is quite larger. I dont know if pics will help, but the only thing i can say is it is bigger than the normal one.






Done know if this helps but hey, what the hell.



And here is the origianl swallowtail one. see the diffeerence in size and shape.


any help would be appreciated.

[Preen59]

Looks like it's off a Mk2..

[GeorgeMK1]

Well these past few days have been putting things back together. What had to be done was, take off the pressure plate off my 1.6 and put in on the 1.8 as i cant afford a new clutch flywheel etc for the 1800, so i thought i'd stick with the one i have.

As removing the pressure plate from the 1.6 i just couldnt unlock the bolts at all. In the end they just snapped off. Its a shame as that engine could have been used somehow i guess, but anyway. pressure plate is now on the 1.8 Manifolds are also on and hopefully when my dad comes hoem from work the engine will be going, in and perhaps the gearbox as well.

Blocked off the hole to the water gally as well and im hoping it will stay. Also sprayed the manifold and it looks quite nice haha. (im going paint crazy!)
Trying to get it done for the vw jamboree but i dont have high hopes.



The water galley blockage

[GeorgeMK1]

AS well as the broken/snapped bolts. im not too worried as i doubt ill need this engine for anything else.

[Jarred]

Keep it up George! Sunday is ages away in mk 1 time. I'm sure by then something else would have broken. lol!

[GeorgeMK1]

Well, looks i need help again,

Firstly, things have been going quite good. Engine is in as well as gearbox and most of the mounts are on. Was looking like it was going to have no problems at all, but then it was time for the CV joints. Now one of the CV joints seems to be too long and it cant fit into the gear box properly. I thought perhaps the engine is too much to one side, but even if the engine was too much to one side, it would only be buy 10mm max as it is restricted by the mounts. and the CV is a bit more than that to fit. Can anyone please give me soem advice as im in the final stages and trying to get it done for this sunday!!

Heres a pic to try and explain the story, sorry for the sideways photo. dont know what happened there. (by the way one side is just about in, so its only the passenger side with the problem.)


Here is my new shiny fuel pump
Im just a bit confused which is the inlet and which is the outlet, as i think i lost the manual.??



Last but not least the engine. Went around all day today looking for a new Flange gasket and finally found one! I have ONE more question haha regarding the speed adjustment. I had a 4 speed, and now with the 5 speed how do i adjust the settings to allow the extra 5th gear? is it something that i have to do, or do i have to purchase it?
IF anyone can help me with these two questions i have, it would be VERY much appreciated.

(once again, sorry for the sideways pic)

[Golf Loon]

Looks like you need to undoo something to give that driveshaft enough clearance to fit in there.

Either drop the engine down a bit, or undoo the strut on that side.

5 speed you will need to grind a bit off the shifter box under the car to allow enough room for the 5th gear. THe linkage bars are different too, I`d just buy a 5 speed linkage kit from the net and slap it in.

That Booster and master are either Mk2 GTI or Mk1 GTI. But its a good thing. Bigger is better in this case.

Sounds like you are getting close.

[GeorgeMK1]

Matt i did what you told me with the letting down the engine AND take off a strut. what i did was let the engine down but it was no good. the mk3 inner cv's are 5mm bigger than the old 1600 ones meaning that is an extra 10mm and i cant fit it in properly.

i decided to undo the suspension and control arm to let it slide in, and now i cant put the control arm and suspension back together. the inner cvs are just to big, and i think the only way i can get them in properly, would be to have a negative camber to allow the extra 10mm.

if you have any ideas at all just let me know as im willing to try anything at this moment. a mechanic friend told me to perhaps shorten the cv rod thing and that will take away that extra 10mm from the new inner cv's. but i dont know, no matter what i try it just doesnt seem to work.