Still Going...

[Bluerex]

After seeing Big D's efforts, I am kinda embarrassed that the rally-Golf is taking sooooo long.
Anyhoo some pics of the latest progress.

When I stripped the original engine/gearbox out (in May 2005!) I failed to notice the non-standard (read broken) rear engine mount. So it was only when I tried to re-assemble that I realised the the original mount would need some major work. A quick trip to CVW to examine a non-modified mount confirmed my suspicions - some extra metal was going to be needed, and fast. As luck would have it I found myself at the Transborder workshops with Max and Bruce who insisted that fabricating a new mount was a fair trade for installing in-car video system into Max's Evo9 tarmac rally car (see it really is a case of who you know).
So a new mount emerged


Another new toy (sorry not road legal)
Brother Keith introduced me to this little gem, a beautifully engineered quick-release hub. Finally I can get my fat arse into the high-sided velo seats without pain.


(Also note the sexy black dashboard - no more scruffy silver for me)

[Bluerex]

continued...

With the gearbox solid, I finally installed the briliant Missing-Link shortshift kit. WOW what a difference. 50% reduction in forward/back movement and everything is so tight now. This is what I bought,

Roger also makes teflon transfer shaft bearings to replace those melted cr@ppy old ones.

Installed

[Bluerex]

continued...(some more)

And while I was down there; driveshafts and brakes went in today.





The T4 outer CVs are a tight fit, but luckily I didn't have to break out the die grinder.

[Bluerex]

continued...(some more II)

A little work on the interior - co-driver side.



The panel will hold the trip-meter and a bunch of switches



And did I mention the re-painted instrument panel?


And finally (for now) the electrics have started to happen..

[Bluerex]

One last Pic

Could not resist fitting the re-painted grill and headlights. The hover-car effect thanks to being up on stands while the driveshaft work was in progress.

[GoLfMan]

superb work as always Charles

[alex g]

[QUOTE=Bluerex;81283]After seeing Big D's efforts, I am kinda embarrassed that the rally-Golf is taking sooooo long.
QUOTE]

i know exactly how you feel

the car is looking excellent charles, really great work

can we talk a little about the cv's and shafts combination??

and what size tube did you say you used for the brake lines(next on my list)

[Bluerex]

can we talk a little about the cv's and shafts combination??

The inners are (I think) std 100mm (to suit the 020 five speed), shafts are my original ones BUT have had an additional circlip groove cut into them to suit the massive T4 outer CVs. Really Peter is better placed to describe the process, he has been successfully trialling a set in his caddy for the past year.

and what size tube did you say you used for the brake lines(next on my list)

The hard (steel) line is the regular 3/16 bundy tube from your local brake place. I took samples of all the bits I needed to attach (MC, hand-brake etc) and got all the nuts too. Flaring was a pain until I borrowed an industrial strength tool from Total Traction Services - then it was easy.
The stainless lines came from Bildon, 6 lines cost $US130.
**** Post Rego update****
I always meant to find this post and update it incase someone else followed my suggestion regarding the Bildon stainless lines - in short DON"T DO IT!! These lines are great quality BUT not ADR approved for street use. I had to replace them with locally made ones that had the requisite ADR approvals before the inspectors would pass me. There might be zero difference between them but if there was ever an accident and the US lines were discovered.... let's just say that any insurance you may have thought you had just evaporated.
c

[Jarred]

looking good mate, can't wait to see this thing running

[HillFlog]

Bluerex, its looking fantastic! Dont worry about being slow, you are actually going way faster than me ha ha. How close are you to getting a pop of noise out of her?

[golfnutracing]

Love the black dash!! car is looking great! That engine mount should work well till you get some more torque, looks like the culmination of a lot of good ideas!

[Bluerex]

Some years later I have added a note to the stainless brake-line post on page 1.

c