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I have just finished two full days of working on the car, and although it may not seem like much, this is the first chance I've had to sit down and type anything, and have a bourbon...
I have to dedicate today's work to my mates Adam and Alister... But Adam stayed the longest today! His drill also came in handy!!
So, Friday, I decided to install the new pedal box...
NOTE: This job is an absolute pain and can't be done without removing the steering column. Which VW so kindly has installed and bolted to the chassis with bolts that have heads that sheer off when tightened.
So, only after Loon recommended using the angle grinder, or dremel in my case, was I able to undo them. I had to cut into it so a flat head screw driver could turn it, but, in my case i had to attack it severly, and use a screw driver and hammer to get it to "crack" and turn freely.
Otherwise, that means i was able to install my clutch master cylinder, which is now complete and hooked up to the brake fluid reservoir by a bit of fuel hose, the piping to the slave has also been installed, but yet to be hooked up to the slave.
If you were to use an O2A gearbox, just use a cable clutch operation. They are sometimes hard to find. The only reason I never went that route is because I could never find a kit, most places wouldn't seperate the kit with a gearbox. But after I ordered stuff, a kit popped up for around $299US.
I also removed the exhaust down pipes and catalytic convertor so I could remove the coins and rubbish that fell down there.
I took off my rear wheels, and installed my spacers, but only before beating my rear guards to fit the 15mm spacers without sever rubbing. My wheels are obviously skewed, because it doesn't rub on the drivers side, but does on the the passenger side. I got two mates to jump up and down while standing in the back doors...Any sugestions? Bushings?
And Today:
I was able to make it to the local VW dealer today and pick up a steering linkage boot that comes from the firewall and goes to the steering rack. My orginal had a hole burnt into it by the exhaust manifold. Thought i may as well do it when the engine is out. It also keeps outside stuff out from around my pedals inside the car.
It was time to prep and paint things like the gearbox and the alternator and brackets, and a general clean up. I did a small part of the engine bay, but got bored of that. So we began stripping bits off and using the wire disc to prep it, and the painted it silver with high temp enamel.
Everything looks great!
Except for the alternator... HOW IN GODS NAME DO YOU UNDO THE CASING??
I need to break it apart and just spray the casing, thats it, but it won't budge. Is there a special trick. DO i have to undo the bolt on the pulley thing, if so, how? It stands out like a sore thumb on all this new looking stuff. ARGH!
I also pulled out all the pistons to clean them in preparation for the new rings and bearings.
Gearbox before:
After attacking it with the wire discs and taped up:
The final result, with all ancilleries done:
The aux gear with a dirty alternator, and me in the background:
I have to dedicate today's work to my mates Adam and Alister... But Adam stayed the longest today! His drill also came in handy!!
So, Friday, I decided to install the new pedal box...
NOTE: This job is an absolute pain and can't be done without removing the steering column. Which VW so kindly has installed and bolted to the chassis with bolts that have heads that sheer off when tightened.
So, only after Loon recommended using the angle grinder, or dremel in my case, was I able to undo them. I had to cut into it so a flat head screw driver could turn it, but, in my case i had to attack it severly, and use a screw driver and hammer to get it to "crack" and turn freely.
Otherwise, that means i was able to install my clutch master cylinder, which is now complete and hooked up to the brake fluid reservoir by a bit of fuel hose, the piping to the slave has also been installed, but yet to be hooked up to the slave.
If you were to use an O2A gearbox, just use a cable clutch operation. They are sometimes hard to find. The only reason I never went that route is because I could never find a kit, most places wouldn't seperate the kit with a gearbox. But after I ordered stuff, a kit popped up for around $299US.
I also removed the exhaust down pipes and catalytic convertor so I could remove the coins and rubbish that fell down there.
I took off my rear wheels, and installed my spacers, but only before beating my rear guards to fit the 15mm spacers without sever rubbing. My wheels are obviously skewed, because it doesn't rub on the drivers side, but does on the the passenger side. I got two mates to jump up and down while standing in the back doors...Any sugestions? Bushings?
And Today:
I was able to make it to the local VW dealer today and pick up a steering linkage boot that comes from the firewall and goes to the steering rack. My orginal had a hole burnt into it by the exhaust manifold. Thought i may as well do it when the engine is out. It also keeps outside stuff out from around my pedals inside the car.
It was time to prep and paint things like the gearbox and the alternator and brackets, and a general clean up. I did a small part of the engine bay, but got bored of that. So we began stripping bits off and using the wire disc to prep it, and the painted it silver with high temp enamel.
Everything looks great!
Except for the alternator... HOW IN GODS NAME DO YOU UNDO THE CASING??
I need to break it apart and just spray the casing, thats it, but it won't budge. Is there a special trick. DO i have to undo the bolt on the pulley thing, if so, how? It stands out like a sore thumb on all this new looking stuff. ARGH!
I also pulled out all the pistons to clean them in preparation for the new rings and bearings.
Gearbox before:
After attacking it with the wire discs and taped up:
The final result, with all ancilleries done:
The aux gear with a dirty alternator, and me in the background:
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