Fitting SA clutch bellcrank and brake bar

Howdy,

I though it was time for some winter work on my Golf.

Previously my bulhead clutch repair plate had given way, thanks to mark watson on the forum I had the SA bellcrank on hand so I whipped up a repair plate and fitted that to keep the car going.


I just bolted the new bellcrank thru the repair plate using large washers inside.



Unfortunatly due to the condition of the bulkhead, rust, cracking and prior repairs, there was still a lot of unwanted flwexing in the bulkhead.

That was a few months back so I thought it was time to weld in the plate and do a proper job.
Also thought it was the ideal time to fit the new brake bar so started to strip out to gain access.



On closer inspection I did not feel comfortable welding the plate in as the rot had spread to the lower front edge of the scuttle panel, (now I know why the drivers side floor has been getting wet) and I'm not the best at welding overhead on light gauge material. Sorry, no pics of the naked damage.
Instead I removed most of the rust, treated the remainder and went with a repair plate bolted through the bulhead to a matching support plate at the rear, combined with a bracing plate inside the scuttle to spread the load and also double up as additional reinforcement for the new mounting point required for the SA brake bar.
The location of the new brake bar also requires the clutch bellcrank and hole for the actuation rod to be moved upwards.







All going well so far.

The next issue was that the new brake bar was pushing on the heater hoses, not good, so I made a bracket to mount to the side of the new servo mounting box to push the top hose down enough to provide clearance, it constricts the hose a little, but I'm happy with it.



So far so good, clutch and brakes all hooked up and all feels great.

Now for my next problem which I'm currently scratching my head over, the original servo mounting box is not square and thus points the servo and master cylinder towards the centre of the engine bay.

The SA one is square, this has caused the master cylinder to move to the left, so much so that I cannot refit the air box assembly with further unwanted surgery. Looks like I need another 50mm or so to refit it.





Anyone else succesfully fitted the SA brake bar? Do you have the same issues?

Any input greatfully received.

 

Very interesting, as I have one to fit sometime.

I wanted one of these for my GTi,  will keep an eye on this thread


Sent from my iPad using Tapatalk