Rallye

Oh looking good - now the best bit, reassembling !!
And the dreaded, don't scratch it !!

Hairyarse said

ETA for completion?

It'd be nice to have it ready for the rallye meet at the beginning of April but I'm not rushing it to make it for that.
Most parts are ready to go back on but there's still a few awkward obsolete parts that we've got to source, make or repair.

I bet the owner is like a dog with two dicks at the moment! lol

shell looks fantastic  

theres a great rake of great looking shells coming out at the moment, great to see  

matt

Looming hell!! - Must be twice as many as a mk1!  





 

Definitely more wires there good progress mate

She's gonna be a beauty. Good luck putting her all back together again.

Looks great, can't wait to see updates but I really don't envy you doing all that wiring. I've enough trouble swearing at the wires round the back of the TV let alone that      

Great work going on here…..

Have you realized the steering wheel is on the wrong side of the car! 

Few more pictures of progress, although it doesn't seem much in relation to the number of hours put in but there's quite a lot of hidden detail going on!

ABS pump tidy up…


and fitted along with new brake pipes and foot pedals…


Some new roof insulation panels cut and fitted before the roof liner went in… A lot easier than a MK1!



Bulkhead and behind dash sound deadening back in. Some of the wiring loom goes behind it and the rest goes in after it. Don't ask me why!



Rear loom in and rear washer, central locking vac pipes and pump. Had to make a repair to the loom where it passes between the roof and the tailgate as the wires break up from the opening and closing of the hatch over time. Common fault on mk2's.



Filling the cavities with wax oil. Sticky horrible job! And sticking new sound deadening pads back on the rear quarters…



Rebuilt turrets with new oem springs both front and rear..





Replacement of sticky felt pads that hold some of the wiring loom down. The photo below showing the rear abs sensor wires running under the back seat..



Started to reassemble the rear axle now but got stopped in my tracks as I need an 8" piece of 2" round nylon to push against the underside of the wheel bearing to oppose the force of the bearing press otherwise it'll just push the inner inner race out and destroy the new bearing.





I must remember to take my decent camera instead of using the iphone.!  

Nice work Graham, you are definitely the man for detail!! I'd love you to put my car back together

Wow Graham, fantastic attention to detail!

Few more updates…..seems like another week of little progress but I kept getting pulled of it to do other things.

Like cut a rear quarter off a scrap MK4!……



Rear arms and arb assembled and fitted. Standard bushes are obsolete so using powerflex black series…



Rebuilt the heater box….

New LHD matrix fro ClassicVW

 

New foam on the flaps!







New Sound deadening from Newton fitted but needed to be modified to suit the 4wd tunnel before I could then fit the front carpet, fit the heater box, the fusebox dash and then steering column.

Never managed to take many pics at this stage as I seemed to get zoned into getting it all back together. Some of the loom runs up under the dash above the glovebox so you have to lift the dash so far and then fit the loom to the dash before pushing the dash fully home whilst making sure all the vents line up and not trapping any of the loom where it shouldn't be.






Waiting for a speedo cable before I can finish off the top half of the dash.

Plans for next week……

Turn my attention to the propshaft as I'm going past the balalncers on Tuesday so will drop it off for balancing.

I need to put the exhaust downpipe and the front section of prop onto the engine assembly before wheeling it under the car as its next to impossible to get at the bolts for either once the engine is in the car.

Fit the sunroof mechanism and other parts to finish off the roof.
 

Nice  

Making great progress graham  

Yes, making progress but it does take time!

Latest progress includes fitting the fuel lines which involved a day taking the originals to a hydraulic hose shop to replace the rusty fittings on the original pipes. The hose shop also supplied new vac hoses and all the eared clips required.

Also fitted the pump and the tank.

Sunroof frame is back in and have mounted up the rear axle…….









Waiting for a downpipe gasket before I fit the motor but it should be back on 4 wheels soon


 

 

and

 

oh and     

Fantastic detail as always Graham. I have to ask, are you getting at all attached to this one? Will it be hard to hand it back to the owner??  

Now we're starting to empty some of the boxes of parts that have been stored up for 18 months I'm starting to enjoy it! I have learnt you cant take too many photos.

It won't be hard to see it go - jubilated will be the word but James who owns it only lives a couple of miles down the road from me so I'm sure we'll be convoying to a few shows together, so will get to see it regularly.

Another job that's been playing on my mind has been how to sort out the heatshields on the underside of the car. Again only 2nd hand ones are available at the usual rallye prices and are probably no better than the ones we have already.

Where they are connected to the body there had been some electrolytic corrosion. The shields were also quite badly marked.

On the back side on 3 of the shields was a felt layer sandwiched by foil. The foil  had virtually disintegrated and the remains of it can be seen here in the bin along with the pink felt!……



After removing the foil and the felt, they were put in the vapour blaster to give them a keyed surface and after drying stuck some aluminium discs using polyurethane glue to the corroded mounting points………



Stuck on some new foil backed heatproof felt with high temp contact adheisive…….







Then wrapped the whole shield in self adhesive foil tape to bring back some bling to the shield and to seal in the new discs and felt…..



First one finished fitted to the car…..



Quite pleased with the result if I do say so myself , considering the state they were in!

Only another 4 to sort out!

Hang on where's the evening gone?!

Bet you're a wizz at Christmas with the turkey!!

Well done. I'm loving the updates on a different car.