84 Driver resto, KR turned AEB conversion

I was aching for abit of time off over christmas to crack on.. but instead i'v been rolling around my pit dying with man flu..

But put an effort in over weekend..
So the floor was next on the list to get painted..


I noticed the masking tape was giving up on some masked areas so i re masked, and masked the floor.. After buying some static sheet stuff that made life a little easier..




Now i started to mask the engine bay off.. plugging as many holes as i could find..




I was going to paint it sunday but it was chucking it down and sure i read somewhere not to paint with moisture in the air so i left it for monday, give abit more time prepping..

So the time has come to get some color on the go
I mixed the stuff 2-1+10% and got to work..




Then today exited as a little kid at christmas i started to un wrap the thing..
I was gona leave the floor down for protection but was dying to se what it looked like..






The detaily bit's came out not so bad..




I'm so exited about what i'v done that i don't even care about these..!!! lol



I suppose i'm not too bothered because i at least i know what i did wrong… never had enough fags between coats.. lol once i noticed the runs i aired them about as much as i could so want much of a nipple to get rid of when i sand down again.. but that wont be for a while because now i can start building the thing…

Made a start this week cleaning a few bit's up.







Hit a couple of probs already building back up.. lol the main one being vagcat being boring and not letting me sign in or re sign or any thing.?? Right pain in the ass.!! Jamesa has kindly offered the help of posting me some diagrams. but it's invaluable to have easy access to a list of the part codes for ringing VW up and the real names of things. lol

I persisted and got the steering rack on easy enough maybe the wrong way round to fitting steering wheel and pedal cluster but need a boot for that.. (but don't know code.!! lol)



Then i tried building the brake bell and servo back up.. a couple of snags with that, the clevis on the servo was a squeeze to get on the hinge and i had to open it up.?? when i put the pin in, the clip didn't go on right. And i'm not happy with it at all(if that goes wrong am in for it.!!) Any clues on this prob.?? I'm sure i swapped the bigger 16v clevis for the smaller mk1 one when i chopped 10mm off the thread of the servo.

Another prob in this area is theres a spring that i guess pulls hinge back after the brakes have been pressed.?? but that don't seem to hook on anywhere.? It's hanging on th right of the clevis as you look at it. if you get all that.? lol.



One more thing here.. haha i thought the hinge looked abit set back..??



I got it all mounted anyway. Stop it from being scratched lying around.. and i wanted to see what it looked like, lol..



I carried on cleaning a few bit's steering wheel thing and pedals. Oil filter housing and oil cooler which i decided to change for tha A4 one (it looked abit easier to clean)



Run out of paint and nuts so made a start cleaning the 02A Gearbox..

That's a fair load of elbow grease! Nice one

Thanx. that's the easy part, lol

Cracking Job mate…  :mrgreen:

Thanx man

Mid week update

Got the servo thing sorted, Thanx Rubjonny.. Simple thing if you know (o.. by the way.. still know vagcat ) I'd gotten the clevis mixed uo some how.? it wasnt the 16v one nore the mk1 one.? god knows.. but when i tried to get it off it was well jammed on the bearing, so i chopped it off..


Looks a bit better now..


Found my accelerator pedal so cleaned that up and got all the steering colum and pedals mounted. Managed to get a new U/V boot as mine was split..



Some where in the middle of this i knocked my semi organised nuts and bolts over, lol. So i tried to make it a bit better..



I'd sent off a plate design for IC mounting.. came today, but needed some feteling.. the holes where a few mm off and the press had bent it out of shape abit.. So sorted that and  some local good man from WR gaskets donated me a bit of rubber to make a gasket..




but it's all prob gona have to come off again as i mainly wanted to see if i had room for an oil cooler.. Wish i never did the nut's up, haha..

looks great so far...i wish i could do this to mine...

Thanx Phatone

My oil cooler came which fits with bags of room, maybe could have sqweezed a ten row in.? I drilled a few holes and got that mounted, i din't need to take the IC of which was a bonus and din't have to drill any holes to get socket in to tighten from in the front rail..


I went to a friend's garage who had a reciprocating saw and chopped my alternator bracket in half and chopped a chunk out the bush ring to get out the mount.


I was having a clear out in the atic and found an old steering wheel off a polo i had before it passed away.. fit's like  a charm..


Had some post come.. a set of conversion mounts for the o2a gearbox, also new bush for the other side and rear from crazyquiffs. A new breather assy, reverse light switch and a shroud for the actuator clutch actuator when it comes from VW.


Also had the arrival of a New/recycled Sachs vr6 clutch kit..


I gave the gearbox a bit more of a scub then painted/lacquered it.


Gave the engine another coat of blue and painted the head. Gave it a few coats of lacquer



All the bit's i'd took off the engine and gearbox got a clean, paint, lacquer..


Built the gear box back up.


And put some bit's back on the engine..

Just spent the last god knows how long reading through this…. Should've been putting a report together on an electrical installation but was drawn to this!

Awesome build…. gonna look amazing when its done mate!

Keep the pictures coming!

Andy

Haha, Thank you for your kind words Andy but sorry to hear i distracted you from your work    
if you ever need any help with electrics i know what i'm doing there :wink:

While i'm here i thought i might aswell put a picky up of my mounts i just picked up from the powder coaters


Just to point out the one at the top is a bracket from vw to suit the mechanical actuator when it arrives..

No worries Shaun.. But a time served spark... For all my sins!!!!

Haha.. it aint soo baad, lol.

So been on a bit of a mission to suss cover plates out between engine gearbox, think i'v cracked it now.. with help obviously,

But this weekend instead of bolting i went on a little road trip to Wales..
To collect this little puppy.!


Not much of an update but i'm buzzing i'v got a cage

Great work, nothing scares you! Great attitude

Random question, what size is your garage? I'm looking at renting one that looks v similar in size but i was concerned it was a bit tight.  But looking at what you've achieved I'm thinking it might be ok!

Spiders scare me

Cheers Honky. I apreciate the compliments

It is abit tight in there, i think the garage is about 2.5mx4.5m. Not too bad in length but it's a pain with width having to have it pushed up to one side..

But at least its a roof over her head

Has been abit of a tedious month gagging to get the engine in, but alot of research been going on and sourcing part/part numbers..
Been thinking i din't want to clog this thread with my reasearch.. but should I.??

Anywho, i'll try and remember what i'v been upto..

Erm.. Rollcage, I had this out on a warm day to see what it looked like set up and get an idea where the feet are gona mount to, and some of the feet need straightening aswell.


I'm converting the gearbox to cable clutch and got the bracket from vw and still waiting for the actuator which was ment to be here on the 24th Feb.!! But got all the brackets powder coated in the mean time.


At some point i tried sourcing a starter motor but once again making things difficult i got a VR6 one fist which had different mounting holes, then got a 1.8t one which i thought was wrong till i realised the starter cog comes out to engage.

Had a little trip out to Caddy one weekend..


Nice AC there..


The clutch cable bracket i shelled out for at VW..


Got the chop.!



I thought while the engines not in the way i'd get the heater unit in and the leaf grill on.


Bought some heat wrap for my exhaust manifold..


About got all the bits together to mate engine and gearbox but i thought i may aswell change the cambelt first.. Which as usual want simple The AEB comes with to different belts I fist bought the 153 tooth but looked wrong so got the 152 tooth which looks better, the marks don't quite line up at the mo but it turns fine..

So no more hiding.. the engine's getting mated to the gearbox.! It all went fine, haha i wish..
First thing was the stud for the rear mount had half shared


I was hoping to get away with it but na not today.. drilled it out for a new bolt


I cleaned the flywheel up but it's quite badly pitted, the pins where bent too.. i got the friction disc set but as i tightened the pressure plate up the release bearing "muff" thing moved.? as if it was engaging a bit/bearing pushing/release the clutch…? if that makes sense.?
Think there was a few more pain in the asses, but there together..


Even with the flywheel/clutch doubts i'v pressed on.. set myself a new "1 year later" dead line of august(got to get to the ring )
So today i stuck the lump in the bay…



Went quite alright bit of up and downeness trying to get best position to not scratch the bay, but it did happen in places.. mainly one a think.? also the engine was on a tilt which made it a pain to get in the side mount's and the rear on but it's in
Never torqued the mounts up fully just incase it hast to come out again.? But at least i can start thinking about my next thing to tackle now.. Thinking Turbo and down pipe.?

awesome job there pal.

Yeah the engine does tilt on these, i tried modifing my gearbox bracket to make it more level, but it just wouldn't have it once everything was bolted up

If your using the AEB exhaust manifold, there is no downpipe on the market (least that i could find) that you can physically buy off the shelf :/

Where as the AGU manifold will fit the qpeng downpipe which allows for a k03/k04 turbo depending on your choice. Btw loving that bonnet catch. I might have to order one of those from ya

Cheers fella.. just hope it dont have to come out again due to the flywheel and clutch.??

Bit brave modding a mount..? mind you your not short of skills :wink: i had it lent back more on my trile fit with 020 box, but the front mount was way off..

I'v got a BAM exhaust mani on, but still.. Qpeg don't do the k04 downpipe any more.. So gona have a bash fabing one up.. i'm picking a flange up on Tuesday along with some sump baffles.

You've got enough detail in your's.. gota let me have something!

hah mate, its not a competition.  

Yeah, I wouldnt want to be the chap who says, ' I would recheck that bearing/ retaining clip'. But you might want to consider rechecking it if your not happy.

From what i can remember, the Bearing has a retaining clip in place and the clip should not move only flex ( the bearing will turn on the shaft i think). When tightening the pressure plate your clutch should be in position using an aligning tool. You will find the screws will only tighten so much before the lot starts moving.

When you fitted your gearbox to the block, did you have any problems putting them together as in alignment?

Haha.. I know mate i was only joking.. you are wining tho! or should i say won??

GaryGTi83 said

. You will find the screws will only tighten so much before the lot starts moving.

Thats what i wanted to hear!

I tried an alignment tool but it was naff then i tried loosley doing the pressure plate mating so it would find it's own home on the shaft and pulling apart again and nipping up but that never worked.. so i just give it a good fingering.. and jobs a good en..
I've had a god all mighty good tug on the clutch actuator and that seems to pull normal?  that prob don't mean anything?? but it's not coming apart now until i've broken it!