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Mars red Series 1 Mk1 golf Driver G60

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golf1980's 1980 golf driver G60

cheers mate. still got those door handle scratch plates for you.
shame your entusiasm for it has gone but your escort is so rediculously mental so i'm not suprised!
get on it over the winter. when summer comes, you will love it :)

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golf1980 said

cheers mate. still got those door handle scratch plates for you.
shame your entusiasm for it has gone but your escort is so rediculously mental so i'm not suprised!
get on it over the winter. when summer comes, you will love it :)

yeah still want em

used the escort for summer and its a blast :mrgreen:  

Golf will be done, but its a good 5 or 6 miles from where i live and the guy has not strengthened my floors up yet :roll:

so might just go up there one weekend and get on it if i get some time :lol:

everytime i see pics of yours it reminds me of mine,just mine has the steels, and yours is more flashy :D

not been on here for a while so is good to catch up 8)

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edit. thanks liz (girlfriend). very funny

mine is on steels too now. those bbs' are away for the winter. may put them on my other car in the summer and stick with steels on the golf.
make it look less 'flashy'! lol :)

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progress has slowed due to the garrage getting robbed of all its tools and diagnostic equipment.

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Oh that sucks, gutted for you

Andy

LINCOLNSHIRE REGION - https://www.facebook.com/groups/467122313360002/

1983 MK1 Golf GTI Campaign Model - Under (looooong) resto!
1962 Rover P4 80
2002 BMW 745i
2008 BMW Z4 2.5Si

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ok. i decided to make a little photo story board thing to show you what went into and how we made the cam cover.

i started with the cam cover that came with the engine i bought off of mk1jim;


i vapour blasted it clean and took measurements;



then Chris was let loose on it to do his computer magic;
 



once we agreed on the design, we needed to make the patern;








patern for the mould pressure plate and oil filler cap;


once they were ready, i rubbed them smooth and we treated them for the next stage;



the next stage is to laminate the mould off of the patern. we use carbon that has the perfect amount of resin already applied. it is known as pre-preg carbon;
 

every few plys, the mould gets de-bulked under pressure to make sure the carbon is even and in every corner;


when it has finished being layed up, it goes in an autoclave to cure under huge pressure and heat for ages. we left this one over night just to be sure;


once cured, it gets cracked out and i prep the mould for the next stage;










once the moulds were ready, we made a templete for the carbon plys that we need to make the component;


we then plot them on to a computer which works out how many of each ply we need, weave direction and how best to fit it on the carbon as not to waste any;


then a machine cuts out the carbon. we used a material that we use for Red bull F1.


once all the plys were cut out, adam laminated the cam cover into the mould;



more pressure de-bulking;

and more plys! i made 2 aluminium cubes as inserts for tapping later as carbon threads are not very good;


then it was bagged up and ready to be cured over night again;



once cured, the component gets cracked out for the final time. It is then my job to trim, tap, bond and buff till i think it is ready to go on the car;







a good sanding is essential for a good finish. we use no laquer. all components are buffed by hand unless requested otherwize.





oil filler cap finished. i had to grind so much carbon off of the back as adam got carried away and made it over twice as thick as it needed to be.
i countersank the outside face for the live lock stud and hand trimmed a circle on the inside face for the rubber 'O' ring seal;


i then gave it a jolly good buff!

as for the cam cover, i drilled and tapped the ali inserts and bonded in some ali top hats to stop the carbon getting chewed up when the bolts get done up;
i sealed the inserts and live lock recepticle with a high temp glue;


then i gave it the best buff i could. i even bought some fine compound to give it an ultimate shine!



on the car;


better pics to come once the bay is finished.

not long now. wiring is complete. needs some welding still and then the new interior can go in.

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:notworthy:  Amazing!! Cracking work, didn't realise quite how much would be involved!

Andy

LINCOLNSHIRE REGION - https://www.facebook.com/groups/467122313360002/

1983 MK1 Golf GTI Campaign Model - Under (looooong) resto!
1962 Rover P4 80
2002 BMW 745i
2008 BMW Z4 2.5Si

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attention to detail is awesome, wish i could make some carbon

serious work put into it all, your gunna be well pleased when you have it on road!

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cheers guys, i cant wait till it is finished!
next year is going to be so good going to all the shows. it has been ages since i went to any. i only go to look at mk1s really. but i do like all the old watercooled stuff.
no more updates today on the golf but it isn't far off being finished!

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Without being rude, how much would something like that cost to have commisioned?  I know F1 parts like wings etc are £20k plus! The amount of work gone into that must have taken an age. It looks really good and as a one off will certainly be unique.  I know other people have carbon covered stuff, but this is the real deal, F1 grade cam cover!

Awesome.

Mk1GTi
Rallye Golf
Mk5 GTi
Mk7 GTD

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That cam cover is EPIC!

My hat is well and truley off to you sir!

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in all fairness this is superb

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thanks guys. it means alot to get feed back. especially good feedback!

as for price. i'm not sure. there are roumors going around the company of a price but i dont know if i should say on here. putting things like that may get my car nicked or something! it is stupid money though.
the first one is always the most expensive because you have to make the mould and all that. after that, it is easy to make another.
they may go into production if there is enough interest at shows. still a hefty price tag for one though.

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waiting on silicone hoses then it is mot time!

i'll post up some pics soon too

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well many things have happened. the garage is messing me around big time. don't want to go into it just yet but here are a few pics to keep the thread interesting;




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Excellent thread.  Really enjoy the progression and love that has gone on over the years.  Carbon cam cover is beyond awesome!    :notworthy:

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i'd go back to 8v just for that cam cover!

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very nice work  8)

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thanks for the nice comments guys


i did some more to my cam cover

i thought i should put a cam wheel cover on so i needed to make an attachment plate and bond it on so here are some pics to do the talking;






full size templete;













i bonded it on using some of redbulls high temp glue that we had left over
this is what it looks like now;









the cam cover needed a breather hole. annoyingly i had no choice of where to put it because there was a blemish in the carbon.
i trimmed 2 carbon squares and shaped them to fit both the inside and outside curved profile. this is so the breather pipe has a flat face to seal against.
i skin pinned them in place whilst they were bonding. i will trim a hole to fit the pipe fixing once i have decided excactlty what i'm going to do.





as for the breather. i thought about making an oil catch tank using a red bull can which would then have an air filter comming off of it.
not sure about this anymore though.






i popped in to earls performance at silverstone race circuit and they gave me a bit of pipe and a fixing which was nice of them.
so here is where i am with it at the moment. not sure on what to do.






let me know what you think
please erase all memory of top secret drawing partially in view in some of these pics.

Thanks!


Rich
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