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Rallye

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Great job yomp! Your attention to detail is second to none. A mk2 rallye is definitely a car worthy of a full nut and bolt restoration, looking forward to the end product  :thumbs:

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cheers guys! feels like I'm making a bit of progress now.

Another 2 holes disappeared today!!






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Crikey, I thought Mk2s, esp later ones, were much more rot resistant?

Looks like a 70s MK1 that's lived by the sea for too long.

1983 Mars Red 1.8 Golf GTI
1987 Alpine White 1.8 Clipper Cabriolet

The trouble with doing nothing is that you never know when you are finished.

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Early-1800 said

Crikey, I thought Mk2s, esp later ones, were much more rot resistant?

This car certainly doesn't have the wax coating that our series 2 MK1's have.
Rallye sills are prone to rotting.
This particular one lived on a farm all its life before being laid up in a barn for 7 years The rear chassis legs were full of mud.

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Got the back panel cut and tacked today.



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Excellent work mate, looking good. :cool:

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Finished the welding and leaded the joint.





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like the wooly hat mate

problem is with the welding masks they never fit over your wooly hat so it's either arch eye or cold head

Last edit: by jellybelly


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I went to take some pics of my rear panel for you this morning Yomp  as promised, (better late than never!!) However, got under the car and realised with the big bumper attached you can't really see anything.

I can tell you that the lower edge is the same as yours, if that's any help?! lol

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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No worries Andy. Its only to satisfy my "why?" question.

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What is "leading a joint"?

Matt

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pazwaa said

What is "leading a joint"?

Matt

Lead as in the metal.
Its an old method of building up a body panel similar to modern day fillers.
The beauty of it is it seals the joint and is more flexible than the steel its on so it doesn't crack.

Loads on youtube……..

Lead Loading
 

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Cheers, good to learn something new  :thumbs:

Do you sand/grind it smooth or do you put a skim of filler over it?

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File it with body files which have course teeth. The swarf that comes off the file is large and heavy so drops to the ground. Sanding it makes it air born - not so healthy!

It'll get a light skim of stopper to sort any slight imperfections.

Its much more reliable than just filling but does come with the obvious hazzards.

It doesn't suit large flat panels so well due to the heat you have to put into the panel to get it to flow.

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Turned my attention to the transfer box today as I should have the new gear set arriving soon.

I've managed to find the technical information for setting all the bearing  pre loads and back lashes but there's an awful lot of VW special tools used in rebuilding it.



Some home made improvisations are going to be required…..

puller..




Now the roller bearing is out the damage to the needle rollers is more visible..


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That is a big list of tools!!  :o

You should stick this up on MK2 forum too - they'd love it over there.  :cool:

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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Nice work Yomp

I found this site a while ago that list a lot of vw tools buy there number, most are expensive but the images may help you figure out what they look like  http://www.dieselkontor.de

:)

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:o Thought I had my work cut out lol O_o

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The new bevel gears turned up yesterday but I have a dilema.

On the bevel gear a number is etched by the manufacturers during testing. This number relates to the location of one gear against the centre line of the other gear to give optimum running quietness.

These are the numbers etched on the original gears…….





The "25" is to identify the paired gears.
The "33" is to identify the measurement that one gear runs in relation to the other gear 33 meaning 0.33mm

On the new gears I have this:



Now is this "119" or "611"? If its 119 then its written upside down compared to the old gear. this number is however only to match the paired gears.

The important number is this:



Which to me reads "50" (0.5mm). The etch after the 50 is just an initial I think.

Now if I read it as a 50 then its etched up the other way to the original gear.
However it could also be read a "09" meaning 0.09mm which is a completely different setting.

What do you think?!

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I would agree 50 and initials, can you check with supplier or are they not the ones that marked it?

Or can you make the measurement or is that a daft question??

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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