No Time Toulouse Golf Mk1 Build Thread

That's cool. What was that photo on? Looks a bit big for a beer mat?!

Whilst obtaining various parts off ebay, forums and anywhere else I could, I got to play 'guess the parcel' a lot. This one had me stumped:


Turned out to be a VERY well packed parcel…



Back to the engine, it was pretty uneventful. Routine cleaning, painting and reassembly. There are a hundred photos but i'll keep it brief!

Starting with it head back on:


Inlet manifold came up pretty well



then skip the boring bits to fully reassembled:



Here it is being lowered in:



Now you have to imagine around 5 hours of pain and struggle getting the gearbox to marry up. I nearly put  my back out getting the f*&^ing B£"$%^d back in. On and off, on and off, no way was it ever going to go on. I checked I had the clutch centered; the right way round; nothing in the way, everything. Then on the 51st attempt, it slipped in like a knife through butter, like it was a dovetail made by the finest craftsman, hand in glove, made to measure, easy as anything. daffodil knows what was different, but at least it went on.



And yes, before anyone mentions it, I was using nylon rope to lift the engine. I know its not the right thing to do but, each length has a 1600kg breaking strain, I doubled it up, and had two lines. That makes nearly 6.5 It worked.

At home I had been working on the wheels. A CHEAP set of knackered P slots won off ebay. Painted more times than the Severn bridge. Cue the Nitromors:







Cleaned up with the flap disc



First coat of white goes on, now for the sanding, spraying, polishing, lacquer and polish… At this point i'm regretting saving money by not getting them refurbished!




 

Rebuilt engine looks good    and at least it's finally back in  

Love p-slots  

Matt

Progress looks good.
PM me if you are really stuck for parts and I can drop them to you if you donate fuel money to charity  

Haha that package is amazing! Also that engine does look good, you've turned it around so quickly!

Next up, refitting ancillaries and connections.

New exhaust manifold and cleaned up anti roll bar. Yes, half the old manifold is there. Still trying to get it off the mid section!



Driveshafts with new boots back on.



New lower ball joints:


And tarted up brake back plates:


Next up came the suspension. It was sitting stupidly low and it was impractical so it was one of the few places I actually spent money on new parts. I wanted it slightly lowered eventually, but standard height would be needed for the road trip, so adjustable was the way forward. I didn't buy the cheapest, but it was still a long way off expensive. And this is what I got for my money:



First time of fitting and the bolt came away from the mounting… It only happened on one and it was easily fixed, but it doesn't inspire confidence!

Once fitted it looks pretty good. No idea of how far to wind each spring up at the moment, so starting with a middle distance and will work from there.





Discs on and calipers, but it turns out the new retaining screws are twice the length they should be!



The next problem I had was a big one. When I went to fit the hub nut to the off side, it wouldn't go on. It took me a while to work it out, but basically, when I had trouble fitting the CV's I was using a 3lb hammer to get them on. And that meant that I had managed to compress the thread on the outer CV shaft… No amount of filing or cutting was going to put it right, so a new outer CV was needed… To say the air was blue would be an understatement. I HATE changing CV's!

Ah mate, nightmare that! You got it all sorted now? I did read this Sunday and forgot to reply - what do you reckon the chances of you having it done by the weekend of the 10th are then, we'd love to have it at the AGM!

36thCrazyFist said

Ah mate, nightmare that! You got it all sorted now? I did read this Sunday and forgot to reply - what do you reckon the chances of you having it done by the weekend of the 10th are then, we'd love to have it at the AGM!

10th July… Hmmmm…. I think this weekend will be key to everything. First fire up is planned… Subject to parts arriving and being the right ones… We'll see!

stumpymatt said

36thCrazyFist said

Ah mate, nightmare that! You got it all sorted now? I did read this Sunday and forgot to reply - what do you reckon the chances of you having it done by the weekend of the 10th are then, we'd love to have it at the AGM!

10th July… Hmmmm…. I think this weekend will be key to everything. First fire up is planned… Subject to parts arriving and being the right ones… We'll see!

Nice, that's exciting! Reckon you can post a little video? Where about's is the car based mate?

The car resides near the Sussex / Surrey border… We are nervous / excited as it's nearly ready… Just short of  few vital parts…

stumpymatt said

36thCrazyFist said

Ah mate, nightmare that! You got it all sorted now? I did read this Sunday and forgot to reply - what do you reckon the chances of you having it done by the weekend of the 10th are then, we'd love to have it at the AGM!

10th July… Hmmmm…. I think this weekend will be key to everything. First fire up is planned… Subject to parts arriving and being the right ones… We'll see!

Well as it's for charity if you can make it, there's a free ticket in it for you, and make sure you bring a bucket to collect some cash

No Time Toulouse said

The car resides near the Sussex / Surrey border… We are nervous / excited as it's nearly ready… Just short of  few vital parts…

Let's hope you get some parts!

Made some good progress on the electrical front last night. Got all the front lights working apart from the indicators as they're not attached yet. Started work on the rears. Not such an easy task as they've been butchered over the years. Not looking forward to the dash area as it's a complete birds nest!

I've moved your topic into general chat so more people can see it how's it coming along now, nearly ready??

Well its been a bit frantic over the last couple of weeks and not a long of spare time to update. In essence, it moves, some lights work, others don't. The brakes are proving to be a nightmare to bleed and we can only get fluid out of one side. Even using a pressure bleed system, it just will not come out. Thinking either airlock or more likely some crud stuck in the master cylinder. I'm afraid unless there is an act of god in the next few hours we're not going to get an MOT before the AGM. Gutted 

Well it went from bad to worse. Whilst you were all having fun at the agm, I was plugging away trying to get everything finished for an MOT yesterday. Then I started it up to move it and the annoying rattle, became more like the sound from a broken washing machine, then went bang and the engine died. Experience / intuition led me to drain the oil and yup, there were lumps of metal in it.  Dropped the sump next and out fell the remains of No.3 big end It was one of those complete silence moments, when I realised that there was no hope of getting it fixed as well as finish everything else and the trip to Europe was off. Then I got angry and threw the broken remains god knows where, kicked the sump, spilling oil everywhere making me even angrier! Covered it up and went home to sob quietly into a stiff drink. So the Monte Carlo or Bust Rally is off. We're all gutted, but agreed that it wouldn't be the same taking another car. We've re-booked for next year so I've got 12 months to find out what damage a flailing piston has done and try and fix it! 

stumpymatt said

Well it went from bad to worse. Whilst you were all having fun at the agm, I was plugging away trying to get everything finished for an MOT yesterday. Then I started it up to move it and the annoying rattle, became more like the sound from a broken washing machine, then went bang and the engine died. Experience / intuition led me to drain the oil and yup, there were lumps of metal in it.  Dropped the sump next and out fell the remains of No.3 big end It was one of those complete silence moments, when I realised that there was no hope of getting it fixed as well as finish everything else and the trip to Europe was off. Then I got angry and threw the broken remains god knows where, kicked the sump, spilling oil everywhere making me even angrier! Covered it up and went home to sob quietly into a stiff drink. So the Monte Carlo or Bust Rally is off. We're all gutted, but agreed that it wouldn't be the same taking another car. We've re-booked for next year so I've got 12 months to find out what damage a flailing piston has done and try and fix it! 

Gutted for you guys - could you not quickly put another engine in?