Campaign resto

Next on the list was the cam breather union and hose replacement. Part no's 035103247A and 049103223B for those interested. The union had perished badly and as the OE hose was reasonably priced I went ahead and ordered that too. Shout out to Mark at Classic VW who got the parts out to me in super quick time - ordered Friday afternoon and they were with me by Saturday morning!  

Campaigning for Dave said

daztheoneclaw said

Hello mate, hope you are well. Good to see that you are picking up where i left off and appear to be making a cracking job of completing the resto.

I will certainly watch this with interest and don't hesitate to contact me if you have any questions about the car.

 Thanks Daz, your work was nothing short of exceptional! So good in fact that as I mentioned earlier I was a little overly conscious of finishing the golf properly! I've done a good bit of head scratching over the past few weeks trying to iron bits out but am thoroughly enjoying it! I've a few days off now and have a long list of jobs ahead of me so should have a good few updates.

Thank you for the kind words. It certainly became a labour of love and not what i had set out to do originally. It has been apart for well over 10 years now so i guess some of the parts that were decent when they came off will have perished. You are doing a cracking job and i look forward to seeing it at the NEC some day on the club stand  

Small details today. I have a box of old wipers that I've picked up along the way and needed to refurb a set so decided to do the lot so I'll never need to do this again - also had an old rocker cover knocking about that I thought I'd do at the same time.

Tried out the new spot blasting gun for the first time and got stuck in! 







Starting to feel like Henry Ford at this point as I had a sizeable production line. Gave the bits a blow off with the compressor, quick sand by hand and then a degrease before paint.



Next repurposing an old coat hanger into hooks, hang the arms on the washing line and paint.





All done! Pleased with the results.

Be vary carful shot blasting a rocker cover as you need to make sure the hole for the breather gauze is blocked and don't blast underneath as I've heard of someone who had one shot blasted and power coated, over time it killed his engine as there was grit in the gauze which got sucked into the engine, sand in the engine cylinders is not a good mix….  

mark1gls said

Be vary carful shot blasting a rocker cover as you need to make sure the hole for the breather gauze is blocked and don't blast underneath as I've heard of someone who had one shot blasted and power coated, over time it killed his engine as there was grit in the gauze which got sucked into the engine, sand in the engine cylinders is not a good mix….  

 Yeah you're right. I was pretty particular when blasting it but as you'll be able to see from the photos it's been blasted before outside and in. On close inspection there is a very fine grit that's sitting in the gauze. Nice piece of wall art then! 

All plans to make more progress over that last week have gone to pot as I've been far busier with work commitments than expected.

Earlier last year I did some work restoring some bits I had lying around that were originally were going to be fitted to my Lhasa green DX but as I sold that there's now a new plan. 

(Apologies to those who have already seen these pics, thought they were relevant though as they're now going onto this build instead.)

I'd never swap the engine for a G60, 16V etc as that's not really my thing. What I am planning though is to have two top end setups for the car, one completely OE and the other something with a bit more pep. All of the parts removed will be carefully packed up and stored allowing me to revert back to OE when I fancy. Sounds simple right?!

Below is the rebuilt metering head, ported inlet manifold with an Audi 80 throttle body and a ported and gas flowed head with fast road cam that'll give me a bit more power. This'll be mated to the lovely stainless Powersprint system (thanks to all who supplied great advice with this) and 4-2-1 manifold I've just purchased - 140-150bhp when complete?…… if I can get it to run!





Thoroughly enjoyed rebuild the metering head, pics below. Can supply links to rebuild parts if anybody wants them.

The metering head.

Condition when I started
 

Next up, after a good bath in the sonic cleaner I then took to it with the wire brush attachments on the drill. 



A coat of high heat clear then into the house to rebuild.



Once back together this was the end result, really pleased with how it turned out!

Porting the inlet manifold to take the Audi 80 TB. Really inexpensive mod that I'm hoping will work well with the setup.

I picked this ported, gas flowed and fully rebuilt head up from a chap last January…… and eventually ended up buying his Campaign off him too but that's a story for another day. The work on it looks great so all I had to do here was add the new cam.



All new ground for me so involved a bit of head scratching but seemed to go together alright in the end.

Great job Dave, that spot blasting worked a treat. Hope you didn't get too messy. Still finding abrasive all over the garage

Coming together nicely, not sure if you know but just checking….   the cam is 180 degrees out in your picture cylinder 1 (cog end) should have the cam lobs pointing up like cylinder 4 in your picture, then you can check the timing dot on the cog is in the right place as you can put the cog on either way.

does not really matter where the
lobes are pointing at the moment
 

Rich. said

Great job Dave, that spot blasting worked a treat. Hope you didn't get too messy. Still finding abrasive all over the garage

 Thanks Rich, you're right that bloody stuff gets everywhere! Next time it'll be a balaclava, painting suit and rubber gauntlets gaffered at the forearms! 

mark1gls said

Coming together nicely, not sure if you know but just checking….   the cam is 180 degrees out in your picture cylinder 1 (cog end) should have the cam lobs pointing up like cylinder 4 in your picture, then you can check the timing dot on the cog is in the right place as you can put the cog on either way.

 Thanks Mark as always for your eagle eyes!

Should I just rotate by 180 assembled or is what you're talking about more involved?

As nicci21paul said, it's makes no difference at the minute with the head on the bench, I was just checking you have put the timing cog on the right way round, there is a small timing dot on the cog which you need in the right place when you fit the timing belt and set the timing, the cam will need to set in the right place for this.

You can just turn the cam with a spanner on the bolt either with the head on the bench or when you fit it to the car.

There's some pictures in this thread and you can just see the timing dot on my cam shaft cog.

View topic: 1800 DX idle low (Update Now Sorted) - The Mk1 Golf Owners Club

VW did move and change the timing marks for later cars  so you will need to check which marks are on your cog.

After a busy time with work and family I'm getting on with a few bits again now and couldn't ignore my rusty parts pile any longer. I've had these callipers sitting around for a while and wanted to test the cabinet out so popped them in and gave it a whirl. The paint was a bit tricky to apply but I'm happy enough for a first attempt.

Another small step towards the finish line today. After years in storage wrapped in blankets I dismantled these earlier, removed all of the old silicone, put them back together and resealed them then headed off to the tyre fitters. An easy job but so bloomin exciting to be one step closer. Will fit the these and the G60 callipers soon I hope.

Also headed off to Power Flow exhausts to get my Powersprint 4-2-1 stainless manifold cut down by 10mm at the flange. I asked the guy to take some shots when he does it so fingers crossed he remembers to. 

Finally a clear run to make some progress. Pretty major strip down for me as this was my first time taking a head off. I'd done plenty of research and watched countless videos so went into it reasonably confident.

First up getting the standard down-pipe and manifold off.

 


Next up the inlet manifold.

Once these were off it was time to get the head off and swap it out for the ported and gas flowed head with a Schrick cam fitted that I've had waiting.