What prep work did you do under the car? Or was it just a case of a quick wash?

Got underneath there with de-greaser first, then Tardis. Really scrubbed it with a solid brush to get the dirt off. Another pressure wash. Got absolutely soaked! Checked for corrosion (very clean underneath) and took off any old sealant that was loose.

 

Took a blummin' long time before I could start the new sealant!

Good effort.

You powdercoating/painting items like subframe and rear beam etc?

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You powdercoating/painting items like subframe and rear beam etc?

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That one is gonna be a job for another time unfortunately. Already struggling for money and time at the minute! Gotta be up running and new clutch bedded in for Combe in September...

Probably on the cards though!

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Ok, so bit of work done today. Things are taking a fair amount of time, having to clean every part as I go.

 

So, first thing today was to get my hubs painted up. A drill & wire attachment, lots of rusty dust, brake cleaner and some black satin Hammerite later...

 

 

 

Left them for a couple of hours whilst I got on with other things, then turned them over and gave the front a coat. Looks so much better!...

 

 

 

After the first coat I moved my attention to actually start rebuilding something for a change! So I started to put back the steering and suspension components. First off was the track rods. As it was all stripped down I put some grease onto the rack whilst I was at it to help keep it smooth...

 

 

A bit of thread lock on the new track rod...

 

 

I screwed the track rod in and immediately came across some problems. Due to the new rod only having 2 positions you can insert a spanner into it, as opposed to the traditional hex, I couldn't get the spanner on it. So I had to remove the wishbone to allow me to get an adjustable on it with the steering at full lock...

 

 

After I did the rod up tight (not possible to torque it due to the tool I was using - hence the thread lock!), I put some extra grease onto the movable part of the rod...

 

 

I popped the plastic boot back on and attempted to use cable ties on the small end. Unfortunately I couldn't close the gap with them, so I reverted to a Jubilee clip. I did it up not overly tight so that you could just about still twist the rod for when it's re-aligned...

 

 

Cable tie on the other end which was nice and secure...

 

 

I then took the opportunity to clean up my Superpro rear anti-lift and front wishbone bushes before re-greasing and re-fitting...

 

 

 

I had a similar problem with the other side. I took the wishbone off again and just nipped it a tiny bit. Then I could get the spanner on properly...

 

 

I used my old rods and ends as a guide and fitted both track rod ends...

 

 

 

Next up was to fit the Superpro inner ARB bushes that I'd bought off Ben...

 

 

Greased them up completely and fitted them. Actually surprised me that they were ok to fit...

 

 

 

As I won't be fitting my hubs until the paint has gone hard, I went to the back now.

 

First thing was to clean up the stub axel with a drill and wire attachment and then some brake cleaner...

 

 

Cleaned up the old bolts, thread locked them and torqued up...

 

 

Next I fitted my new bearing. Popped it onto the shaft and tapped it on with a socket and hammer on the inner race. Then did up the new multi-point socket to the torque and angle...

 

 

Popped the new cap on. This was an absolute pig to get on. Ended up having to use a flat headed screwdriver to slightly bend in the part that was stuck. Smashed my thumb with a rubber mallet quite hard in the process. A few choice words were uttered!

 

Next up I thought I would clean up my KW rear shock. I'd bought some new bump stops and dust covers, as my old ones were slightly buggered...

 

 

All cleaned up and back together...

 

 

With this corner back together I greased the mating face of the hub and fitted my new disc...

 

 

 

 

That's all for today! Tomorrows jobs... do exactly the same to the other rear side. Fit my front hubs (loosely fix bottom ball joints for when shafts need to go back in). Re-build the brakes with all the new seals and pistons, then fit as many as I can (can't fit Brembo's yet as the hub bracket is at the powdercoaters at the minute).

Edited 29 October, 20178 yr by alex_e3

Sorry for all the pictures! I figure it's good for people who may be tackling some of these jobs. Plus good for when and if I choose to sell the car

Looks great excellent attention to detail. I think the disc is on the wrong side though. The slots need to go in the other direction

I was going to ask about that actually!

 

I've seen people put the grooves on both sides. So was hoping for some clarification off some people on here

 

Just read something that says that if it's a straight groove then I have them the correct way???

I'd love to have a proper garage space to do this sort of work to mine, extremely jealous!

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Here's an old thread with the grooves the same way as mine...

 

http://www.briskoda.net/forums/topic/142044-grooved-and-dimpled-brake-discs-which-way-round/

 

Can anyone clarify? Or is either way fine?

I always thought it helps to expel the heat etc. what way are the vents facing through the middle of the disc?

Bit of research and it seems it doesn't really matter which way the grooves go, but it is the vanes through the middle that are important

Works coming along nicely Alex, was good having a catch up and giving you a lift over the weekend with the diff, you will love it once it's fitted.

The way the grooves run aren't that critical unless the vanes internally are angled.

Discs running with grooves in the direction of the rotating wheel work fine and are generally more suited to town driving and quieter.

Having the discs run the opposite way gives more bite and better braking, however it does make more noise.

Cheers guys. Just researched this also! Will check the vane direction tomorrow and adjust if necessary

 

 

As you know Southy, I can't bloody wait to drive her again

where are the front ARB bushes from, could do with some myself

where are the front ARB bushes from, could do with some myself

 

I bought then second hand (but new) off a forum member mate. You can get them on eBay and from Awesome etc...

 

Measure your bar first though, as there are different sizes.

Ok, today's update.

 

First off I got the other side of the rear to the same standard as the other one. I checked my vanes on the discs and they're not curved. So either way is fine. I prefer this one

 

 

Next I fancied a change, so started rebuilding my Brembo's. I took it a caliper at a time. First thing I did was remove all the old nipples and screws that were screwed in to protect the threads. I also sanded down the surface around the fluid connection so I can get a good seal for my banjo. Next I gave them a damn good clean with brake cleaner to get out any crap from the powdercoating process, including a good clean out of the seal recesses. Next I lubricated the new seals with the assembly grease provided and installed them...

 

 

Next up I cleaned all 4 pistons thoroughly, lubricated the inside of the dust seals and placed them onto the pistons ready to fit...

 

 

I then installed the pistons carefully. Most of them went in flush with a push, but I had a couple of tighter ones that I used my handy tool for...

 

 

Some of the dust seals were a bit tight, so I used the above tool with a large socket concentrated on the edge that was sticking out. All sit nice now ...

 

 

Next I fitted the new bleed nipples. These were quite tight to get in, so I took them in and out a few times and got progressively further. Nicely worn in now, complete with new covers...

 

 

I then cleaned up the pad shims. I couldn't find new ones to buy, so opted to give them a good clean up and polish. They've come up good! New vs. old...

 

 

I greased up the back of these lightly and the threads of the new bolts I had. All fitted now...

 

 

Finally I measured up and used tape to get the new 'Brembo' stickers on...

 

 

I was debating between black or white. I think black is the right choice ...

 

 

I cleaned the caliper back up and protected it with some Carbon Collective wheel sealant to help it deter brake dust. Finished product...

 

 

I found the calipers a nice job to do. It was surprisingly very time consuming though. Probably because I wanted everything mint! They were 100 times easier to do than my Yamaha monobloc motorbike calipers!! Now they were a complete nightmare - seized on and 8 seals per caliper...  :peek: 

 

 

So time was plodding on so decided to put my hubs back on. Fitted my bottom ball joint to the hub and torqued up correctly first. Then mounted the hub in position. I've just put the bolts loosely through the holes for the ball joint to wishbone for now, as I'll be refitting the driveshafts later on, so might as well take advantage of the extra movement. Track rod ends also bolted and torqued...

 

 

 

 

I then got my V1's out and took them apart ready for them to be cleaned up and re-greased tomorrow...

 

 

 

So, I'm off to TPS tomorrow morning in Shrewsbury to pick up a few parts including my gearbox oil seals. Dropping Kev's oil cooler off from the group buy, then back home to get back to work. Plan for tomorrow is to get the front suspension all clean again and bolt it back up. Then rebuild my rear calipers - should be interesting    If I've got time I have a few parts to clean up and give a coat of Hammerite. I want to have all the chassis sorted by Sunday evening so that I can spend the next week putting the engine back together. Time is ticking down for Combe!

Edited 29 October, 20178 yr by alex_e3

Mint

Black Brembo stickers look spot on

Car is looking great. Enjoying reading the daily updates

Might see you on the road tomorrow then Alex. As I'm popping to Oswestry sometime

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Loving all the updates mate

Great work Alex!

Cheers for the comments guys

 

 

 

Might see you on the road tomorrow then Alex. As I'm popping to Oswestry sometime
 

 

Doubt you'd notice me, as I'm in my sister's Corsa C! Unless you see the light reflecting off the top of my head first of course

Doubt you'd notice me, as I'm in my sister's Corsa C! Unless you see the light reflecting off the top of my head first of course

PMSL

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Not a lot gone on today, which I'm annoyed about.

 

Spent nearly all of the day running round getting parts sorted. Trip to TPS in Shrewsbury to pick up my diff bearings & side cover, new bolts for slam panel & headlights, and the plastic rear cambelt backing.

 

Also picked some more parts up off Kev that have been powdercoated   Trip to Skoda to order some little parts also.

 

Spent the remaining time trying to clean up threads that have been powdercoated over.

 

 

Tomorrow should see quite a bit more progress, as I plan to spend nearly all day there