Rob's Ur Quattro

[RobClubley]

You know what Rusty is missing?
Well, a few things but one big one is some doof doof noises. And of course something to make them work, as the Out of Sight Audio device is winging its way back to the US because of a loud hissing noise problem.
Anyway I happen to have a rather nice 10" sub in my garage which I want to install somewhere. Of course anything like this must be reversible, so I got the spare side trim out, from the GT donor car, to work out how it might fit.
There's a big space inside those lovely box flares which really wants to be a bass box

[matt_theforce]

Do you really need any doof doof noises with the sound of that stunning engine tone?

[RobClubley]

10 hours ago, DarkPeakCycles said:

Do you really need any doof doof noises with the sound of that stunning engine tone?

Well... no. But why not have both?

[RobClubley]

I did a bit more playing with the sub tonight. I looked into doing a fibreglass enclosure but I really don't want to get into that much mess, fumes and time! So:
Step one - make a CAD template (Cardboard Aided Design, thanks Project Binky!) 

Step 2, cut a piece of leftover MDF to shape.

Step 3, make a hole in the spare trim piece.


Step 4 - test fit the sub. It fits well, plenty of room.

I'm planning to keep it simple, bolt the MDF to the bodywork, fit the trim over the top then screw the sub in place.
See what it sounds like! If it's not right it'll be plan B
Next step after that is to get some thin ply and use it to strengthen the trim, then find some vinyl and leather to try and match the existing stuff.

[RobClubley]

Sneaky school run on the way for more rust repair.

[kentphil1]

That looks so cool, I'm not jealous at all

 

Top stuff so far Rob

[RobClubley]

7 minutes ago, kentphil1 said:

That looks so cool, I'm not jealous at all

 

Top stuff so far Rob

 

Just wait - in two weeks it goes for a full paint correction and ceramic coat. It's going to look epic. Then I'll need to clean it

[kentphil1]

What coating brand are you going for Rob?.

[RobClubley]

CQuartz Finest.

 

https://www.detaildepot.co.nz/for-the-best-protection-carpros-cquartz-finest/

 

[RobClubley]

Did a bit more tinkering with the spare side panel to work towards get the sub fitted. I bought some thin ply to strengthen the panel so I can line it - couldn't find red leather but I got some vinyl which I think will look okay. We'll see if it does!
I used contact adhesive to bond the two wood surfaces together. The scrap metal pile came in handy to  weigh it down.

[RobClubley]

Looks promising.

Got another speed sensor.

It's the same shape as the Audi one but same connector as the VW one!!

Will have a play at the weekend.

Just collected the car from Kohl after getting the last of the rust repaired, and a battery clamp made. Pics later

[RobClubley]

The battery clamp that Kohl Rod & Custom Ltd made for me. Great job, very neat.

Fitted the new speed sensor but couldn't be bothered to move the wife's car out of the way to test.
So I spent half an hour trying and failing to get the centre rubber exhaust mount on properly, eventually leaving a cable tie on there which won't last long but might hold it until I can have another go when the car's on a ramp.

I did a bit more on fitting the subwoofer today. Test fitted the panels, and spent lots of time lining it up, trimming the MDF piece, making a metal bracket, bolting it in, realising it didn't line up, adding another MDF ring as a spacer and finally covering the trim in red vinyl.

[RobClubley]

Pretty pleased with this. Just needs the grille fitting now.

Don't know how this happened, just old age I guess, and sun damage making it brittle. Ah well, time to break out the old heavyweight shift knob I had in the Skoda.

Got the water blaster out and gave Rusty a quick rinse. Only a week to go until Finer Details NZ do their stuff, can't wait!

[RobClubley]

More fiddling with the speed sensors today. The factory one works and produces a 5v pulse as expected. The two VW ones do not! Unless the pins are in a totally different order and I wired them wrong, they don't seem to produce the same outputs. I continuity tested the wiring to the dash - all good. So the fault is either the dash itself, or the connector on the factory sensor, which I have now replaced with some spade connectors 
Next step - test drive. Can't do it now as I'll wake my daughter up

This is the shape of the passenger side under-dash panel I'm missing.
Thanks Takas for bringing yours round, much appreciated.

[RobClubley]

Another sneaky school run in Rusty 
You can tell where I went by following the trail of oil drops 

No speedo on the way there. Working speedo on the way back!! As soon as the car starts to warm up, oil starts leaking, possibly from the dipstick, hard to tell. Need to sort that out though.

[RobClubley]

Amp is mostly in place. Need a fuse and a longer power cable.

Looks like the oil leak culprit. I tightened it a little bit. Not sure if that will do the trick or it needs to be replaced.

Also I can't resist taking pics of Rusty.

[KenONeill]

@RobClubley - Oil leaking from the dipstick tube suggests the sump is pressuring to me. Can you legally replace a Positive Crankcase Ventilation system with a catch can on a 1985 car in NZ?

[RobClubley]

11 hours ago, KenONeill said:

@RobClubley - Oil leaking from the dipstick tube suggests the sump is pressuring to me. Can you legally replace a Positive Crankcase Ventilation system with a catch can on a 1985 car in NZ?

 

Looks like it's the oil pressure switch actually leaking. I tightened it a bit, and have ordered a new one.

[RobClubley]

Yep that's a broken cable from inside the seat. The one that lets the seat fold forward. I wonder sometimes if this car is actively fighting me.

[KenONeill]

12 hours ago, RobClubley said:

 

Looks like it's the oil pressure switch actually leaking. I tightened it a bit, and have ordered a new one.

If the leak was from the thread you've probably got it already then. I've also fixed one of these with some PTFE tape on the threads.

[RobClubley]

Thank you so much to John Stone for sending me these. The manual was a huge unexpected bonus and I'm really grateful for it.

WoF re-test called off due to intermittent speedo.
Also I need to fix the stalling at idle. 

Edited 1 December, 2017 by RobClubley

[RobClubley]

It's time for the long awaited clean! Dropped Rusty off today at Finer Details NZ. Imagine how good it'll look after several days of attention from a pro detailer, plus a ceramic coating. So excited to see the results!

I just realised when I pick it up I can get the pinstripes on and the rear badges. And the door rings.

[mannyo]

Hey Rob,

 

I've been out of the loop for a while, last time I dropped by here rusty was still off the road.

 

It's great to see you have persevered and Rusty is roaming in the wild again.

[RobClubley]

6 hours ago, mannyo said:

Hey Rob,

 

I've been out of the loop for a while, last time I dropped by here rusty was still off the road.

 

It's great to see you have persevered and Rusty is roaming in the wild again.

Thanks  It's not quite officially on the road but I have snuck in a couple of sneaky test drive/school runs.

Need to get the oil leak fixed and speedo reliable, and it should pass the WoF (MOT)

 

 

[RobClubley]

The detailing has begun!

Test fitting the rings and pinstripes. This is after one of three stages of polishing, and the phone pic really doesn't do it justice. Finer Details NZ are doing an amazing job.

Some from my real camera.
I am so excited about how good this looks, and there's three more stages of polish and coating still to go.
Finer Details NZ are detailing wizards