I had the southbend clutch and 'silent' flywheel kit. It was the quietest single mass I've come across, but weighed 14kg! In comparison the new Sachs clutch and flywheel weigh a little less combined!

I thought your other thread was tidy, this is awesome, your work is spot on. Very nice mate.

Still doing odd little jobs. 

 

The injectors are are being replaced with a recently built set of DSSR 130% ones, and instead of just chucking them in I ought to replace the seals on them. 

 

Now the genuine Bosch seals are easy enough to source, the factory recommends fitting them with the proper installation tools which saves the seals getting nicked or twisted which would be bad news..

 

Bosch seals

 

 

Laser kit.

 

 

And all done

 

 

Need to get to TPS tomorrow to order a set of cam carrier retaining bolts so I can then get the camshaft fitted and the engine timed up.

 

 

Got the ancillaries carrier finished and fitted, along with the dipstick tube and new genuine auxiliary belt tensioner that I forgot I had...

 

 

 

 

The postman should be delivering the new oil cooler tomorrow and as you can see the new seals are in place ready.

 

Another trip to TPS tomorrow will see the cam carrier bolts collected and I'll order up the new water hoses I'll need. 

 

Need to to do something with the air con pump and alternator in due course, then the front of the engine is near completion. 

 

Once the cams timed timed up I can get the new covers on then turn my attention to the turbo side.

 

 

Just noticed the dipstick tube is the wrong way round... bo11ocks!!!!

That's one tidy looking engine 

 

Genuine question; how long will it stay like that?!

Edited 6 February, 20179 yr by jars

Prob quite some time!!

 

It'll get used hard but it's never going to be a daily. 

13 hours ago, Lofty said:

Just noticed the dipstick tube is the wrong way round... bo11ocks!!!!

 

I have left mine that way as mine wouldn't swivel round the other way because of the tab

Oil cooler fitted and dipstick tube realigned the correct way

 

 

 

 

 

Looking extremely good!!! And probably cleaner than new. Are you going to be fiting a aftermarket oil cooler to?

The new VW cam carrier bolts arrived so last night we fitted the cam and then the the genuine VW cambelt kit also fitted and timed up spot on.

 

 

 

 

Some parts have been dropped into Bournes powdercoating in Birmingham who do the intricate stuff for me and I've picked those up today as well.

The engine mounting triangular bracket...

 

 

 

and after..

 

 

 

 

The fuel rail before..

 

 

 

and after..

 

 

 

 

 

 

Engine mounting top bracket before..

 

 

 

and after..

 

 

 

 

 

How are you planning on attaching the fasteners to the engine mounting parts? I had mine coated previously, and as soon as you start to tighten the bolts, the coating started to crack around that area. Maybe worth popping a nylon washer under all the bolts/nuts...

I'll prob use a washer of some sort Alex, I'll have to look into it. 

 

More work done today, fished the oil filler neck extension off the donor engine and was disgusted at the state of it..

 

 

A thorough clean, new seal for the neck and the actual filler cap and it looks much better.

 

 

Fitted the powdercoated triangular engine mount support and middle cambelt cover and bottom aux belt pulley.

 

 

Now the actual bottom pulley is supposed to run a rubber blanking cover in the middle of it, these normally get forgotten about when folks do cambelt changes and they end up in the bin, however there was one on the donor engine and this is how it looked after prolonged cleaning....

 

 

The rubber has aged and is now pockmarked and porous so I've popped it back out and will have to source a new one from TPS

Once that was done I turned my attention to the gearbox. This has been rebuilt by a specialist, the Peloquin limited slip diff checked and various enhancements/fixes made to it, but it still looked like a 12 yr old gearbox, i.e. Nasty!

 

I removed both driveshaft flanges the other day, and sorted those out.

 

 

They will be refitted with new genuine VW oil seals in due course.

The gearbox has seen some cosmetic love as well..

 

 

The tandem pump has been refurbished and has gone back on with a new gasket, and the bolts torqued up to the right spec

Gearbox is now finished and put under the dining room table... just wait till the missus stubs her toe on it

 

 

At least it's freed up some much needed room in the garage. 

 

Camcoat have received my parcel of tubular manifold and turbo housings and they will be back in the next couple of weeks then hopefully the engine will be near complete.

Can't wait.

everytime I see an update I hope it's an engine running but it's always more shiny bits!

37 minutes ago, hutchysrs50 said:

Can't wait.

everytime I see an update I hope it's an engine running but it's always more shiny bits!

 

Lol that's gonna be quite some time off yet, the whole underneath of the car will be next up for attention, floorpan will be stripped and painted Sprint Yellow, all the running gears gotta come off yet 

Great Build thread Lofty!

carry on the good work...will keep watching for when its finished!

Awesome work buddy! Braver man than me having that gearbox in the house, my wife would be on the warpath! The dishwasher makes a good parts washer tho, just don't tell her

Done some more tinkering with the rear beam I had off Danham..

 

Stripped it of all the mechanical parts and it's ready to go to powdercoating. However when Skoda/Vw had these beams built, they never cleaned off the welding splatter... does it matter? Probably not but it would make my teeth itch to see it through the powdercoating.

 

So I used the grinder with knotted wheel to rip the paint job off (thanks for painting over the rust Dave...) to reveal what I'm on about 

 

 

 

A few minutes with the flap disc on the grinder et voila!!

 

 

 

The acid dip and shot blast will see to the rest of the paint and rust removal for me.

 

Should be able to pick it up next week then I can rebuild it all with the refurbished stub axles and new wheel bearing kits

Amazing work as ever! Putting the rest of us to shame!!

 

Although part of me thinks that you have serious issues and should get yourself booked in to see a specialist