Saving a MK1 Octavia VRS Police Car, FJ54 WYP

[a1topdog]

While the tailgate trim panel was off I cleaned up the years of accumulated grime.

[a1topdog]

50/50. Its cleaning up ok

Edited 16 January, 2022 by a1topdog

[a1topdog]

The passenger door was slightly out of alignment and was catching on the wing at the bottom of the door and had chipped off the door paint. You can see in this photo how the door gap is not even all the way down.  I thought I'd adjust the door hinges on the A post. I removed the wing to make it easier to get the hinge bolts then realised one bolt was inside the A post. Having recently just refitted the interior I wasn't taking it apart again. A plan B was required. 

 

[a1topdog]

I inserted a couple of washers between the bottom hinge and the door. These were just the right thickness to bring the door back into line. 

[a1topdog]

Chipped paint and gaps all sorted

[a1topdog]

That basically brings progress up to date. I've started to delve into a front end headlight / front panel alignment issue. I'll write that up once I've had a chance to look into it. 

[MikeTheThinker]

12 hours ago, a1topdog said:

All of these tailgate repairs will be covered up the chevron decal shown here. But as these will be expensive to buy

@oldunsmight be able to point you at good suppliers.

 

[MikeTheThinker]

11 hours ago, a1topdog said:

front end headlight

I have a pair of the original glass-lenses headlights buried in my garage if they're any use to you.  Not sure if they're off a standard or a vrs - or if they're any different at all.

[a1topdog]

1 hour ago, MikeTheThinker said:

I have a pair of the original glass-lenses headlights buried in my garage if they're any use to you.  Not sure if they're off a standard or a vrs - or if they're any different at all.

Thanks Mike, I have already sourced some replacements 👍🏻

[a1topdog]

I removed the front bumper to investigate my headlight issue and was presented with this mess. Not a lot of cooling going on there ......

[a1topdog]

Got the degreaser out. That's better. 

[a1topdog]

So this is the issue with the headlight. There is a big space between the top lug and the car front panel, yet both sides of the headlight fit flush against the panel as they should.

 

Also there was no way the headlight could be removed with the plastic bumper cover fitted. I was suspecting the crash bar was bent.......

[a1topdog]

And I wasn't wrong. Look at the state of it. 

[a1topdog]

I got lucky and found a brand new genuine crash bar at an excellent price. Shame the courier decided to drop it on its end and bend it! Luckily it's only minor, I'll sort that out

Edited 16 January, 2022 by a1topdog

[a1topdog]

It was only the crash bar that was bent. No damage to the front panel or chassis legs. 

 

Fitted, before and after.

 

 

Edited 16 January, 2022 by a1topdog

[a1topdog]

And now the headlight slotted in a treat, and lines up as it should do. I can actually see the adjusters now.

 

I can also now easily remove the headlight with the front plastic bumper fitted.

 

 

Edited 16 January, 2022 by a1topdog

[Dean]

Excellent work, mate!

[a1topdog]

16 hours ago, DeanVRS20VT said:

Excellent work, mate!

Thanks, getting there. I need do a bit of suspension work next then start using it.

 

Can you believe this car came with nearly a full years MOT. There were so many issues that should have been MOT failures,  some I've not even documented yet.  Lucky I wasnt expecting much and bought the car expecting problems and knowing I could do most of the work myself.  Someone else could have easily been burnt. 

[a1topdog]

The original headlights on the car were knackered. Broken adjusters, burnt bulb holders, cut wires and missing covers from the rear. I found a lovely replacement set and fitted them. This pic shows one original next to the replacement

Edited 23 March, 2022 by a1topdog
Spelling

[a1topdog]

I've had the car just over a year and never driven it. Even though I'd done a ton of work and it wasn't yet completed I thought I'd put it in for an MOT. Remember I bought it with a clean MOT, no advisories. It should sail through 😂. Suprise, suprise it failed. 1 perished steering rack gaiter and the front brake Flexi hoses. Also some advisories on the rear brake pipes.  I was quoted 3.5hours to do the gaiter and front brake pipes. No thank you, I'll do it myself.

 

[a1topdog]

Gaiter done and new track rod end while I was at it. I cleaned up the track rod and gave it a quick lick of paint. 

[a1topdog]

I cleaned up and re greased the track rod arm and used a bit of red grease to help slip the gaiter onto the rack. 

[a1topdog]

I was dreading doing the brake Flexi hoses as I was sure the hard brake line fixing would be seized and snap. I used plenty of penetrating oil, wire bushed what I could and took my time. Do not even attempt this job if you don't have correct sized flared open end spanners and suitable sockets. It will end in disaster.  Before pics (I had changed the bleed nipple first) 

 

Edited 23 March, 2022 by a1topdog
Correct

[a1topdog]

And new hoses fitted and new securing clips.  On this car I tend to replace every bolt and fixing I touch. It's just not worth the hassle latter if I skimp and reuse the old stuff.

[a1topdog]

And as it stands now with a years ticket on it. YeeeeeHaaaaa. (I know I've got to raise the rear exhaust box a bit!)