Finally got my cupra bushes installed in the console. Wanted to post up the 'tool' that's needed to do it. Will get out the measuring calipers and put every single dimension down later, but the critical ones are mentioned here now.

Basically the tool consist of bits that you assemble to get out the old bushes, and those you cobble together to put in the new ones.

To get the OEM out:

1- High tensile bolt M12 x 1.5. 250mm long (not pictured)

2- steel disc with a precise lathe-cut diameter of 61.75mm, center hole to suit bolt (I used 10mm steel and a lathe to get an exact sizing) PIC.2 below

To get the Cupra ones in:

1- same steel disc as above

2- similar disc as above but with a rough irregular (!) diameter of 65mm (I just crudely hacked this out of 10mm steel plate) Hole drilled in centre to suit bolt used below.

3- shorter bolt with matching washers and nut- I used a m12 regular thread about 150mm long. Should be a high-tensile one also as you're using quite a bit of oomph here... PIC.3 below shows the arrangement how you squeeze in the bushes.

I found that washing up liquid worked really well as a lubricant - they slid in pretty easily - it's rubber-friendly and dries sticky, doesnt remain long-term, all of which are desireable here. There is a proper VAG bush-fitting lubricant, but I find SWMBO has many useful things laying about that work well with working on the car......

Gotta watch the alignment of the bushes and to stop them initially twisting, but they seem lined up a treat...

Had to drop the console as the M12 x 1.50 250mm bolt wasn't available commercially locally and the workshop that made it up made it out of mild steel... It broke off flush in the console necessitating me taking the whole console out to get the broken bit removed. Oh well, here comes another wheel alignment....

Found that when the console's out - all you need to do to get out an OEM bush is to place the magic 61.75mm steel disc on top and whack that with a regular hammer. OEM bush dropped out intact happily.....

Cheers

Bas

You are a legend.

Great stuff, gets my vote for a guide/sticky?

Great stuff, gets my vote for a guide/sticky?

Agreed.

Means the console still has to be off the car though, that's my only quarm of what is otherwise invaluable information.

Agreed.

Means the console still has to be off the car though, that's my only quarm of what is otherwise invaluable information.

No mate you don't have to drop the console - I was forced to 'cos the poor quality mild steel M12 x 1.5 x 250mm bolt broke off in the thread and it needed extraction.

What you do is:

1. jack up the entire front end, remove tires, undershield tray

2. Underneath and inside the wheel hub you see 3 bolts where the black "wings" off the console insert - using a typing correction fluid pen you mark their position and mark the position where the hub bit inserts into the "wing" (so you can put off a wheel alignment till much later)

3. open the three bolts, pull out the console "wings" from the hub (if you remove the ARB arm that inserts into the shock absorber, it makes it easier)

4. Mark the single bolt holding the "wing" with the same pen - remove it

5. carefully twist out the "wing" being careful not to damage the front rubber bush

6. Good pull forward and the "wing" is out.

7. Place the 61.75mm steel disc on the rearmost end of the OEM bush

8. Thread the long M12 x 1.5 bolt through it and wind into the rear opening of the single bolt you removed until the bush pops out. Take out the pusher, bolt.

9. Mark the Cupra bush so its alignment is identical to the OEM one (there's an alignment rubber "button" on the OEM one. Extend this mark on the ally cover of the bush, so you can check it as it slips in.

10. Rub in undiluted washing up liquid into the cavity and onto the new bush

11. Place the 61.75 steel disc on the forward side of the cavity over the new bush, put your regular M12 bolt though the (irregular) 65mm disc on the other side, washer and nut on the smaller steel disc. The rubber part of the bush should be shallower towards the rear of the car.

12. watching alignment, tighten up the bolt (there's an alignment mark on the top one side and bottom other side of the console)

13. keep tightening until you hear a loud squeak and/or it gets noticeably tighter. The smaller front disc will go into the cavity by about 10mm.

14. Reassemble everything - clean the inserting tip of the "wing" and use a little silicone grease to help things along. You may need a rubber mallet...

15. You're done!

its the info we've all been waitin for. nice one

can i ask tho why you used the finer pitch of 1.5 on the m12 bolt?

its the info we've all been waitin for. nice one

can i ask tho why you used the finer pitch of 1.5 on the m12 bolt?

Finer pitch enables the bushe to move in slowly and requires less turning force.

Bit like first gear on the fabia, not much effort to move but only move slowly for fast engine movements.

its the info we've all been waitin for. nice one

can i ask tho why you used the finer pitch of 1.5 on the m12 bolt?

Some way in front of the entire bush affair, there's a threaded hole in the console. This is aligned along the centre line of the bush. It can be used to extract the old bush and pull on the new bush.... Unless your 250mm long threaded bar or bolt snaps!

ISTR machining aluminium in school, we used castor oil or similar to lube it. Can't quite recall now... It's too many years later.

J.

Or, be a posh git and buy yourself a hydraulic press. :P

Reason for the pitch is that the hole in the console is threaded to that pitch - it's the far end of where the OEM bolt holds in the "wing" bit. You are pulling the OEM bush towards the front of the console with it.

You would strip the fine ally thread using any other pitch..

Or, be a posh git and buy yourself a hydraulic press. :P

I really would love to mate - but I hear that ally consoles and hydraulic presses don't get along very well..... (not referring to any one incident of course!)