I love reading your Build threads, your work is always brilliant. :)

Therefore i'm keeping an eye on this.

thanks cutmore :-D i'm hoping this will turn out to be quite special if it all comes together.

Olly

yesterday i cleaned up my calipers and carriers, here's the first one cleaned up

comparison

then i took them down the shed, gave them a lick of paint and left them to dry overnight

now i'd got the loom where i wanted i started pulling bits off the engine, i got the crank case breather / oil plate off as i want to adapt the outlet breather pipe.

took most of the bits off the front of the engine

and took a pic of the cambelt thats done about 6k, it was replaced along with the tensioner and water pump just before i got the engine but unfortunately they fitted a plastic water pump so i'll chuck a new kit on with metal pump.

stripped off the p/s tank, header tank and washer bottle while i was there too.

Olly

today i was supposed to be doing some work on a mates ibiza but someone crashed into him last night so that was off. instead i thought i'd enjoy the weather and plod away doing some bits to mine instead.

first job of the day was to fit the rear brakes up but while i was cracking on with that this arrived

i though it rude not to fit it up

once i'd done that i trimmed the lips off the dirt shields and fininshed fitting the brakes.

then i was bored so i started pulling more bits off the lump, while i was doing that a mate arrived in his 1.6 mk4 golf and told me he'd been in humphries for and hour and a half while they tried to get his locking wheel nuts off because he'd lost the key and they couldn't do it so i wacked them off for him, then he asked me to fit some wishbone bushes. i agreed but sent him to audi to get the s3 items.

before i could crack on with mine much more another mate popped round with a saxo strut and hub - he wanted me to fit a wheel bearing to it, so i did that just in time for my mate with the mk4 to come back with the new wishbone bushes, so set about fitting them up too.

now i could continue what i was doing, it seemed most of the bay had been stripped iut so i popped off the shafts, gear linkage and DP and dropped the engine out.

once it was out i just kept stripping bits off; gearbox

clutch and flywheel

engine mount

turbo

next i want to clean the bay then i'll drop the subframe out too.

mini update of what i've done so far today....

it's been on the to do list for quite a while now, so now the engine's out i thought this was the best time to do the chassis notch.

here's how it looks standard with the little rusty patch from where the shaft had been rubbing

wire brushed it back

and knocked up a template from an old section of exhaust

then chopped out a notch from the chassis using the template

once i was happy with the shape i obviously needed a more substantial bit of metal to fill the notch with so knocked this bit up

then i tacked it in place

i then ran a seam round the whole thing and ground the welds back

gave it another quick brushing up with the wire brush so i could apply this

so on it went

then i thought i'd quickly try the shaft in the slot while i was waiting for the seam sealer to dry

gave it another clean up round the area and threw some paint on

the only other thing i managed to get done was a very quick clean of the engine bay

Olly

excellent work olly, keep it up :)

thanks Kuzpit - there's no stopping now, i have to keep going.

not real progress but yesterday i dropped the subframe after work and then it rained so i downed tools for the day.

today i got home from work and a parcel had arrived for me -

my R32 rack, got it off ebay for £105 - stated to be R32 60k rack, i wasn't sure but when it arrived it looked to be a from a low miler so i slung a knuckle on the spline and checked it had 2.5 turns lock to lock and it did []

compared to my original rack

so i cleaned the subframe, removed the lower arms and arb and fitted the rack to the subframe

thats all at the mo

didn't manage to get much done yesterday apart from painting my wishbones, today i got a few more bits started

these arrived

so i fitted the ARB back on to the subframe

refitted my wishbones

i also ordered new track rods and ends to fit onto the R32 rack so set about stripping the old ones off

then gave the bay a 'final' clean

i also gave the block a lick of paint, not sure on the colour but ut's better than rust for now [:DD]

unfortunately my new rods and ends didn't arrive today as planned but i won't go into that, so instead of fitting up the subframe i got on with a couple of other little jobs

first i trimmed the lambda loom down as the lambda is mounted near the manifold with the k04 and i'd just rerouted the original loom first time round. next i removed the plastic bits next to the master cylinder and taped the loom up.

i then set about re-routing the fuel lines so decided where they were going to go and drilled (easier said than done) holes in the base of the engine mount

then put a bit of paint on the hole edges

to keep the fuel lines together i slid some heavy duty shrink wrap over them and heated it up

then i routed them where i wanted them to go and put some rubber grommets round the lines to protect them and trial fitted the clip on elbows

with mount

and header tank

All the work you do is so neat and done to such a high standard, brilliant stuff

thanks goose :-D

looking good pal, you going to be rolling up on the stage in this at edition this year?

Keep up the fab work!

Brilliant write up with loads of photo's such a good read , Keep up the good work mate look forward to seeing the engine back in :)

Stevie

thanks Dale + Stevie, i am hoping to make it to edition this year :-D

not alot of progress but my new rods and ends arrived from ECP finally yesterday.

compared to R32 items i removed

fitted the rods

measured each side to get the rack central

slid the boot on

and tightened up the clips

then fitted the lock nut

and track rod end

then i mounted up the subframe to the body

today i didn't get alot done which was frustrating, mainly little bits here and there

my superpro dogbone bushes arrived

so i cleaned up the dogbone and fitted the bushes up

with the k04 down pipe running close to the rack i decided i need some extra heat shielding so i dug out some adhesive heat reflective fiberglass tape

and put some around the rubber between the rack and the body

then some shielding around the p/s har pipe on the rack and a strip of tape across the top of the rack

that's obviously not enough so knocked up a little heatshield but haven't got a proper pic of it somehow.

while i was doing that i got another package from ibanezDan - top bloke [Y]

it was a 6 speed clutch line to replace my 5 speed item

fitted

5 speed line removed

after my last pair of track rod ends turned to red rust after 6 months i decided to give these ones a coat of gloss black

also cleaned a few engine parts

painted the alternator mount, cleaned the p/s pump and refitted both, also fitted the crank / knock sensors

i also cut down the plate between the engine and box as the rerouted loom will be going across it now.

need to get a cambelt kit and water pump - (with METAL impeller) now amongst other things...

good work

one think get a new coolant bottle from the dealers only £8 will look loads better

good work!

thanks chaps. :-D

yorks - if i had a quid for everytime someone said that i'd have a van load of them. i have a new one though anyway, thats just my test fit item.

Olly

small update today with alot of pics though

got some bits from GSF earlier - supposed to be a cambelt kit and water pump but they had to get the other bits in. also got the much anticipated CLEAN header tank, oil filter and new thermostat.

i started by fitting the thermostat

and seal

and housing

i stripped the cambelt etc off the side of the engine ready for the new bits making sure i lined up the timing marks first

while i was waiting for GSF to drop off the other bits i cleaned the bottom covers and painted the oil cooler plate

sanded the seat for the waterpump seal

pic of the old pump with plasic impeller - nothing wrong with it but bound to fail sooner or later

then GSF dropped off my other bits - new pump with METAL impeller

so i fitted the belt up

refitted the bottom covers and pulley and marked the timing marks with white paint

then refitted the top cover and mount

getting there dude, was waiting for the daily update, looked about 20mins ago, was dissapointed, but then this popped up haha. doing well.

How much are new header tanks, must get one for my car, makes it look so fresh, might aswell get all the tanks though will make alot of difference

Edited 28 April, 201016 yr by dub17

yea was a bit late yesterday, i had a run in with a burgalar who was cutting through my garden to escape.

header tank was about £8 from GSF bud. :-)

didn't get alot done today at all - what i did manage to get was a lupo power steering tank and mounting bracket from the scrappy, i've been looking into the possibility of relocating the tank a bit more out of the way.

it started to rain so i went down the shed and assembled my oil distribution block with the cooler plate and fitted it up with a fresh filter

the rain eased off for a little while so i marked up where i wanted the p/s tank to sit and modified the bracket (still needs finishing)

once that was about right i opened the hole up where the base of the washer bottle sat and filed it to size

then it started raining again so i called it a day.

weekends are rarely ever a time i get to work on my own car due to being too busy working on other peoples, this weekend is much the same. weather is mainly to blame for the lack of work today.

i tidied up the hole for the p/s tank

finished off and painted the bracket and bolted it up to the chassis leg

got my discs mounted up and the brackets for the porscheys

unfortunately the spacers for the bigger discs are too thick so will need to be machined down a mm or two

i originally intended to paint the casing of the alternator but when i started to clean it up with a wire bush attatchment on the drill i decided to leave it at that, so i mounted it up and refitted the tensioner and belt

looking good mate! I'm saving for mine now soo keep an eye out for a nice 20vt for me