Ok if anyone's following this, here's another update. There's no pics of expensive split rims and 'cool' stickers.

My car likes to mark its spot:

Funnily enough, so does our old cat . She left a nice steaming pile under the car, twice , along with several pools of urine just to make my workspace more fragrant

After much buggery:

Once the tank and beam were out of the way I set about sanding down the surface rust and kurust/chassis paint over the metal just to keep the demons at bay.

Again, after much buggery involving a lot of grinding of the handbrake bracket (took off a thick chunk of metal) and other things to make this fit, Mk3 tank in early Mk2:

Next on the agenda is fuel pumps and then refurbished beam.

whats it like for rust underneath? any pics

had the tank off mine..aint too clever under there , took a fair while cleaning up scabs n treating em etc

no pics, it wasn't too bad tbh. just a few little patches of surface rust, no proper rot (as my dad calls it, owns 4 campers). there is some patches of rot emerging that will be sorted elsewhere. these aren't in structural places though thankfully.

glad to see this is still going mate, inspiration for mine :)

just read the whole thread, and massive respect for doing it your self, cant wait to see this beauty finished! :)

its still alive :)

just read this all the way threw and love what your doing and thumbs up for doing it all your self. will be keeping an eye on this 1 good luck and hope it all goes to plan :-)

yep still going, pushing on into the unknown (for me anyway).

thanks for the comments they really mean a lot to me. Just started a new job working 40+ hours a week now so I think the halogen will see more use in the coming weeks!

hit a bit of a snag today. got the rear beam bolted up at the chassis side, but I see now where it will foul the Mk2 handbrake bracket. What have people done to sort this out? Here are some pictures to illustrate what I mean:

The beam itself clears, just the bracket that holds the cable to the beam fouls the bracket that holds the cable outer to the chassis. Bit stuck as to what to do. Thankfully Pete93 has put some handbrake parts in the post so I can see how it all goes together later on this week. So I have it all on hold for the moment, even tho there are other bits and pieces to be done I've decided to fix my push bike instead!

I chopped it off now, obviously gonna have to just weld in a bracket somewhere else once I know where the handbrake cable is going to be held.

Hi mate, what suspension set up are you running?

Thanks.

Hi mate, what suspension set up are you running?

Thanks.

Just cheapo springs and shocks for the mo, 60/40. Would love an H&R kit really but will have to save up for that.

All 4 flexis could do with being replaced so for the little extra I got this:

:)

Now I just need the rain to stop......or I might rig up a tarp somehow. Think Saturday is meant to be nice?

good to see this is coming together

and thanks again for the help re the obd plug, think i've got it pretty much figured out now

good to see this is coming together

and thanks again for the help re the obd plug, think i've got it pretty much figured out now

no problem dude glad it helped!

not much progress this weekend I've been a bit lazy lol

refurbished fuel pump assembly ready to go on though:

also might have bought some wheels

Edited 3 October, 201015 yr by Narrow_Lane

Looking good chap

cheers jon boy!

Wonder when these were last changed (never) ?

Better:

^ surface rust looks worse than it really is in that pic

Fuel pump assembly fitted and awaiting wiring:

Can someone with a Mk3 tell me if the main fuel lines from the pump assembly go over or under the filler neck?

Finally got round to checking out the handbrake. Proper stuck here:

]

The old cable has a different attachment to the handbrake lever than the new cable... not sure what to do?

Could fit a differnt pin that is in that circlip with a hole thru and nut the other side? Bit of a puzzle :S

Edited 9 October, 201015 yr by Narrow_Lane

This is looking good.

Fuel lines run along the body between the filler neck and body.

Looking good Matt.

Can see what you mean about the handbrake cable, but surely it would be really difficult to adjust as the nut would be inside the lever?

Don't want a set of derby lights and grill do you? :p

This is looking good.

Fuel lines run along the body between the filler neck and body.

thanks mate

will route them properly in the morning :)

Looking good Matt.

Can see what you mean about the handbrake cable, but surely it would be really difficult to adjust as the nut would be inside the lever?

Don't want a set of derby lights and grill do you? :p

Cheers goose

Yea you're right it would and I did thing about that, but I can't see another solution at the moment. I'll keep my thinking cap on tomorrow lol

Its funny I used to always want derby lights, now I prefer the round ones! I am tempted though

What are you driving now btw? saw you had the coup up for sale a while back

Cheers goose

Yea you're right it would and I did thing about that, but I can't see another solution at the moment. I'll keep my thinking cap on tomorrow lol

Its funny I used to always want derby lights, now I prefer the round ones! I am tempted though

What are you driving now btw? saw you had the coup up for sale a while back

I think you should defiantly be tempted, are a good set

I'm driving a Discovery now, quite a change from the polo but I like it!

Can you pick up a later handbrake..

this is what one looks like... ignore the bend

lol I don't think its meant to look like that? :p

yea I see how it differs now. the mounting is definitely different, I'll see if I can get my hands on one in the for sale section, could weld the old one and new one together?

Ok luckily I have sourced a handbrake section from fonzooorooo on here who happened to have just chopped one out!!

What I'm going to do is drill out the spot welds and cut the template out of the Mk2 tunnel, then spot weld the new section underneath.

Also had a change of plan. I will be using the Mk2 clocks now so a few more things have to be done:

Fit Mk2 oil pressure sensors (not sure which ones I need since they went with the old engine) and a T piece

GSF are less than helpful on their website:

931VG0030 OIL PRESSURE SWITCH PO All

931VG0031 OIL PRESSURE SWITCH(BLUE) PO All

931VG0050 OIL PRESSURE SWITCH PO >9/90

931VG0060 OIL PRESSURE SWITCH PO 10/81 >

Does anyone know the VW part numbers?

On vagcat I have:

Low press. 028919081D

High press. can be 1.8 or 1.4 bar 056919081E (1.8 bar white) or 068919081 (1.4 bar black)

Fit Mk2 temperature sensor this is for the clocks so black.

GSF lists these:

929VG0100 TEMP.SENSOR-2 PIN BLACK PO 8/85 >7/88 2 Pin

929VG0110 TEMP.SENSOR-2 PIN BLK/GRN PO 8/88 >

Which one? Does it translate to the year the clocks were made (mine are rev counter ones, not standard)? I guess I could check with the part number.

Narrowed it down to VW part no.s 251919501 or 251919501D

Rev counter wire (red/black from Mk2 loom I think, just gotta connect it to the Mk4 coil)

The rest of the clocks should be ok, including the fuel gauge running off the Mk3 sender.

Reason for the change is the 16v clocks were just too big for the dash and no way am I chopping up the dash.......it would be gash....

Edited 24 October, 201015 yr by Narrow_Lane

Why have you had to change the handbrake setup then?

I fitted a Mk2F tank, you can still use the old cable setup but have to relocate the bowden pulley wheel stud. Slightly less work involved but I wanted to do things properly. I prefer the late Mk2/Mk2F handbrake setup as well, the lever will sit further forward (my seats are late spec I think) and you can adjust the cable inside the car which is handy.

Ah, i see. So as long as i stick with my early spec tank, i can keep the hand brake? Thought it was something to do with you changing the rear beam. Which is what i was planning to do. Didnt want to go chopping her up like you have though.

Where is the adjustment on the early ones then? I prefer the style of the newer ones, but cant be asred with the faffing around its going to cause!