Did some investigation this evening, Both paddle clutches have 24 teeth or did in the case of the deceased above, and both input shafts on the actual and spare known good gearbox had all splines intact.

Span the cvs and the guide for the input shaft was wiggling about, after removing the bearing you can just make out the snapped lug on the guide.

Stuck a new paddle clutch on, reused the pressure plate, and popped on the perils atv, gearchanges and selection feel really good now. I do want a new 4 speed shift finger tho as there is play in the current one, so back in daily action woop

I'll probably get the other box checked out by Tameside or geartorque to know its sweet

The box i'd get checked mate, make sure no teeth are damaged from the clutch not engaging properly, ends of teeth could be abit fubared. IF alls good i'll buy that ATV

Hah I need two one for the peril! You have a broken one atm?

Mate that looks so good.

Is it quick?

Compared to the engine before, undeniably but compared to the peril no chance, but it's only running 0.4 bar atm.

It makes a nice daily cruiser, probably about std g power atm

Mate that looks so good.

Is it quick?

not as quick as me Gave him a nasty shock on the way to alltypes until he remembered it wasnt a gt anymore :lol:

Yeh man I was like faaaaack it's a racking gt, oh wait afh phew!

Quick off the mark but tails off top end, needs some green injectors, a new fuel pump and remap, but still deciding whether to put a schrick cam in or just retain the gt

For the time being until I get the mk1 polo on the road it can stay at this power, as I need a daily!

Finally I have all the parts for the wishbone brace.

It's all packaged ready to go out dude.

Bolts are 12.9 Allen head, 5mm longer. Unpainted ready for that epoxy mastic!

legend dude! Arrived today :)

MOT's coming up for the golfie, so its that time to rectify all the lil faults that I've never got round to doing.

Yesterday was spent making up stainless steel brackets for the radiator, realinging the bonnet catch, tucking the exhaust up some more, and welding a rear hanger on the backbox.

Also spent some time investigating the front suspension to assess what needed to be replaced.

Waiting for the following bits before I can rebuild the front of the car :-

Seam Welded Wishbones

New Steering Rack

New Steering Arms

New Track Rod Ends

New Balljoints

New Wishbone Polybushes

New Steering Rack Polybushes

(Big props to EuroCarParts for the 25 percent discount on all the service items)

I would really like to replace the universal joint but at £250+ from VW Heritage, I think i'll pass!

Also got a front lower wishbone brace thats been made up by RandomBadger69, so will be putting the 15's back on when the front is all rebuilt, which should give me the ground clearance I need to be able to not smash the brace off the world!

Further jobs for the MOT include

Welding to passenger floor and inner

Exhaust hanger for both shell and exhaust, for the midbox.

Fit new rear handbrake cable (as the old one is impossible to get fitted, as its too rusty for the springs to move freely enough to connect the cable to the shoes)

Need a new passenger door handle with key

looking good saf? hows the mk1 olop getting on?

Possibly getting a full G engine cheap (still not cheap enough for my wage ), transporting it is gunna be difficult with the mothers astra

Oh wacking ads charger meant i had about a litre of oil in the intercooler

PS. could you pass onto ad that il have his charger monies on the 15th, cheers buddy

Hoping to be ready for the poloshow YOOOOO!!!

Edited 6 June, 201214 yr by Matt G40

legend dude! Arrived today :)

New Steering Rack Polybushes

Cool man, should hopefully look good with the epoxy mastic finish!

I did my one satin black and it looks alreet, but I doubt it'll last.

Be interesting to see if it clears your downpipe. I have only tried it with my standard G40 manifold and downpipe and on Jims 1.8 GTI mk1 Rocco lump. It wasn't overly tight though, so fingers crossed.

I see prothane do the steering rack bushes "loose"..

http://www.candrenterprises.co.uk/shop/pro...974-1984-4.html

Oh yeah.. wheel conversion studs are done, chaps shut this week though, so should hopefully get them next week. I'll keep you posted. Looking forward to seeing them. They should be good, hence the cost. 12.9 tensile, rolled thread with a raised-profile "shoulder", 65mm overall.

Let us know how you get on!

Will be ready to paint a load of stuff on Sunday so I'll do it all then.

Downpipe clearance isn't a worry haha nothing a sledgy can't sort for the meantime!

Those mounts are bugpack ones gsf sell tried a full set a fair few years back and they were far too hard, settled for new VW ones and an autocavan rear mount, which transformed the car!

I'm trying to find new small block engine mounts for the engine n front side box mount. They are smaller than gtis. I really want those two new and a poly rear mount that me n Arun will knock up.

Well looking forward to the studs mate, was readin thru the Ali thread last night, you boys are smashing it out. Bit some more welding today on the comet blue as I'd got the buzz again!

looking good saf? hows the mk1 olop getting on?

Possibly getting a full G engine cheap (still not cheap enough for my wage ), transporting it is gunna be difficult with the mothers astra

Oh wacking ads charger meant i had about a litre of oil in the intercooler

PS. could you pass onto ad that il have his charger monies on the 15th, cheers buddy

Hoping to be ready for the poloshow YOOOOO!!!

Yes lad! It's looking rustier by the day :( just removed the rear towing eye and I need to replace a good amount of the rear chassis leg :(

Buzzing about the g dude, I'm gonna be ma busy myself but if you gets tuck you know where I am :) boom yes gfowty!

Will be ready to paint a load of stuff on Sunday so I'll do it all then.

saf you are are best painter in north west

pauseeeeeeeeeeeeeeee nattttttttttt.

Edited 6 June, 201214 yr by vw-nay

If nays free on Sunday then he's painting haha! We have a compressor and a spray gun now woop!

Will be ready to paint a load of stuff on Sunday so I'll do it all then.

saf you are are best painter in north west

pauseeeeeeeeeeeeeeee nattttttttttt.

I liiiiiike this post so maaach. I swap you genuine Mankini only fotty wears few skidmarks, for carbon camel.

You buy now, pay Tuesday.

Will be ready to paint a load of stuff on Sunday so I'll do it all then.

Downpipe clearance isn't a worry haha nothing a sledgy can't sort for the meantime!

Those mounts are bugpack ones gsf sell tried a full set a fair few years back and they were far too hard, settled for new VW ones and an autocavan rear mount, which transformed the car!

I'm trying to find new small block engine mounts for the engine n front side box mount. They are smaller than gtis. I really want those two new and a poly rear mount that me n Arun will knock up.

Well looking forward to the studs mate, was readin thru the Ali thread last night, you boys are smashing it out. Bit some more welding today on the comet blue as I'd got the buzz again!

at hammer for clearance!

The prothane bugpack mounts are 95 shore rating. I'll see how I get on with them in my rear beam, wishbones etc. They really have increased vibration from the engine, gearbox makes a load of noise now!

Has been some good progress in our unit of late.. good buzz going and Bakers just on it with the VR conversion, which spurrs me on a bit. Had a lull on the welding/body front, been assembling engine mostly this weekend. I'll get an update going at some point!

You keeping your comet blue mk2 then?

Your a ledge you have as many if not more projects than me, move the love around between them! :-D

Yesterday got these..

They measure 65mm overall. From the back of the shoulder to the end of the thread measures 40mm.

yeaaaaah boi!!! looking good!

my week off work arrived, so deconstruction could commence

car needed welding on the sill and around the clutch cable, so best option was to remove the dash, and part of the cage

with the dash out gives me the perfect opportunity to upgrade to the later style wiring loom, as the previous one was bodged with random switches all over the place!

had always wondered why a load of air came from the top of the dash, thought the venting system was afray, but it turns out theres just a section of the window screen surround thats rusted away in the middle, you can see it better in the below picture

there was loads of glass there, so i think when the screen was last changed, the old one broke.

the clutch repair wasnt just a simple section around the clutch cable area, it's previously rotted through and been repaired so took out the entire steering column so i could get good access with the grinder and welder

also whipped off the old wishbones, and steering rack, ready for this little lot to go on

Edited 19 June, 201214 yr by grungeisdead

Yes boss, good stuff! More pics of the wishbones please! Good luck with the fab work!

Hows the gaitor looking for the steering rack/UJ?

Ta mush I took a load for you will pm u the link tomorrow!

Old racks gotta come off first hopefully it's ok as a new ones 45 quid plus, shocking like!

Can't get back on it till thurs as I'm painting my kitchen tomo boo

Hmm suspect repair panel

Boom - nice repair job LAD!

Bye Bye Rot

Heres where progress was halted as I ran out of gas :( on a saturday at 6 no less arggggggggh

So I gave up on welding missions and thought I'd crack on with getting the front suspension and steering rebuilt so I could get the car rolling again and do other bits and bobs.

Tried the UJ from the old steering rack on the new rack and the spline on the rack was too small, after investigating the new rack has Volvo! stamped on it FFS!

So stripped down my old rack, cleaned it all up and refitted it. The UJ gaitor came up like new with a clean inside and out, really chuffed as replacements are expensive. The racks now held on with Powerflex rack bushes and theres fresh tie rod arms and ends, with vgc VW boots for good measure.

terrible picture below

mainly due to the fact that i happened to mention the word food, tez mentioned nandos and next thing we know I've got a double breast chicken pitta in front of me. BAM

doesnt look like ill be finished tomorrow now with the lack of gas, unless i decided to get ass raped at hellfrauds for disposable gas canisters! so ill get all the mechanical stuff done, and chop out all the rusty bits and make all the repair panels so i can just zip round them all in the week when I have more gas.

random rambings of stuff I've got left to do before i can drive it again, looks loads more than whats left but a few are fairly time consuming tasks

fit wishbones to car

remove heater matrix

remove instrument panel from dash and affix in place (running no dash for a while to sort out welding jobs - windscreen surround and heater surround)

finish making bulkhead repair panels

welddddddd

weld wiper mech bracket back on

epoxy mastic that sucker

repair front left sill and floor section

refit steering column

fit sheer bolts

refit clutch cable

refit brake linkage clevix pins

Fit new handbrake cable

refit cage

refit seats

refit harnesses

check tracking, adjust and tighten - inner steering arms, outer steering arms, steering arm balljoint

wire dash instruments and switches back in situ

trace and replace dodgy wiring in series 1 loom

fit new fuel pump

driiiiiiive

Awesomeeeeee! Wiring missions on your week off, not good!

What you driving now this is in the unit too lol.

my own two legs, nah just random lifts or the occasional taxi.

wish i could have spent all week on it but 3 days were taking up by painting me kitchen n bathroom

Well with no gas and being on foot I just thought I'd get to the unit and crack on putting the front end back together.

Managed to persuade the polybushed wishbones in place and the rich popped down and nipped my over to halfords to get some gas so cracked on with the welding!

My phone battery died ages ago so no pictures from the day and I had no concept of time. By the time I'd refitted the steering rack and wiring, cabletied dash n wiring in place it was about 3 in the morning. Fitted the seat and harness and got the fook home

Seam sealer is lethal stuff haha nearly set fire to the car. Good thing I always keep a fire extinguisher close now! Water is useless people!

Edited 26 June, 201214 yr by grungeisdead

My phone battery died ages ago so no pictures from the day and I had no concept of time. By the time I'd refitted the steering rack and wiring, cabletied dash n wiring in place it was about 3 in the morning. Fitted the seat and harness and got the fook home

Seam sealer is lethal stuff haha nearly set fire to the car. Good thing I always keep a fire extinguisher close now! Water is useless people!

Happens to me too much. I really need a big clock.. especially with the summer being in its longest days, I often think "it's not dark, it cant be late!?".. think again!

Seam sealant burns.. without much persuasion.. worst thing is you cant always see it burning! Firewatch and a C02 extinguisher are good practise!

If when your welding it gets a bit lighter.. then its a good indication your on fire!

Good efforts dude! I feel your pain with the no car and unit logistical.. I live in fear when I only have one car on the road (esp. when its haggard or "high performance").

Have a look at Albee (also Air Liquide) for a local dealer. mine is United Welding. A bottle will cost you circa £150 (for a full bottle of pure Argon, Argon mix is usually cheaper) but its yours then and you just pay per re-fill. So if you were not using it its not costing you 33p a day rental like Air products etc. Depends how much you use it though.. if you use a lot of gas reguarly, then BOC/Air products doesn't work out too bad.

Edited 26 June, 201214 yr by randombadger69

I got a bottle depo of 20 quid a fill is 20 quid, reg was 30. It's a co2 fill, boc wanted a license or summat for argon.

I tried a lil argon bottle from halfords when I first started and wasn't too keen on it.now I've had a bit more practise welding I think I'd be prepared to give it a shout but expensive start up cost. Heard the splatter is less. Is it far better?

I want to weld everything now so whatever I get I will use it regularly.

Fire watch would be good, deffo! However noones about in the unit on regular occasion. I need a good place to refill fire extinguishers and I have some good race ones that somehow depleted when I left it at a friends. Musta been some good times.

The car felt nice and tight on the road with all the new bits, however couple of mistakes, when I adjusted the steering arms one of the arms I took off is fixed length and I forgot to set it to the same as before and do the tracking on the other arm! Therefore my full lock to the left is appalling haha!

Also there was a lot of play in the inner steering column, the random spring that was lying on the floor when I was clearing it out on the early hours of monday morning to refit the interior and drive home actually fitted between the UJ and the cap at the base of the inner and outer steering columns. Feels proper nice now!

Will crack on with doing the handy b, steering arms and couple of other odd bits tomorrow, and then jump on the lupolo until the weekend comes!

I got a bottle depo of 20 quid a fill is 20 quid, reg was 30. It's a co2 fill, boc wanted a license or summat for argon.

I tried a lil argon bottle from halfords when I first started and wasn't too keen on it.now I've had a bit more practise welding I think I'd be prepared to give it a shout but expensive start up cost. Heard the splatter is less. Is it far better?

I want to weld everything now so whatever I get I will use it regularly.

Fire watch would be good, deffo! However noones about in the unit on regular occasion. I need a good place to refill fire extinguishers and I have some good race ones that somehow depleted when I left it at a friends. Musta been some good times.

The car felt nice and tight on the road with all the new bits, however couple of mistakes, when I adjusted the steering arms one of the arms I took off is fixed length and I forgot to set it to the same as before and do the tracking on the other arm! Therefore my full lock to the left is appalling haha!

Also there was a lot of play in the inner steering column, the random spring that was lying on the floor when I was clearing it out on the early hours of monday morning to refit the interior and drive home actually fitted between the UJ and the cap at the base of the inner and outer steering columns. Feels proper nice now!

Will crack on with doing the handy b, steering arms and couple of other odd bits tomorrow, and then jump on the lupolo until the weekend comes!

Argon/carbox mix gives a better finish, something like 5% Co2 (argoshield light @ BOC or Cougar 5). My mate got a bargain bottle of argoshield light through a guy on the volkszone forum iirc. He set up a discount code for forum users. I'll try and glean some info for you. Bottle only costs about £30 for a refill on a half size bottle (stands waist height).

Nice work!