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Andy

Turbo Squareback - 20 year refresh

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Andy

I presume it's a bit they didn't treat, or didn't take back to bare metal - frustrating given how many months they had the car. If it was the only issue I'd had, I think it wouldn't bother me so much. I'm now hugely nervous that in a couple of years most panels will look the same. Not sure what to do about it at the moment, but I think taking it back for re-work isn't an option after the joke battery tray repair, so I'm probably faced with forking out for a different place to fix it.

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mark_crox

:-(

Any chance of getting some money back from them. If you need a place the guys at PanelnPaint are very trust worthy and if you mention me would look after you or run away screaming... :-)

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Andy

I doubt I'll get any money back, but I think the best I could hope for is an offer of free rectification. I'm wary of going down that route again as they were cutting corners even when I was putting money in their pocket. Could you PM me the PanelNPaint guy's details please? I'll get in touch once the car's on the road, and will take it to them to have a look at - I'd hope as it's new paint that it'd be easy to match.

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KiZ

makes me angry when i see stuff like that. can you not just take the door off and take it back?

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Andy

Been a bit slack on the update front... Anyway, ended up stonechipping the whole of the underneath of the rear end - only realised tonight that I'd not taken any photos. Now it's all metallic mint again:

41D37040-DC7B-4AB8-BBDE-68B3773F54DE-334

Got new hubs and bearings for the Gaz coilovers:

F6CBC105-E1A2-45AA-BF4E-1BE0AD4F7754-334

Stripped down the original rear axle, as I'd decided to retain drums at the rear - don't need discs on the back, and having completely stock off-the-shelf parts wherever possible only makes it easier to maintain in the long run:

07F1B7AB-A75B-479E-A215-DD3F409E3C94-334

The G40 axle I'd got had been blasted and powder coated in the past. A few bits had got chips and cracks, so they got wire brushed back and the rust treated.

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The axle then got a massive dose of black satin Hammerite over several evenings to ensure it was well covered. It's now got new rear axle bushes popped in it. At the same time I cleaned up and repainted the drum backing plates for the rear:

63F7F8DD-5899-4AA7-89DB-86F338108A20-334

Have a massive box of goodies from GSF to rebuild the rear brakes with all brand new parts, so they'll be getting put together this weekend. Hoping to get the time to put the front coilovers and brand new 256mm brakes on too.

I really can't be arsed with making up new brake lines, so I've measured up and checked ETKA and will get Automec to make me some up in cupro-nickel.

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Andy

Bolted the axle on with the rear coilovers, didn't take many pics. Spent ages tapping out all the threads - especially important on the captive nuts for the bolts from axle bracket to body, as the bolts are thread-locked from the factory, and new ones come with thread lock already applied. If you don't clean out the thread, and are using a new bolt, the bolt will bind. Carried on with the tapping:

EB0CCE75-6EA2-49AB-A1DB-61889BBED77F-504

Newly painted drum back plates, new stub axles bolted on:

71CE4F98-4F85-4ED2-AB54-56C9D8F9B56A-504

New brake shoes and brake cylinders:

B70A484E-EAF5-4040-9645-7A9D56895396-504

Finished them off with new bearings in new drums and put it all back together with some help from Yoof. Forgot to take pics, so this is the best I can do!

D71ACB01-F29A-41D3-8B75-A887AAC3F0D5-504

Might need to get some longer springs for the rear coilovers, as the arse end is a bit lower than it was before - and I'm pretty much as high as I can go on the adjuster:

932BBA6F-841B-4AED-83DB-6E6B8650956A-504

Shit pic, but I bought some coilover socks. They're neoprene sleeves with a velcro strip - idea is you cover the threaded part of the coilover with them to prevent it getting wet and shitty, hopefully helping to stop it seizing. They were cheap, so I'm not expecting much!

0363E659-FC27-4220-89A4-BB17DB914102-504

Fitted new PPP/Bartek bushes to the adjustable TCAs. I'd initially tried these with the standard rubber bushes in the name of R&D, and the conclusion is - don't bother...

98661B39-B803-495C-9CF7-F9A79DBBECBF-504

The repainted brake servo I'd done previously was a bit shit. My garage is a pre-fab, so it's damp and cold. Seemed that when I'd painted and rust treated the servo some moisture had got behind the paint. Anyway, Kiz very kindly gave me a pimped-up servo at the Club Polo RR day - so I fitted that today:

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As it upset PeteG40 so much, I removed the steering arms for paint.

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Dismantled the brake fluid reservoir and gave it a clean.

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And clipped it back together. Have a 22mm master cylinder to plug it into, but ran out of time this evening to put all that together.

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Some new brake lines from Automec. Originally they didn't have the Mk3 Polo lengths on file, so had offered to do them for a bargain £25. Unfortunately for me, someone beat me to it in giving them the lengths! I got them to make me a custom set anyway though, as I'd got the proper lengths from ETKA and what Automec had on file wasn't quite right (but should be now!). Properly nicely made in copper-nickel with brass fittings, and sure beats wasting a day making messy pikey flares myself.

C2C7BA4E-3FFE-4409-9945-147D4039DFE7-504

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harris.racing

Nice update mate, will have to pop round and have a look sometime.

Rear coilies yeah, pretty much at the top they're lowered a fair bit over stock - and if you wind down a bit there's no preload and the spring is loose - certainly with my rebound travel anywho, so iv fitted helpers on the rear also.

Liking the attention to detail - I enjoyed building up my beam with all new parts, which now looks shit like everything else that went on new - pretty saddening how when you use a car it just ruins it haha.

Good stuff though

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Jake

How much were the brake lines in the end Andy? I presume cheaper than ordering new from VW

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Andy

@Jake - brake lines were £125. VW will only sell you a coil of pipe and the fittings, you have to flare them yourself. I think they're pretty good value if you're replacing the lot. I've got a couple of hand flaring tools, but they require a lot of patience to get a really good flare - which is fine if it's a one-off repair, but I really couldn't be arsed with doing a whole car like that. Did half of it about 8 years ago now, and that was a proper chore.

@Harris - think I'll probably get a pair of longer rear springs, though I'm tempted to just get some helpers instead. At least with helpers I'd be able to go lower if I wanted without worrying over the spring coming unseated. It's blatant that Gaz have done no R&D on these coilovers themselves - but they're cheaper than the competition and I expected to have to dick around with stuff myself.

Plan is to fit the front suspension ASAP and get the brakes finished off. Then it's the fun bit of building the engine back up with the end in sight!

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Frascano

Looks savage man! Bet it will be a ballache for the brake lines.

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KiZ

You get my text mate?

Got a brand new VW genuine G40 header tank here if you want it???

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Andy

Got the coilovers put on the front.

IMG_1320_zps3a97b8fe.jpg

Whipped the steering arms and rack off, and fitted a new 22mm master cylinder and the brake fluid reservoir.

IMG_1322_zps3cc043f8.jpg

Audi caliper carriers for Girling/Lucas 54 calipers, cleaned up and strung up ready for high-temp paint:

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Rack got stripped down, cleaned and re-greased. Now refitted, along with the steering arms.

IMG_1328_zpsbbe54c59.jpg

All new brake lines in. I hate doing these, but the kit from Automec at least took the pain out of having to flare some new pipes up.

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Fitted the front brakes, caliper carriers all painted up. New calipers, Ferodo DS2500 pads and braided lines.

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New/refurbished Lucas 54 calipers done by TRW.

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Just got to finish off the hard brake lines at the rear and then it's finally on to the engine!

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Andy

Finished off the brake lines to the rear, new clips for the flexi to solid line mounts and plenty of grease on them to stop 'em corroding:

6410ED37-B8A0-448C-BEA2-E940F7245419-474

ED461926-C9E4-4C5E-BA80-E750DF2D3DE0-474

Fuel pump assembly was a mess, and the crimped rubber onto the nylon lines was buggered:

7F0DA99B-205B-4EB6-84D3-AF24B0683E30-474

New powder coated fuel pump bracket went on:

3F237A8E-FA58-47FE-BE39-5C30856EC716-474

Cleaned up pump & accumulator with new filter and new rubber hoses & clips:

3C85AAA3-C9F6-4B03-AA95-89ED24654448-474

And now installed:

ACF44DE1-7194-4643-8D7C-DEB79FE1A9DD-474

Car's now back on its wheels, and it's time to start on the engine - FINALLY!

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Had a tidy up of the garage, and sorted stuff out. Still a few more boxes of stuff to bolt back on - more than I anticipated! Still, three of the boxes are full of shite, so maybe not so bad! Anyone want to buy a 10 year old FK suspension kit?!

340E28CA-AE79-4AA2-ACB2-29070420BACB-474

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Andy

Been a bit busy with other stuff, but went to go and get my tyres put on the refurbed steelies yesterday lunchtime. Apparently my local tyre place now only fit tyres they've supplied due to health n safety/insurance/time of the month or something, so the fat lump went back to sitting on his arse with a brew. The owner/gaffer was out, so I guess doing any work to make money wasn't on the agenda today!

Fortunately work have a tyre machine and balancer in the workshop... ;D It's a shit machine as it doesn't get much use, but as of last night I'm now a tyre fitting pro, lol.

37A9900C-9D04-47F8-9A20-54CB62A16EA8-151

Made some progress tonight with help from Yoof. New cambelt and waterpump, and repainted the lower auxiliary belt pulley. Dipstick tube painted in silver engine enamel.

E1B9052D-049D-4921-BD1F-AE7DB5A9E5BA-151

Powder-coated inlet manifold on, along with injectors etc.

Also fitted the powder-coated Mk2 alloy rocker cover with some freshly painted bolts/washers.

98CE1B03-743F-43BB-91CC-464BD2F64652-151

Bit hard to see in the pics, but the block's been painted in satin black high temp paint now, cylinderhead cleaned up and cam end cap repainted to tidy it up.

The dizzy had a spesh hall sender in it, so I've pulled that apart tonight and cleaned it up. The body of it is now freshly painted - pics to follow when I'm building it back up again with the new VAG hall sender.

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harris.racing

Good progress again dude.

Should have dropped W+Ts down to me I'd have done them for you on a non spesh machine lol

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Andy

Cheers Nick! Should be reet in the future now I've got the machine sussed. Satisfying doing even the little jobs like that yourself.

So, rebuilt the dizzy this afternoon. Painted it up yesterday:

D7FF3B71-3167-4D0C-8FDC-F78A13A208F8-151

Removed the masking:

FBB55ED6-A4EE-446E-B06C-2B25988C10B3-151

New VW hall sender installed:

6D510A39-3F0C-42F7-A1B3-F16B83BEB155-151

Screws in and paint-penned:

FA777B35-CFE2-4B41-907B-03019DC6D623-151

Shimming the shaft - the genuine hall sender kits come with some new shims:

15C887BF-A629-43A2-BF04-334635888CF3-151

Smacking the pin back in to secure the drive disc. This can be a real pain in the arse to get out and to get back in. Ended up finding a nail that was a perfect size to use as a drift for this.

63E5542F-C0A6-4ACF-8071-94B78A531941-151

Re-assembled:

0D71A284-C6C7-44EF-B89F-A01E94C91354-151

New o-rings go on:

81F264E9-27F9-42ED-9179-1FED4805EEE5-151

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Done:

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Alternator back on the engine, along with freshly powder-coated bracket/mount:

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New wiring harness for the alternator to go on:

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Fuel lines back in with fresh clips:

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New bonnet catch on with new fixings. The new bonnet latch is shite quality compared to the original - new is only thinly painted, whereas the original was coated. Anyway, greased it up and have kept the original for when this inevitably rusts to pieces.

A2257FCC-4AF6-49EE-BB06-FE52E25173FA-151

Getting closer to being able to fill that empty space!

FB84B752-6440-429E-A69D-F5780FD27802-151

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harris.racing

Yeah mate, I like doing things myself purely because I know it's done properly.

"if you want something doing, do it yourself" lol.

Nice this, doings things as they should be taking no shortcuts :thumbsup: you working on it tomorrow afternoon?

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Andy

Pushed it out into the sun earlier whilst I got on with rebuilding the driveshafts and giving them a lick of paint:

64118973-C3D2-4166-AEB1-79BD58861FF3-151

And then fitted the new wheels - still need to clean the tyre lube off them!

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At the moment it's got a Polo-friend keeping it company while Yoof moves house. Hopefully mine won't get jealous that the red one is currently wearing its Compo MOs!

7D0CF8FA-E5E3-48D6-A4A3-AE28FD5F2C85-151

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mark_crox

Looks great out in the sun!

Not too much more now then! :)

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Andy

Been cracking on with this again.

Dug out a PeteG40 lightened flywheel I've had for years. It's not that much lighter than stock, but the material's been taken away from the right places, so should make a decent difference. Comparison with stock one:

IMG_5592_zpsd1fdbc1b.jpg

Helix paddle ready to clean up and go back in. Was going to get it re-lined, but new lining thickness is 7.6mm with a wear limit of 6.6mm - and mine was 7.4mm ish, so it'll be reet. Fair bit of bluing on the friction plate, probably from experimenting with 2nd gear launches off the rev limiter on the drag strip.

IMG_5593_zpsd660754b.jpg

Engine off the stand for the first time in over a year!

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Clutch and flywheel on:

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Gearbox bolted on:

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Engine finally back in the car. Managed to get it in without scratching any of the paint which was a bit of a mission! Now got the driveshafts etc. all back on too. Cooling system, oil cooler, wiring and lights still to do.

IMG_5608Medium_zpsdb603766.jpg

Out in the sun again:

IMG_5607Medium_zps8aaa5210.jpg

Bought a PSD intercooler with a new lower bumper bar someone had made for it. The bumper bar is utterly pikey, so I spent ages grinding down the chicken-shit welds. Using it for mocking up purposes, and then will either tidy it up or replace it.

Behind the intercooler is the new ally radiator (Radtec Westfield one - actually based on a Mk3 Polo!) which is about twice the thickness of the original. Wrapped it in bubble-wrap whilst I was mocking it up to avoid damaging stuff.

AF991AF3-7441-4437-BD6D-2F962E271AB8-176

Making some radiator brackets out of ally.

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Marking up where to bend the strip.

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Lower rad brackets before I trimmed them with some rubber strip from my random box of useful shit.

CF84B9B8-72FA-46F2-AB31-02838F4F22CA-176

With all 4 brackets in place the rad feels pretty secure, but I've got a plan to run some studding forward into the bumper iron to make sure it doesn't hit the intercooler. Neither the rad or the intercooler are dynamic parts, but with pipework to the engine coming off them they'll get pulled around as the engine moves, so they need to be secure. Ordered some rubber bobbins to secure the top of the intercooler to the bumper iron too.

Am really tempted to just throw it all back together ASAP, but want to do a proper job so need to take my time. I'm hoping that once the cooling pack is in, then the rest is relatively straightforward as it's pretty much just bolting stuff back on.

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etches69

Looks great this Andy, I'm impressed you managed to get the engine in with the turbo on. Its a bloody nightmare getting past the bonnet catch area using the lifting points as the engine leans forward. Much cleaner than my engine haha!

Edited by etches69

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MartinB

Lovely work here!

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Jake

Looks better every time you update! Who is TRW who did your calipers? only seem to hear of people using BigRed?

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Andy

TRW are a tier 1 supplier of braking, steering and active safety systems. They do a lot of brake stuff for the OEMs, but they also have an aftermarket parts division. I bought the calipers from http://www.vwspares.co.uk/, they're refurbed originals with the VW part number ground off them.

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etches69

Forgot to mention, people don't realise how tight it is around the brace bar when you have big intercoolers, rads and oil coolers. Proper decent work here! Had to butcher my bumper cross member to get the intercooler to fit at all, just a bit too tall! At the min its just sat on the bottom rad brace on the silicon of the end tanks. Looks like a really smart job this

Edited by etches69

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