Great progress, like reading your updates.

I've been lurking in the background and don't often post but i've been enjoying the updates too so keep them coming

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Goldie the track car.

Looking good man

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Ph2 Black GTI 6!

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But now a Black caged rallye owner

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Did to mine didn't last too long

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But now a Black caged rallye owner

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Fair play to you Tom ...fair play looks good m8

Thanks for all the positive comments . Looking forward to getting it back on the road although I'm a way off yet.

I've been thinking about what to do with this. There was no doubt that it was going to get repaired properly just at which point in the reassembly.



That area of rust came to light after I'd got home from having the bulkhead repair done. I hadn't fully removed the sound deadening only pulled it over so that the work could be done on the passenger side of the bulkhead. This patch is on the driver side and the peg supports the 'pedal panel' whilst you put the bolts in from the engine bay side.

This is the head of the peg in the wheel well.



The car now needs to be mobile enough to get it on a trailer and down to Sean to sort out. Time to bolt on the freshly powder coated subframe...



... with the refreshed subframe cups...



The o/s wishbone needed new front bushes. It had already had a P-bush and ball joint but the front bushes were fine at that time. Wishbone got a wire brushing, some Hydrox 80 and a coat of gloss black. It now matches the all new TRW one on the n/s.



And all fitted up.



I'd soaked the BJ heat shields in some citric acid and given them a coat of high-temp silver.

Steering rack bolted on along with strut and hub assembly and all linked up. Nice to see it back on all 4 wheels!

Along with a load of other bits I had the 'pedal panel' powder coated. That's been put back on along with the steering column and wheel etc so the car is now maneuverable. Just need to arrange a date and time to get it looked at.



Whilst the engine's out I'm making sure that's as tidy as it can be. Having pulled the box off I could see that there was some oil evident. Now, I'm 99% certain that this is gear oil from when the n/s diff seal wasn't installed completely straight, it certainly smells of gear oil.



However, it's going to be much easier to do the main seal and hockey sticks whilst the engine's out. Also, provided the latest welding job doesn't cost too much, I'm keen on fitting a lightweight flywheel and I wouldn't want that piece of art getting covered in oil!

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1343Z4 coolant hose o-rings for sale
198131 injector o-rings for sale

Cheers, it does make me happy seeing it all fresh bolted on to the car

Thought I'd come and do a little update as work's a bit slow and progress on the car has paused whilst I wait for Sean to have a space free to do the bit of welding, hoping that it'll be done in the next couple of weeks.

A few bits have been done in prep for the Rallye reassembly, mainly refreshing bushes on various bits. Back near the start I'd attempted to fit a lower engine mount with the carrier still on the car. That didn't go so well and I fitted a Powerflex polybush instead - that really wasn't up to much in my opinion, it felt softer in the hand than what came out. With the engine out and with easy access to remove the carrier I got a decent OE style lower mount pressed in. Also got some new driveshaft intermediate bearing retaining screws as mine were slightly bent.



You can also see a powdercoated gear selector arm with a new bush inserted in the above pic. I also replaced the gear stick bushes. The ball's a bit cracked but seems to work fine



I'm going to need tight gear changes when I'm smashing through the gears because of this




It's a shame to sandwich it between the engine and box really, it's so pretty. Bought some new flywheel bolts and larger M8x21 capscrews for the clutch too.

Hockystick and crank seal look fine. The oil present is, I believe, from a leaking n/s diff seal, certainly smells of gear oil. Won't hurt to do the seals whilst I'm this far in to it though; OE Pug and Payen bits.





One thing leads to another and the block has been wire wheeled, coated with Bilt Hamber Hydrate 80 and then a can of high temp black over both sides.

Before


Hydrate 80


Painted.



You can see in the background of the above pic that the plate on the end of the gearbox has been powder coated and re-secured with some stanless bolts. I had to helicoil a couple of the threads in the 6th gear casing as the original screws were a nightmare to extract.




Sump's been dropped off at the powder coaters today. I was trying to clean it myself but cast aluminium's impossible to get looking good once it's grubby. Initially I'd asked for it to be blasted so that I could give it a coat of high-temp silver however, they've assured me they can just do the outside - we'll see how it comes out. Exhaust heat shields were also dropped off for blast only, really not worth going to town on those.

Once the sump's back I'll be replacing the seals on the crank and #1 bearing cap then refitting the sump (M7 bolts WTF?). Flywheel can go on along with clutch then gearbox with some new clutch fork bushes

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1343Z4 coolant hose o-rings for sale
198131 injector o-rings for sale

Bloody well done Tom nice update m8
Keep those pics coming

Looking fresh mate. Wish I did this when I had my engine out but time a money at the time didn't allow.

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Ph2 Black GTI 6!

EX black 6 owner
But now a Black caged rallye owner

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are you finding your parts man at the main dealer ok? I see you've purchased quite a few seals and other bits...what was your experience of getting these parts? I've found in the past it's a hit and miss whether your parts man can be bothered or not. Some are happy to search for stuff while others try to fob you off with excuses like "it's saying it's not available" or "it's on back order" or "you need to order a bag of 50 mate".

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1999 GTi-6 (china blue)
1999 Rallye (black)

Still waiting on a date for welding

Plenty still to do though...

End of the crank was cleaned and a new seal installed.



And then the flywheel got bolted on with some new bolts.



Possibly something I'll come to regret but, reinstalled the old clutch. Costs are mounting up and there was plenty of meat on the old one. Also, if my seal installation is less than perfect I'd rather wreck an old clutch! Bolt holes drilled out to accept the new M8's the flywheel needs.



Lining-up the 'box. Took a few attempts but went home with a nice clunk eventually.





And then put the whole lot back in the bay without knackering the fresh paint



Much safer in there than in the garden



Thought I'd show off my fresh pipes



Left to do list:
Welding
Epoxy primer the media-blasted exhaust shields and reinstall.
Tidy-up driveshafts and install a couple of new boots.
Repair oil level sensor.
Reinstall inlet manifold and fuel rail etc.
Reinstall sound deadening, heater box, pedals, steering column, carpet, seats and dash.
Reinstall rad & pipes.
Fluids.
Test drive.
MOT.

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1343Z4 coolant hose o-rings for sale
198131 injector o-rings for sale

Very nice. Get the boot out tomorrow for again today

________________________________________

Ph2 Black GTI 6!

EX black 6 owner
But now a Black caged rallye owner

Hunting for Go faster bits!


SEARCH

click here