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Author Subject: Ph.1 Diablo
RetroPug

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Location: Leicestershire

Registered: 15 Jan 2013

Posts: 2,473

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Post #151
Things to do:
Fit new rear beam with new rear shocks DONE
Paint rear calipers and other bits DONE
Fit front suspension DONE
Fit new droplinks and TREs DONE

Paint front calipers
Fit brakes front and rear and flush fluid
Refit all the now repainted things I removed earlier
Remove cat and get the outlet pipe welded (cat 75% off but bolts not budging any more )
Wait for new steering wheel in the post and fit it
Get tyres swapped onto TD wheels
Fit new steering wheel and boss
Get tracking done
Give it a really good clean

Not much now other than removing the cat and doing brakes. Tyre swapping and maybe even tracking can be done at work for free.

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61k miles Ph.1 Diablo '6 Project Thread
Posted 17th May 2015 at 07:53
walker_texasranger

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Location: Sunny Retford

Registered: 26 Jan 2008

Posts: 2,502

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Post #152
Looks really nice Luke Smile

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Posted 17th May 2015 at 09:10
RetroPug

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Location: Leicestershire

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Post #153
Thanks! Definitely needs a deep clean though. Laugh my ass off

Things to do:
Fit new rear beam with new rear shocks DONE
Paint rear calipers and other bits DONE
Fit front suspension DONE
Fit new droplinks and TREs DONE
Remove cat and get the outlet pipe welded REMOVED just needs welding

Paint front calipers
Fit brakes front and rear and flush fluid
Refit all the now repainted things I removed earlier
Wait for new steering wheel in the post and fit it
Get tyres swapped onto TD wheels
Fit new steering wheel and boss
Get tracking done
Give it a really good clean

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61k miles Ph.1 Diablo '6 Project Thread
Posted 17th May 2015 at 12:19
RetroPug

Seasoned Pro

Location: Leicestershire

Registered: 15 Jan 2013

Posts: 2,473

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Post #154
Fit new rear beam with new rear shocks
Paint rear calipers and other bits
Fit front suspension
Fit new droplinks and TREs
Remove cat and get the outlet pipe welded REMOVED just needs welding
Fit new steering wheel and boss

Paint front calipers
Fit brakes front and rear and flush fluid
Refit all the now repainted things I removed earlier
Get tyres swapped onto TD wheels
Get tracking done
Give it a really good clean

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61k miles Ph.1 Diablo '6 Project Thread
Posted 18th May 2015 at 21:56
RetroPug

Seasoned Pro

Location: Leicestershire

Registered: 15 Jan 2013

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Post #155
Progress has been slow, not got much time and I keep being supplied with faulty or incorrect items which slows everything down.

I did get my cat repaired though, and made into a sleeve joint with the centre-section modified to match. It should now seal very well.



Tried refitting it and my cheap fitting kit bolts turned to cheese 75% of the way through. Fire ring is stuck on the manifold as well which is annoying. New kit ordered.

All that's really left to do is brakes but I'm waiting for exchanged bits plus I really hate doing brakes for some reason.

Does anyone know how much the cat should be able to move when the fitting bolts are tight? Mine could still pivot up and down with the crap bolts mostly tightened but I'm not sure they were holding it properly.

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61k miles Ph.1 Diablo '6 Project Thread
Posted 27th May 2015 at 20:49
RetroPug

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Post #156
Had yet more incorrect parts turn up which is getting really old now, so that slowed progress somewhat.

Yesterday me and a friend fit braided lines at the rear, and redid the hard lines from the caliper to the flexi in copper pipe as the unions weren't floating on them and they just twisted as they were being undone, plus they were a bit corroded anyway. I did tidy it up a bit after taking this picture:



Braided lines will also go on the front but will probably have to re-do some more hard-line there are the unions are similarly shagged there.

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61k miles Ph.1 Diablo '6 Project Thread
Posted 8th Jun 2015 at 18:05
RetroPug

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Location: Leicestershire

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Post #157


Spent most of the weekend this weekend getting it to the stage of being on the floor in one piece and running, which is a great milestone! Did so much and can't remember it all but off the top of my head refit repaired cat so exhaust sounds good now and not drony, new discs and pads all round, new hardlines to rear calipers, repaired unions on hardlines on front calipers, new braided hoses all round, new pressed plates, replacement roof gutter trims courtesy of piggy, etc. etc. Of course this is in addition to all the other things that have been being put on as previously mentioned in this thread such as Koni Yellow adjustablesall around all brand new, brand new Eibach Pro Kit springs, Team Dynamcs Pro Race 3s, new droplinks, new TREs etc. etc.

Took it for a drive yesterday evening and the exhaust is hitting the tunnel quite violently so it'll need to go back up in the air to relocate that and have a tinker. That was a loud knocking so it was difficult to tell if it obscured other knocks but suspension-wise it certainly seemed not to be knocking nor clunking etc. which is great news. It is EXTREMELY stiff. Quite a harsh ride over bumps at slowish speeds but the ride gets better as you speed up a bit, VERY planted in corners with very little body roll. Steering is also nice and tight with new TREs. I imagine this will handle quite nicely on track which I'll have to see about soon! I'm wondering whether the ride might get a little more compliant once the dampers and springs have had a few miles put on them. Very happy with the ride height, slightly lower but not silly-low.

Still lots of things I want to fix and tidy up and play with but overall I'm very, very happy!

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61k miles Ph.1 Diablo '6 Project Thread
Posted 15th Jun 2015 at 18:41
RetroPug

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Post #158
This is now a joy to drive. Had a new ball joint on both sides and mounted the radiator more securely which got rid of the knocking. Just needs tracking as I just did it as best I could by eye, tracking will get done at work this week. It vibrates at high speeds. Felt like the cornering was bad as I couldn't feel anything dramatic happening...then I looked at the speedo and realised it was taking corners at speed without even breaking a sweat.

I fit a K&N cone for bwarps and also made a shield to stop muck swirling up from the road straight onto the filter, it will also guard against splashes. At some point I might make one that encloses the filter a bit more.





There's still a fair few things to do and sort out on this car, but it's definitely heading in the right direction and is great for just enjoying for the rest of the summer. Once the winter comes the next round of fixing and fettling will begin!

Bring on Pugfest. Big grin

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61k miles Ph.1 Diablo '6 Project Thread
Posted 29th Jun 2015 at 23:21
RetroPug

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Post #159
Sad



Could not have happened at a worse time, MOT due and got one weekend at Pugfest and then going away for 2 weeks, so basically unlikely to be able to repair it before it is then illegal to drive which is going to make repairing it even more of a ballache.

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61k miles Ph.1 Diablo '6 Project Thread
Posted 8th Jul 2015 at 22:36
Cjwatson27

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Location: Oxford

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Post #160
Save the money and spend on a decent weld job ive been into minis since I was 17 and it pays in the long run

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Old pugs don't die they just get faster
Posted 8th Jul 2015 at 23:50
RetroPug

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Post #161
Yeah I'll definitely be shelling out for a quality repair. If I wanted it attacked with an angle grinder and bird-s**tted back together with random offcuts I could get a cheap welder and a bottle and have a go myself. Laugh my ass off:

The other side is also crusty but not as bad so I'll get both done.

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61k miles Ph.1 Diablo '6 Project Thread
Posted 9th Jul 2015 at 12:40
RetroPug

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Post #162
Well, I haven't had it welded yet due to work being busy and me being abrood on holiday visiting the gf's family for a bit.

This weekend I set about doing the most essential work when your car has no MOT and needs repairing before it goes: cosmetic modifications. Big grin

I started out with these, which were a bit grubby, especially near the driver's and passenger's buckles where people have grabbed them with their grimy hands:





So, I soaked them in warm water with some laundry soap mixed in:



The water which remained after this was a bit horrible. Not very nice to think that these rub against our chests all day:



After this, they looked a fair bit cleaner but there were still some stains and they still weren't as bright as they could have been, so I blasted over them with the pressure washer from a safe enough distance not to cause damage. This created a night and day difference between how they were previously and the colour has pretty much come out bright, primary colour red, as they were when new:







I then pulled the rear half of the interior out of the car in order to swap them over. Had a bit of confusion as the rear belts were labelled for the opposite sides of the car and wouldn't extend which took a bit of headscratching!





They break up the all black of the interior quite well, and match the outside of the car. I'm very happy with them.

Last weekend I also started work on a set of morettes. I sanded off all the paint, then fillered all the imperfections, then sanded again with various grades, and painted them diablo red. The paintjob has turned out fairly well for a rattle can job. Trying to decide whether to fit them, get new inside lights for them, fit them with trumpets etc. I do have inside lamps but they're corroded and I haven't been able to get them to work yet. The outers work with sidelights, dipped and main beams.

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61k miles Ph.1 Diablo '6 Project Thread
Posted 9th Aug 2015 at 15:11
RetroPug

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Post #163
Welder didn't turn up yesterday, did change the aux belt and top up brake fluid while waiting for him though.
Should be getting welded next weekend now.

Very frustrating as I just want to drive it.

Also, when reconnecting the battery on Friday it was evident that the terminals are so old that they've become cheese so will have to replace those as they no longer clamp down properly.

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61k miles Ph.1 Diablo '6 Project Thread
Posted 6th Sep 2015 at 10:46
RetroPug

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Post #164
Shiny new battery terminals fitted:



The car was washed and waxed as it has been sat for a while and I'd like it to be clean for the MOT. Unfortunately the lens was foggy.



The contents of the wheel arches look rather nice. Shame the faces of the discs have some surface corrosion on them but a good hoon will sort that out in no time.

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61k miles Ph.1 Diablo '6 Project Thread
Posted 6th Sep 2015 at 21:33
RetroPug

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Post #165
Well after being f**ked around loads it's finally repaired and it went off for its MOT. Failed on a bulb which I somehow missed when checking, wipers which I didn't agree with but replaced anyway, and randomly during the MOT the airbag warning light came on and reconnecting the under seat connector does not make it go out.

Thoroughly annoyed with this now and it feels like I'll never drive it.

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61k miles Ph.1 Diablo '6 Project Thread
Posted 18th Sep 2015 at 16:52
RetroPug

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Post #166


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61k miles Ph.1 Diablo '6 Project Thread
Posted 20th Sep 2015 at 18:11
99rallye

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Post #167
Great tripoding shot! Car looks great
Posted 20th Sep 2015 at 21:50
99rallye

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Post #168
P.s. what size steering wheel did you go for and can you still reach the indicator etc?
Posted 20th Sep 2015 at 21:57
RetroPug

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Post #169
Thanks!
It's 13" with a 3" dish.

I'm still struggling to make the airbag light go out. I'm going to try soldering the wires under the seats together unless I find some nice electrical connectors from the local factors if I get out of work on time tomorrow. The connectors themselves have been reconnected firmly and the seats are tipped up so I have access to underneath.

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61k miles Ph.1 Diablo '6 Project Thread
Posted 21st Sep 2015 at 19:26
RetroPug

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Post #170
I re-insured and taxed this at the end of January, and have been driving it a bit. It goes really well. I've got a few more updates planned soon I hope.

Before taxing and re-insuring I swapped engine looms to see if that was causing my rev-counter issues but this had no effect. Whilst I was there I did the usual painting up of the inlet manifold & fuel rail, and also painted the slam panel and tow-hook whilst I had the front bumper off looking at the loom along there, which I now suspect to be the problem as it looks like it has a fair bit of heatshrink on a lot of the wires.

I had one side welded but a small hole has appeared on the other side of the car behind the front wheel arch where they all go. I will be attempting to repair this myself as I'm not convinced by the previous repair on the other side. There's also a bit of surface rust elsewhere that I'd like to grind down and treat, hopefully that will be sufficient.

Anyway, right after getting it on the road the bonnet release cable snapped. With a friend at work we managed to fit a new, genuine one. It appears that the ph.1 cable has been superceded by a new part number which replaces both halves of the cable but doesn't include the necessary clip for the slam panel s we had to do a bit of bodgery at the end to get it to work correctly.

No pictures really as my phone camera has totally given up and I'm certainly not allowed to take any at work either. New phone soon so pictures should be following in future updates.

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61k miles Ph.1 Diablo '6 Project Thread
Posted 11th Feb 2016 at 12:56
306 lover ryan

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Location: horley

Registered: 30 Dec 2015

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Post #171
I hope you haven't finished this thread yet. I'm so in love with your car!

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Platinum gti 6 now the daily driver...1 problem so far...fuel economy!
Posted 13th Feb 2016 at 06:08
RetroPug

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Post #172
Definitely not finished, just working every hour of every day at the moment.
Thanks for the kind comments.

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61k miles Ph.1 Diablo '6 Project Thread
Posted 20th Feb 2016 at 22:18
RetroPug

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Post #173
I picked up a set of S16 headlamps with yellow tints from John on here to restore. My headlamps horde now includes the fully restored set of ph.1 twin optics which are fitted, a mostly restored set of morettes, an unrestored, tatty set of morettes and now these.

They needed a bit of attention as the pictures show, but then that's the fun of restoring things!







I pulled them to bits, including removing the yellow-tinted filters inside them. Unfortunately, the chrome of the lenses looks like it might be tricky to save.





The yellow filters that were inside the lenses had lost a lot of their yellow colour, which tends to be the problem with these lights:



I then began re-colouring them:



The "re-coloured" photo is after one coating. I'll be applying more coats which should get them looking very yellow as they originally would have. At the moment I'm unsure whether or not to try to save the pitted and damaged chrome lenses or whether to try to fit these yellow filters into my normal ph.1 twin optic lights, which don't have the tabs to clip these in.

I also fitted a strut brace which I don't have any pictures of right now.

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61k miles Ph.1 Diablo '6 Project Thread
Posted 28th Feb 2016 at 19:33
Day666

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Location: Bristol

Registered: 20 Apr 2013

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Post #174
Love this car Luke ...keep up the good work m8 & keep the updates coming & pics Thumbs up
Posted 28th Feb 2016 at 19:39
RetroPug

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Location: Leicestershire

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Post #175
Thanks! Just doing another yellow coating now.
Any chance of a passenger ride in yours at pugfest? Big grin

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61k miles Ph.1 Diablo '6 Project Thread
Posted 29th Feb 2016 at 19:16

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