Another month passed, I guess I better put something on here ha
A small list of jobs were attacked last week as I managed to book a few days off work.
Not necessarily in order as I was flicking between tasks due to losing my **** on numerous occasions.
Coolant drained again to fit new temp sensor housing and hose.
Whilst I was working in the area I also removed the gear shifter cable mounting bracket for modification as it was basically touching my fat Badger 5 TIP and envisaged it's destroying it in no time with engine movement.
Out with the grinder and a tickle with some satin black paint and ive now got plenty if clearance and also looks a bit prettier.
Up to the other end of the car to get this rear beam on and the brakes built up.
As previously mentioned i was going to be fitting 280mm rear discs and no surprise that I was met with obstacles along the way.
1. My brand new splash guards needing cutting to allow the carrier bracket to fit.
The photos don't actually show how much was required as I revisited them with the trusty grinder 3 times after making that initial chalk line.
I'll get another pic on Monday.
2. The standard LCR rear carriers don't fit as you can see they're pushed up hard against the discs so useless.
I can only assume these brackets are to be used with 4WD rear carriers which are straighter and don't kink outwards like the 2WD version.
According to Creation Motorsport they're definitely 2WD but my install proves otherwise.
Oh well I've got some AUDI S3 8L rear carriers on route now to resolve this...quite frustrating really considering I sold a nice pair a few weeks ago.
Incorrect female unions which don't allow the use of the stock bracket C-clips.
No way of feeding them through the rear beam locating brackets as both end unions are too big.
Loads of pointless rubber grommets?
Stock rear beam hose clips are too small to accept hoses and supplied ones are impossible to attach.
After lengthy discussions with the guy that made them I should expect another pair in the post this week.
I've requested 2 piece hoses instead of the supplied 1 piece as shown in my drawing.
Ok enough of the kneeling beside the car stressing out for one week, time to climb inside and get stressed in there instead albeit with cleaner hands.
Three of the multiple boxes of electrical goodies ive amassed whilst its sat dormant.
1. Genuine VW one touch indicator relay kit
2 Genuine VW cruise control stalk and Kufatec retrofit looms.
3. Infiniti heat shot heated washer jet kit.
The indicator relay kit was pretty straight forward to install as it came with fairly comprehensive instructions although I did have to re-juggle a few pin outs on the existing hazard light connector plug as they differed slightly to the mk4 Golf & Passat it was designed for.
The cruise control kit was a lot harder than I anticipated thats for sure.
I've done them on several TDIs in the past which are an absolute doddle but as the petrol variants use a second piece of loom to the ECU it opens up an entirely different can of worms which when you add to the fact none of the labeling tallied up to the instructions or anything I could find online I quickly found myself in bother.
After many hours scratching my head of what remaining hair I have left and a series of continuity tests with my shiny new multimeter I think I may have sussed it - fingers crossed
Most of the loom along the scuttle to the ECU needed to be unwrapped to accommodate the extra wiring plus whilst I was in the thick if it i finally got around to running a feed from the MAP sensor pin out on the ECU to the green plug on my custom colourMFA cluster so I now gave an accurate and fully functional dash integrated boost gauge.
A few more pieces thrown on this week and yet more issues with parts not fitting.
Another set of custom rear brake lines were acquired, this time in two pieces and were a huge improvement over the first one piece set I had sent out.
3 hoses were spot on but oddly I couldn't get the short piece to fit between the chassis and rear beam on the offside.
After much head scratching and measuring and asking on one of the FB groups I came to the conclusion that my hose bracket had clearly been bent whilst at the powdercoaters resulting in measurements now been out FFS!
OK back onto Wezmoto for help one again who i must say have been fantastic and even sent me out another longer length hose to accommodate my needs free of charge.
Replacement hose worked a treat, P-clips were added to the rear beam to secure the hoses along with 5mm starlock washers as the original white plastic clips were now redundant.
Brake calipers and carriers were fully stripped down and repainted in high temp caliper paint...twice as the first product I used was utter crap (Foliatec brush on)
I ended up paint stripping them all again and spraying them like I knew I should have done to start with.
I'm now running Audi S3 8L 4WD carriers as they allow the correct disc offset when using the 280mm rear disc adapters.
I've also added a new pair of caliper handbrake lever return springs.
I think may have just found out why my idle was a bit high and occasionally lumpy.
Also why I was getting a sucking noise from behind the engine when I shut the engine off.
After spending about 2 hours pulling parts back out of the engine bay and ripping my knuckles to pieces it would appear the rubber seal that goes between the brake master cylinder and servo has gone walkies.
I can only assume it went missing when I swapped it over from the donor car, seriously what a horrible job and I'm dreading the refitting of it.
I think it took about 15 minutes when the engine was out of the way.
Also to add insult to injury I managed to snap a fuel line push on fitting.
Fortunately I had a spare pair of fuel hoses on the shelf but the rubber is quite perished so I've just ordered 1m of nylon braided fuel to make some new lines up instead using the fittings from these old lines.
Top work on the recent upgrades. Sounds challenging that the suppliers can't get the brake lines right. For a very brief moment before I read the text I thought you had it all together rolling again until I read the text of the new car. What's the plan for it? if its a breaker I would be interested in the wheels.