Been cracking on with this again.
Dug out a PeteG40 lightened flywheel I've had for years. Comparison with stock one:
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.
Engine off the stand for the first time in over a year!
Clutch and flywheel on:
Gearbox bolted on:
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, wiring and lights still to do.
Out in the sun again:
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.
Making some radiator brackets out of ally.
Marking up where to bend the strip.
Lower rad brackets before I trimmed them with some rubber strip from my random box of useful shit.
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. 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.