Club G40 Forum

Club G40 => Photos and videos => Ongoing Projects => Topic started by: Andy on February 25, 2012, 09:19:35 pm

Title: Turbo Squareback - History & Rebuild Thread
Post by: Andy on February 25, 2012, 09:19:35 pm
My Polo history started in 1999 when I'd learnt to drive in this, back when 6Ns were a bit too new to be rusty with knackered gearboxes…

(http://img.photobucket.com/albums/v467/amstrange1/outside.jpg)

…but it wasn’t my car, and once I’d passed my test at 18 sharing a car with your Mum is NOT cool. I’d been looking for a Mk2 breadvan, but the local ones were all 1 litre; expensive; knackered; or all three. Whilst on holiday on the Isle of Wight the old man spotted a Mk3 1.3CL in the classifieds bit of the local paper – part-ex to clear at a Shitroen dealer.

Looked like this once I’d added a set of 13”x6” BBS RAs and fitted a Mk2 Golf CL front splitter:

(http://img.photobucket.com/albums/v467/amstrange1/CNV00007.jpg)

It stayed that way for a while, ‘til I got bored of the 55 lame horses and threw a Polo GT (3F) injection system on it in the mistaken belief that it’d turn it into a fast car. It didn’t. With my first year at uni to deal with I had some serious liver-bashing to do, so didn’t worry about the Polo too much ‘til I got a summer job.

With a bit of cash in my pocket from the job, it was time for a G40 conversion:

(http://img.photobucket.com/albums/v467/amstrange1/engineswapmess.jpg)

Yoof (when he really was a Yoof) giving me a helping hand:

(http://img.photobucket.com/albums/v467/amstrange1/yoofonhoist.jpg)

It stayed that way for a while, ‘til I put a chip and pulley on it at a rolling road day and melted a piston on the way home. Eventually it got a 1341cc rebuild done at PSD. I bought lots of goodies along the way, and played with nitrous on a 3F lump whilst the PY was being rebuilt. Once the PY was done, we whacked a 100bhp shot of gas on the 3F as a last hurrah and melted the rings to the pistons - then drove it home.

The destruction continued – the PY lump killed numerous gearboxes, including diffs...

(http://img.photobucket.com/albums/v467/amstrange1/Image93.jpg)

....and 5th gear sets...

(http://img.photobucket.com/albums/v467/amstrange1/Image367.jpg)

...so in my final year at uni I bought a Mk2 Coupe S that was cheaper than a replacement G40 'box. Got fed up with the lack of power quickly, so flogged it and bought a G40 ‘box. The sills were fibreglass anyway!

(http://img.photobucket.com/albums/v467/amstrange1/IMG0071.jpg)

Drove it to Belgium for VW Mania 2005:

(http://img.photobucket.com/albums/v467/amstrange1/GMedium.jpg)

Video of it chasing a Boxster S (38m:42s) abroad here - unfortunately the camera car only had an AFH in it so couldn't keep up:
http://video.google.com/videoplay?docid=8227698405759365404 (http://video.google.com/videoplay?docid=8227698405759365404)

Experimented with 'alternative' fuels:

(http://img.photobucket.com/albums/v467/amstrange1/DSCF0049.jpg)

And generally all was good. I then got my first job after graduating in summer 2005, and started adding more and more tuning goodies to the G40'd motor. This meant lots of grunt, but peak power at high rpm. The lader used to get frequent rebuilds, and it was during one of these that this happened:

(http://img.photobucket.com/albums/v467/amstrange1/P9260161.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/P9260160.jpg)

A slut lader was built with a scroll that consisted mainly of JB weld, but it made shit boost and I decided to look elsewhere for power. So at the end of 2006 in the back garden I started a K03 turbo conversion.

(http://img.photobucket.com/albums/v467/amstrange1/P1140228.jpg)

At the time it'd become a popular conversion in Germany, but no-one else had used a K03 in the UK. Rumour suggested that Jabbasport had tried it some years previous, and had declared it a crock of shit. However, John Marchant was putting one on his long-term Mk1 G40 turbo project and Steve Pitt of Pitstop Developments was interested in developing a G40 turbo kit using his ‘tin-can’ G40, mine and John’s cars. Spurred on by the turbo'ing success of Mark Hunter several years previous and others giving it a go, I bought a cheapo K03 and got stuck in.

(http://img.photobucket.com/albums/v467/amstrange1/561697013_8e610bdbf4_o.jpg)

By now everyone knows you have to fit a 6psi boost switch and Newman 'turbo' cam to get a K03 running nicely - but back then that was new ground. I got the car driving with a PY camshaft and it was crap, so switched to a 3F item used by the Germans as a poor man's turbo cam. It too was crap.

However, t'internet suggested that ze Germans were using Schrick 268° cams intended for the Polo GT to good effect with the K03. After a chat with Steve Pitt, he’d found the same with the 3F cam – so by the time I drove the car down for mapping he’d had a couple of Newman cams made up. One went in John’s car, the other in mine.

With it mapped and running 15psi of boost it was time to hit the strip again:

(http://img.photobucket.com/albums/v467/amstrange1/th_Andy.jpg) (http://smg.photobucket.com/albums/v467/amstrange1/?action=view&current=Andy.mp4)

Had a go at Shakespeare County as well as the Pod:

(http://img.photobucket.com/albums/v467/amstrange1/1795162138_c40a797769_o.jpg)

The best I managed was a 14.0s at 99mph. With Duncan (another Pod regular with a G60’d G40) also hitting 14.0s I decided to up my game – more boost was required, which seemed like a good excuse to bolt on an Emerald ECU as I didn’t have Digifant mapping gear at the time:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_0421.jpg)

Miraculously, it started first time:

(http://img.photobucket.com/albums/v467/amstrange1/th_f634e9e6.jpg) (http://smg.photobucket.com/albums/v467/amstrange1/?action=view&current=f634e9e6.mp4)

That takes it up to the beginning of 2008, where other things started to get in the way of pissing around with Polos. It stayed on the road over the next few years (just!) and got used whenever I could – had an outing to the Pod where I managed a 13.6s 1/4 mile in 2010, only a couple of years late! (Pic shows it at the Pod in 2011, but it's got tyre smoke in it so looks cooler...)

(http://img.photobucket.com/albums/v467/amstrange1/6137325355_671339e2fe_b.jpg)

Two changes of job and two house moves later it was time to prepare to give it some loving! New gaff came with a decent garage – this pic was after gallons of weedkiller and some serious mowing of weeds:

(http://img.photobucket.com/albums/v467/amstrange1/garage2.jpg)

This is what 17 tonnes of gravel looks like:

(http://img.photobucket.com/albums/v467/amstrange1/garage4.jpg)

BTW – gravel is shite for driveways, but it is cheap and tidied things up nicely to keep the missus happy:

(http://img.photobucket.com/albums/v467/amstrange1/garage6.jpg)

So time to get inside the garage, and turn this:

(http://img.photobucket.com/albums/v467/amstrange1/inside_garage_1.jpg)

…into this:

(http://img.photobucket.com/albums/v467/amstrange1/inside_garage_2.jpg)

Got distracted by the 2011 CP RR day:

(http://img.photobucket.com/albums/v467/amstrange1/GEX_20110129.jpg)

And by the 2011 CP trackday:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_3683.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/_MG_3405Small.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on February 25, 2012, 09:33:32 pm
So with the car approaching its 20th birthday, and duties as wedding car looming, it was time for a refresh. It's hopefully going to get painted throughout March, so I've been getting stuck in stripping it down ready.

Crusty battery tray:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_4782.jpg)

Pulling the temporary unwrapped (it's been in there 4 years!) wiring loom out:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_4785.jpg)

Cooling packs removed:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_4985.jpg)

Looms, ECU and other odds n sods removed:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_4989.jpg)

Pulling the interior out:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_4995.jpg)

Unbolting dash:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_4994.jpg)

Motor out:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_4996.jpg)

Another shot of the crusty battery tray:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5000.jpg)

Engine on a stand ready for a tidy-up and check over:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5014.jpg)

Also been doing some R&D for PPP. An ever-growing ARB collection:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_4998.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: cheys03 on February 25, 2012, 10:33:44 pm
Superb thread!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Etches on February 25, 2012, 10:48:52 pm
Cracking andy! I've been looking forward to seeing a progression thread of your sleeper for ages. An awesome motor!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on February 26, 2012, 01:39:23 pm
I've got a fair few of the older pics from this on the old PC upstairs. Another of the originals - great to see it's still going strong(er than ever)! 8)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Jezza-7 on February 27, 2012, 08:17:34 pm
Good read this is. When i got more battery i will watch the entire video you put on.

2 things though, your garage does not look like that anymore lol! And the other im sure that wiring still looks the same  ;)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on March 04, 2012, 07:43:05 pm
Made quite a lot of progress today, so it's not far off being thrown on a trailer and taken for welding and paint now!

I've got loads of rusty fittings and brackets to clean up - going to give this technique a go: http://www.rickswoodshopcreations.com/Miscellaneous/Rust_Removal.htm (http://www.rickswoodshopcreations.com/Miscellaneous/Rust_Removal.htm). Some of the fellow car bodgers at work have been using it successfully, so I'll post up once I get setup and will report on results.

Had a helper - Yoof tearing the dash out:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5030.jpg)

Done, wiring tied back out the way for access to weld up the battery tray:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5057.jpg)

Rest of the front end removed, along with lots of odds n sods like oil cooler; exhaust; cables etc:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5028.jpg)

Also threw on a pair of old steelies on the front so that the Compos don't end up metallic mint! Still need a couple of old wheels to chuck on the rear, will have to see what I can beg/steal/borrow as all my spares have ended up on other people's cars.

Removed rear bumper and lights, no major horrors uncovered:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5018.jpg)

Spent ages stripping down the tailgate, including removing all the harnessing and washer hose from it. De-pinned the vehicle harness end of the rear wiper motor harness to facilitate threading it all through the tiny holes in the tailgate. A few crusty bits, but on the whole not too bad for 20 years old:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5027.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5022.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5020.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5019.jpg)

Tore all the badges, numberplate etc. off the tailgate leaving it naked. There's a really significant difference between the exposed paint that's faded and the stuff that's been protected by trim etc. but this photo doesn't really show it too well.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5059.jpg)

Took all the door cards off and removed the back seats for cleaning. Removing the driver's side rear door card enables you to see the pipe of doom. Remarkably mine's pretty solid!
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5045.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5046.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5047.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: MartinB on March 04, 2012, 09:25:27 pm
One of my favourite breadvans. Top work!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on March 10, 2012, 02:04:01 pm
Minor update, just the carpet to get out and the door mirrors to remove and it's ready to go to the bodyshop.

Took the rubbing strips off both sides, managed to get the fixings off pretty much complete so at least they're re-usable.

(http://img.photobucket.com/albums/v467/amstrange1/IMG_0346.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_0349.jpg)

Removed the wheel arch liners (no pics as my hands were minging), but thanks to several ripped CV boots; oil leaks and my pikey inner arch oil breather vent the fixings were all mint and came out really easily.

With them out the way I removed the aerial. I think this will be staying - often thought I'd get it smoothed and fit a beesting, but I think the comedy telescopic item adds to the sleeper effect.

(http://img.photobucket.com/albums/v467/amstrange1/IMG_0350.jpg)

Pulled off the remaining bits that I'm removing under bonnet - am leaving the brakes and steering rack fitted so we can get the car up my drive and onto the trailer easily. Fuel lines are plugged up and tied out the way, servo has a cork in it and spent ages removing all the random little clips lying around.

(http://img.photobucket.com/albums/v467/amstrange1/IMG_0351.jpg)

Bonnet catch off:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_0352.jpg)

VIN plate removed:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_0355.jpg)

There's a few more bits of car AIDs I found under the bonnet. They passed the screwdriver stabbing test, so hopefully it'll be reet.

(http://img.photobucket.com/albums/v467/amstrange1/IMG_0353.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_0354.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: ereeiz on March 14, 2012, 12:58:06 am
Why not hire a skip and electrolysis the car too :D That'll sort the rust spots!

Loving "the pipe of doom" I burst out laughing and got some odd looks off the other guy at work.

Looking good, I should do something about sorting mine really, got a mate coming to do some work on it this week so I may *finally* get that subframe on. I'm still a few years away from getting to the rebuild stage you're at. If only I had a garage!

Keep up the good work!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on March 16, 2012, 08:33:03 pm
Pulled the remaining bits of interior out, shoved it up the drive and winched it onto the trailer. It's now with the bodyshop - thanks to Yoof for trailering and driver duties!

(http://img.photobucket.com/albums/v467/amstrange1/422058_10151401037450191_506380190_23418633_258544203_n.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on March 23, 2012, 10:34:33 pm
So, the I love paint session begins!

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5081.jpg)

Bit of a hole near the strut. Fortunately patchable rather than needing anything too drastic.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5082.jpg)

Seam sealer stripped back for stitch welding the chassis legs.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5083.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5084.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5087.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5088.jpg)

Rot behind the servo was a bit worse than anticipated:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5085.jpg)

Battery tray rot looks pretty bad, but it's saveable. Luckily with the dash and carpet etc. out it's not too bad a job to do.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5086.jpg)

Bit of grot around the rear window surround, also saveable without too much work.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5090.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5091.jpg)

Filling and smoothing has started...
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5089.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5092.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5093.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5094.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on March 24, 2012, 01:19:45 am
I recognise that workshop!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on April 01, 2012, 09:41:48 am
Nothing too exciting to see, but all of the rusty bits have been identified with no nasty surprises. Most of them have now been treated, and will be welded up next week. All the little dings down each side have been filled and smoothed. Should be welded up and ready for primer next time I see it. If all goes to plan I'll have it back in 2 weeks.

Rear window crust now treated, and almost ready for welding:

(http://img.photobucket.com/albums/v467/amstrange1/aa0c65a6.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/9bd4b5b1.jpg)

Few shots of other treated rusty bits:

(http://img.photobucket.com/albums/v467/amstrange1/e9a919b7.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/b60db5b1.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/f615c723.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on April 12, 2012, 08:38:38 pm
Quote from: Andy on April 01, 2012, 09:41:48 am
Should be welded up and ready for primer next time I see it. If all goes to plan I'll have it back in 2 weeks.
Famous last words! Supposed I tempted fate by collecting the trailer last weekend...

Not really any further forward, except I need to source a new tailgate as this one's too far gone apparently. No pics as they'd locked up when I turned up to view progress as arranged.  :(

Might be needing to insure that Coupe S to ensure I've got a Polo wedding car for June!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on April 21, 2012, 05:10:01 pm
Progress! Mint tailgate sourced - £65 seemed cheap compared to nearly £300 that VW wanted...
(http://img.photobucket.com/albums/v467/amstrange1/bd1f098e.jpg)

Masked up and had its first blow over of primer:
(http://img.photobucket.com/albums/v467/amstrange1/2b558956.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/f2a49d70.jpg)

Next week it should be fully rubbed down and in primer ready for top coat.

Have been spending far too much time on t'internet trying to source little odds n sods for the rebuild. Am a bit shocked by how much is obsolete these days, 'til I remind myself this is a 20 year old car. Anyway, some fairly hefty orders are going into TPS and VW Heritage this week while I crack on clearing out the garage ready for the car's return.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: PeteG40 on April 22, 2012, 12:39:01 pm
nice one!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: cheys03 on April 22, 2012, 03:09:32 pm
Looking good there! Keep us updated :)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on May 01, 2012, 09:17:57 pm
Feeling very poor having just spent a fortune with VW/TPS and VW Heritage. Still waiting for the bits to arrive, and even then I've not been able to get everything I wanted!

New tailgate seal came from eBay:
(http://img.photobucket.com/albums/v467/amstrange1/c998b0d0.jpg)

Was supposed to be genuine VW, but it's about as genuine as the stuff you get from GSF these days... Anyway, the seal is the right profile and length, so it'll do!

Odds n sods
Time for another lambda boss in the downpipe. Unfortunately it's warped during welding, so waiting for an M18x1.5 tap and 16.5mm drill bit to arrive to sort it. Can't complain, a mate welded it for nowt.
(http://img.photobucket.com/albums/v467/amstrange1/8bb54aa6.jpg)

Have never been happy with the old probe location as a probe there always seemed to read 0.5-1.0 AFR richer than at tailpipe. Meant for trouble come MOT time, so will see if this sorts it or whether it's a leak in the ancient Tube Torque pikey exhaust. Ultimately not too arsed as I'll be getting a custom downpipe made once it's back on the road to mate up to a shiny new PPP system I've got.

Cleaned the gearbox up with alloy wheel cleaner - before and after:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5153Medium.jpg)
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5154Medium.jpg)

Cleaned up the water pipe from the back of the block and painted it in stove enamel (I knew there was a reason we paid a fortune to have a fancy wood burner fitted - free paint!):
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5155Medium.jpg)

Decided to get a load of bits powder-coated though, and threw this in with them. Should've been ready today, but have to wait to the end of the week.

Electrolysis for de-rusting
Promised to post some info on the electrolysis process to de-rust stuff. This is my setup:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5156Medium.jpg)

Basically a big bucket filled with water and soda crystals. Then a sacrificial anode is added and connected to the positive of a power supply. I used an old steel baking tray for the anode which needs regular cleaning off with a grinder, but stainless steel works even better - though I think it makes the water a bit more toxic at the end.

You then insert the item to be derusted as the cathode and connect it to the negative supply. In my case I wired the rusty items up, wrapped the wire around the block of wood, and clipped on my negative supply lead.

I measured the current from the power supply, and found moving the parts closer together to get a current of approx 1.5A @ 14V worked well - otherwise you're waiting for hours and hours. Makes lots of pretty coloured scummy bubbles, but gets the rust off.

If you've got utterly fucked parts, this won't save them as it can't magic metal back that's no longer there! But it will save hours with files/wet n dry etc. trying to clean mildly manky stuff up. Might need to repeat it a few times with scraping down inbetween to remove the scabby bits, but worked well. Sadly no pics, as I forgot before dropping things off for powder coating!

Bodyshop update
And finally some more progress from the bodyshop. Was hoping to have it back this weekend, but I think that's unlikely now - should hopefully be in a final coat of primer when I see it on Friday again though!

First up, the 'Yoof' chassis leg re-inforcement:
(http://img.photobucket.com/albums/v467/amstrange1/536143_280322258726696_100002467710649_593811_1339724540_n.jpg)

Secondly, the VW repair manual re-inforcement plates on the inner wings - can't hurt, and made sense while it was in bits:
(http://img.photobucket.com/albums/v467/amstrange1/380706_280324852059770_100002467710649_593816_794773294_n.jpg)

And finally, some stitch welding:
(http://img.photobucket.com/albums/v467/amstrange1/156105_280323042059951_100002467710649_593813_840698173_n.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on May 05, 2012, 08:24:01 am
Few more pics from this Friday's trip to the bodyshop. Should be done by middle of next week! Pics of it in primer to follow.

Weld and filler, final bits of rust are fucked off:

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5169Medium.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5168Medium.jpg)

Some higher resolution pics of the stitch welding and battery tray repairs, still in the process of being tidied up ready for primer. Metal used is plenty thick enough, so hopefully that battery tray will last at least another 20 years before deciding to rust to bits again!

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5159Medium.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5160Medium.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5161Medium.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5162Medium.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5170Medium.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5171Medium.jpg)


The only brand new panel that I bought, and although it's not rusty, it's dented to buggery. Not initially apparent from the satin primer, but looks like warehouse staff or the couriers have played football with it. Still, it'll only require very very minimal filling, but it's still annoying! The secondhand tailgate I bought is utterly mint though and ding free.

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5164Medium.jpg)

Got some bits done by ASAP powder coating and blasting in Coventry. Turnaround was just over a week and was £60 for a big box full of brackets and things.

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5173Medium.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5174Medium.jpg)

Sorted the lambda boss too. Time for the big shag drill bit and tap. Considering the bung that'd seized in there wouldn't shift I was expecting to be unable to resurrect the threads, but came out okay.

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5177Medium.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5179Medium.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: cheys03 on May 05, 2012, 10:34:56 am
Great work Andy, really is steaming along
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: breadman on May 06, 2012, 10:35:47 pm
Coming along nicely Andy. :)
What did you use to remove the factory wax from under the bonnet in preperation for paint?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on May 07, 2012, 07:51:54 am
Seam sealer was scraped off with a sharp tool and heatgun - bodyshop did it uber quickly!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: djtez on May 07, 2012, 10:47:48 am
Is this all going original colour again andy ?

Really liking the work done here.!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on May 07, 2012, 11:58:45 am
Yep, metallic mint again! Should look like a different colour given how much it's faded.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: djtez on May 07, 2012, 12:15:03 pm
Awesomes!

should be a really strong shell.. like all the updated welds ..

The end results should be fantastic, keep up the good work the progress is brilliant
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: breadman on May 07, 2012, 07:53:20 pm
Quote from: Andy on May 07, 2012, 07:51:54 am
Seam sealer was scraped off with a sharp tool and heatgun - bodyshop did it uber quickly!

I did mean the factory wax as opposed to the seam sealer - that's fairly easy.
When originally applied the wax was sort of translucent but it normally ends up black as it attracts the dirt due to being slightly sticky. Can it be dissolved/washed off with thinners etc?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on May 07, 2012, 09:14:38 pm
What factory wax?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: cheys03 on May 07, 2012, 10:14:54 pm
That explains the battery tray!
In some spots around the engine bay there's some translucent-yellowish wax knocking about. At least in mine and the gf's bready. Personally only ever really noticed it around the alternator/engine mount and battery tray area. Before I knew what it was I cleaned some off with petrol.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on May 07, 2012, 10:33:05 pm
An F-reg Coupe S I had was covered in waxoyl type stuff under the bonnet, but the C-reg one I recently had didn't seem to have it anywhere.

Mine's never had paint in the engine bay before, and I'm not really one for cleaning stuff - so I assume a previous owner cleaned it off (12 years ago!) or that it never had it?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: djtez on May 07, 2012, 10:58:14 pm
couple of my coupes have and the others have not..
and one of the have not's was a 1.0 shell, and i doubt the previous owners would bother cleaning it off..

strange.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on May 08, 2012, 08:24:26 pm
In primer!

(http://img.photobucket.com/albums/v467/amstrange1/6007f16a.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: cheys03 on May 08, 2012, 08:55:03 pm
Missed a bit.....

<runs away> ! :D
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on May 08, 2012, 08:57:56 pm
Haha! :D Primer's only gone on where it's been filled/derusted, hoping to have some pics of it in colour within the next couple of days.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: randombadger69 on May 08, 2012, 11:15:00 pm
Looking good. Paint does wonders for motivation!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: djtez on May 08, 2012, 11:18:50 pm
Oh yes deffo!

i cant wait to see it shining!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on May 18, 2012, 04:19:14 pm
Paint is now going on after door and tailgate have been fitted. I've not had a chance to look at it properly, as this was just a peek into the booth mid-painting.

(http://img.photobucket.com/albums/v467/amstrange1/efc34385.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: randombadger69 on May 19, 2012, 06:33:22 am
 ;D

She'll feel good as new!

Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: mark_crox on May 21, 2012, 10:23:24 am
sweet!!

I missed all the painting pictures of mine...

what colour is it btw?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on May 21, 2012, 11:22:08 am
Metallic mint, LB6U - its original colour.  :)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on June 23, 2012, 08:23:05 am
Now back home after over 3 months!
(http://img.photobucket.com/albums/v467/amstrange1/40b41186.jpg)

Bonnet will need repainting as there's some shite in the paint they couldn't mop out, but will do that once it's back together.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: mark_crox on June 24, 2012, 10:57:54 pm
Looking good!!! :)

it it being put back together now or have you got some other bits and bobs to do to it?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on July 01, 2012, 05:53:52 am
Missed this - looks good! Can't wait to see it all back together :D
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on July 01, 2012, 09:46:41 am
Quote from: max_crox on June 24, 2012, 10:57:54 pm
it it being put back together now or have you got some other bits and bobs to do to it?
Still got some bits to do - the bodyshop didn't Shutz/underseal the other side of all the stitch welding, they did more when I pointed out the bits they'd missed - but still left a lot. Bit annoying when they had 5 weeks to sort all the bits I wasn't happy with!

Also the battery tray repairs were left bare metal on the inside and covered in grinding dust, so I've been busy hoovering and treating that with Vactan before getting some Shutz on there too. Found some holes in the welds on the battery tray whilst doing that too, so will have to make sure I seal that well if I want dry feet!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: POLOMON on July 26, 2012, 01:34:21 pm
Hows this going Andy, any progress?  ;D
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on July 26, 2012, 08:36:32 pm
Some slow progress, got distracted with a work trip to India, Polo Show, BVF and buying a new daily. Now has all glass in apart from the doors, vactan'd the pipe of doom behind the fuel tank and currently part way through dismantling the front suspension to underseal the stitch welds the bodyshop left bare metal.

Might grab some pics over the weekend as the underseal goes on. Then going to re-do all the brake lines.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on July 27, 2012, 08:20:37 pm
Right, so it's about time for an update!

I've been a bit distracted, came back from honeymoon and the day after collected the car from the bodyshop. I was quite disappointed as they'd only sorted about a third of the bits I'd ask them to whilst I was busy getting married etc. - and in 5 weeks they'd had plenty of time...

Anyway, brought the car home and sulked for a bit. Cheered myself up by getting a new daily!

(http://img.photobucket.com/albums/v467/amstrange1/fe6117a2.jpg)

Then after Polo Show, BVF and a whole load of shite weather I got stuck in. This is how the bodyshop left the battery tray welding on the inside:

(http://img.photobucket.com/albums/v467/amstrange1/3793f3a2.jpg)

Pretty isn't it?! It's seam sealed on the outside, but the welding's rather crude to say the least and there are plenty of holes. Anyway, it's now Vactan'd to treat the surface rust, and will get undersealed to hopefully keep it water tight.

The stitch welding they'd done on the turrets and chassis legs had unsurprisingly melted the underseal on the inner arches. Unfortunately the bodyshop saw fit to leave most of it as it was. This photo is after I've quickly whacked some Vactan on there to protect and treat the bare metal before it gets any worse:
(http://img.photobucket.com/albums/v467/amstrange1/122f6ec2.jpg)

So tonight I've scraped all the burnt underseal off and wire-brushed all the welds so I can treat them:
(http://img.photobucket.com/albums/v467/amstrange1/995beeec.jpg)

And now treated with Vactan:
(http://img.photobucket.com/albums/v467/amstrange1/9808f0f5.jpg)

Here's the stuff in question - available on eBay pretty cheaply. It's like Krust, but better... Used in marine applications so I figured it'd be reet on a car too.
(http://img.photobucket.com/albums/v467/amstrange1/801023d0.jpg)

Random photo of one of the topmounts. These are about 25,000 miles old - but aren't half as fucked as Polo ones usually are. I can only assume that as circa 20k of that mileage is with a subframe, the frame stopping the struts wondering around must help!
(http://img.photobucket.com/albums/v467/amstrange1/078ba3d4.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on July 28, 2012, 09:22:32 pm
Undersealed both front arches:

(http://img.photobucket.com/albums/v467/amstrange1/cd370475.jpg)

Painted the underside of the battery tray repairs too:

(http://img.photobucket.com/albums/v467/amstrange1/a4e3885e.jpg)

And also added more underseal to the topside of the battery tray to fill a few pin holes in the bodyshop's Stevie Wonder welding - will have to repaint the battery tray myself once it's dried:

(http://img.photobucket.com/albums/v467/amstrange1/06b0fb71.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: POLOMON on August 02, 2012, 11:32:39 am
hmmm, i might go look for another bodyshop then.... few bits like that dont seem great do they! especially when your paying good money for it.

 Glad to see your back on this anyway Andy ;)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on August 02, 2012, 01:03:23 pm
TBH you get what you pay for, and maybe I was expecting too much. I've seen what a £7k paintjob looks like, and even then there are things you can criticise.

Unless you're acid dipping the shell, getting it welded by a full-time welder, buying all new bolt-on parts, and then taking it to a perfectionist bodyshop, it'll never quite be 100% perfect.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: POLOMON on August 06, 2012, 02:45:49 pm
Thats very true, but basic things like protecting welds isent something you should have to pay extra for, surely? hmmm.  :-\
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on August 06, 2012, 05:14:07 pm
No, it isn't. I'm surprised, because my arch repair was sealed up properly, and it was done by the same bodyshop. Surprised to see yours hasn't had the same.  ???
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on August 14, 2012, 05:26:21 pm
Driver's side windows in. Still need to order the door B-pillar trim from DKnight, and have got a new lumpy B-pillar trim coming to replace the one I've stuck on there as it's a bit dog eared from being taken off:
(http://img.photobucket.com/albums/v467/amstrange1/395C4EC2-1FB2-4142-9E25-79760FE87E00-1112-0000046DB66B121A.jpg)

Mirror image, note door handles now on along with new armoured door plates (C&R Enterprises in Nottm can do OEM new ones):
(http://img.photobucket.com/albums/v467/amstrange1/AC8D999A-F8F3-4E39-B5F0-0CA3F49089D5-1112-0000046DCEEC4504.jpg)

Painted the re-sealed battery tray:
(http://img.photobucket.com/albums/v467/amstrange1/50FAC146-A4F5-45F6-8D38-1B6131072072-1112-0000046DE70C1FED.jpg)

...but it still leaked when I tested it with water - that's after I added more sealer, primered, painted and lacquered. So I decided to Waxoil the fucker and be done with it. The result is far from pretty, but I kept going 'til the Waxoil stopped dripping inside the car.
(http://img.photobucket.com/albums/v467/amstrange1/786ABE6C-51ED-47D8-B270-EA7450FD4994-1112-0000046DFAC43E32.jpg)

Pimp my brake servo:
(http://img.photobucket.com/albums/v467/amstrange1/37D090F3-74D2-4507-A1A7-B92E16A2CF08-1112-0000046E08AB684E.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/631E4F8F-4BD7-4B8C-96E9-B18C44590361-1112-0000046E2E9BAC48.jpg)

While I had the Waxoil out the pipe of doom got a good spaffing:
(http://img.photobucket.com/albums/v467/amstrange1/BAE50956-382D-49A4-8233-111F523A8031-1112-0000046E390957CC.jpg)

Boot plinth back on:
(http://img.photobucket.com/albums/v467/amstrange1/CFA3B598-A3D7-4B21-8DE0-65896D11C1CD-1112-0000046E16BA780A.jpg)

Brand new numberplate bulb lenses and bulb holders:
(http://img.photobucket.com/albums/v467/amstrange1/0B135986-A495-4619-B170-62E3C8C0B58D-1112-0000046E1D99D6CD.jpg)

Shiny new boot latch:
(http://img.photobucket.com/albums/v467/amstrange1/7E58035A-C9A8-4ED9-A70C-E12BDAA4826E-1112-0000046E24A458AA.jpg)

Tailgate now shuts and latches, added some badges to cheer things up:
(http://img.photobucket.com/albums/v467/amstrange1/0B51F9B9-7C83-4D1F-96E2-4A32186DC15F-1112-0000046E417C94F5.jpg)

Wiring harness now back in the tailgate - I'd de-pinned the connector at the vehicle harness end which is about the only way I can see you getting this harness in and out unscathed. Anyway, it went in okay and routed nicely:
(http://img.photobucket.com/albums/v467/amstrange1/907990F8-31C6-401E-B820-711E9888B4E3-1112-0000046E54CD8B8A.jpg)

New washer hose added and threaded through. This was more of a pain in the arse than the wiring harness, but got there in the end.
(http://img.photobucket.com/albums/v467/amstrange1/465317A8-5A13-43CA-95CC-C86B3D176CC0-1112-0000046E5A937374.jpg)

Wiper motor back in and wiring all clipped up properly - also Waxoiled the fuck out of the inside of the tailgate too, as I didn't want a repeat of what happened to the original.
(http://img.photobucket.com/albums/v467/amstrange1/57DC2E62-FF39-477B-B61B-E930B8613CA0-1112-0000046E618B03C9.jpg)

Tail lamps and wiring harness for them went back in:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5458.jpg)

And chucked the rear bumper back on with brand new bolts for some instant gratification. At least the arse end looks a bit more like a car again now!
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5460.jpg)

Only fly in the ointment is this:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5449.jpg)

...the pedal box doesn't fit!! I've had today off work with the aim of getting the servo/pedal box back in, and re-fitting the carpets so I can get the interior back in and out the way. Instead it looks like it might have to go back to the bodyshop for the battery tray to be modified - this might be a blessing in disguse!

Check how close the bottom right-hand bolt hole is to the battery tray repair:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5440.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Etches on August 14, 2012, 06:15:29 pm
Looking good Andy! Tdh_syorks who had my G before had the tray welded, now the battery barely fits and rattles around because the rear ledge is too tall. I guess its difficult to sort the tray out perfect. Its going to look fully restored after all this work :)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: POLOMON on August 16, 2012, 09:45:30 am
Oh progress! good to see, love this colour. I guess battery tray should have a refit free of charge? given its not correct and that?
 I was going to respray mine in the same colour but given i have very similar engine plans i dont think it would of been quite right to have a same coloured car haha. Went for a rather fetching shade of green though:

(http://i134.photobucket.com/albums/q89/photo123_2007/Polo/IMG-20120810-00578.jpg)

 Anyway, good luck with this Andy :-)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on August 24, 2012, 04:40:51 pm
Back to the Bodyshop for the battery tray to be sorted, along with the bonnet.

(http://img.photobucket.com/albums/v467/amstrange1/22F44315-1760-4E32-8BBF-08AF69C77BCF-1022-000004C553BF0EED.jpg)

Bought some 14" steelies for when stealth mode is required. They came primered after blasting, so I rubbed them down:

(http://img.photobucket.com/albums/v467/amstrange1/6F855E4C-F7CC-40EF-87C5-069668825094-1022-000004C55C345604.jpg)

And gave them a splash of silver. Will lacquer them tomorrow. Probably will keep my MOs for track wheels, not sure what to do with my 14" RAs.

(http://img.photobucket.com/albums/v467/amstrange1/A5E27E8C-77E9-47AB-BC19-FD375A903D14-1022-000004C567223C5C.jpg)

Car should be back from Bodyshop next week!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Jezza-7 on August 24, 2012, 07:13:21 pm
Looking good andy!

If you wanna get rid of them comp's let me know  ;)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on August 24, 2012, 08:53:18 pm
I think if anything goes it'll be the RAs! ;) Always wanted a set of MOs, so think I'd regret selling them and steelies feel right for the car.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: breadman on August 31, 2012, 10:06:40 pm
The car is looking good Andy.
Are those steels 6" ET38? If so, which size tyre will you be using as we all know there ain't a lot of room under the rear arches?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on September 03, 2012, 06:53:30 am
Yep, 6" ET38 - which is what the Compos and Speedlines I had on before were. I use a 185/50 R14 as 195/45 is too wide IMO and makes the car tramline too much.

Rear arches have been slightly rolled and pulled for yonks, so 6" ET33 just fits too.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on September 17, 2012, 09:09:13 pm
Back from the bodyshop...

This is how the battery tray looks after their 'rectification'. The rusty holes on the left were previously hidden by seam sealer that had to be removed to make sure the battery fitted:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5461.jpg)

Yuck! Here's another shot without flash and a torch in the footwell. Had asked for it to be checked for leaks, erm okay...
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5465.jpg)

Here's how it looks inside the car now too. The good news is the pedal box now fits and can be removed, but that seems to be it for the good news!
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5476.jpg)

Noticed that there wasn't much paint coverage behind the servo area, and the skim of filler slapped in there over the welding has already started to crack. Had a bit of a pick at it.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5467.jpg)

I'd really been hoping that things would be properly fixed by now, after all the bodyshop had it back for another 3 weeks... Anyway, the re-painting they've done outside is hopefully going to be good once it's been mopped.

Plan with the battery tray is to do what I should've done in the first place - DIY. Will borrow 1 Yoof and 1 MIG set, clean up the area and re-do the welding. Hopefully we'll be able to tidy it up enough to seal it properly and neaten it up.

At the same time I'll try to smooth the area behind the servo a bit to neaten it up, and re-paint that too. Fortunately they're all bits in areas where the quality of finish I'll get with a rattle can doesn't matter too much.

Lacquered the set of steelies:
(http://img.photobucket.com/albums/v467/amstrange1/6F2EA2C2-1549-44F5-983A-2D091665E0F2-3616-00000E5317BD513B.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: POLOMON on November 13, 2012, 02:03:51 pm
Hows this doing Andy, any news? :-)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Yoof on November 13, 2012, 03:35:52 pm
Battery tray is now welded up, long process of re-sealing and painting everything now, start to look good though.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on November 13, 2012, 08:34:40 pm
Yeah, redoing the battery tray has taken ages - bodyshop made a right fucking mess. Anyway, thanks to Yoof it's welded back up - in primer at the moment so will bang some pics up tomorrow.

Got some new calipers for 256mm brakes for my bday from Yoof, and will order some Gaz
coilovers soon when I've finished fannying around with spring rate ideas.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on November 14, 2012, 03:12:27 pm
Took the seam sealer off the pikey welds and wire-brushed it clean. The weld sloping from middle right of the pic to bottom left was broken along its entire length - no wonder the bodyshop's seam sealer didn't make it waterproof...
(http://img.photobucket.com/albums/v467/amstrange1/B96C0336-4DE8-4AAB-A3FD-AF473B0E5802-1080-000002F4A827552C.jpg)

In the middle of welding it back together. The repair panel they used is thinner gauge than I'd have liked, so it took a few passes with the MIG and grinder to rid it of any holes or cracks. Blue paint pen marks some pin holes.
(http://img.photobucket.com/albums/v467/amstrange1/20C33C5D-CCC4-45E8-A789-77C99B8EA16F-1080-000002F460EB2891.jpg)

How it looks now, welds ground back, painted with vactan anti-rust paint and covered in primer. My garage is so cold it takes a few days for paint to dry properly, so progress is slow. Will rub it down tonight and get a colour coat on. Going to seam seal the nastier parts once it's all painted and then go over with colour and lacquer again afterwards.
(http://img.photobucket.com/albums/v467/amstrange1/3C5F8852-FD21-4EA5-8E55-873AA420579B-1080-000002F44DD5BE08.jpg)

Took the bog-filled area behind the servo back to metal and smoothed the welds back some more. Then threw some bog of my own back on it:
(http://img.photobucket.com/albums/v467/amstrange1/AA116251-A91A-433D-896D-DF612F115EB3-1080-000002F47E9A4990.jpg)

My bog mid-way through sanding back. Most of the yellowy/white patches are primer rather than filler. Much better!
(http://img.photobucket.com/albums/v467/amstrange1/86CAD2F7-EA86-4E90-8E9E-42C0AEF1A60E-1080-000002F4672BE780.jpg)

The servo area is now in primer too. In fact, that was sanded back ready for colour coat 'til I spilled some thinners on it and stripped the primer off, lol.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: cheys03 on November 14, 2012, 07:45:25 pm
I can't believe the job the bodyshop did. Actually shocking. Well done both for sorting it properly
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Etches on November 14, 2012, 07:55:35 pm
Have you not got some sort of refund for the shoddy quality of the work Andy? Really good effort here lads
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on November 14, 2012, 08:40:38 pm
No refund, but it's lost them a lot of potential business - my neighbour has a couple of vintage cars needing full resprays which if mine had turned out nicely he'd have sent their way, plus a couple of guys at work want odds n sods doing that I could've recommended them for.

Behind servo in primer (bad photo!):
(http://img.photobucket.com/albums/v467/amstrange1/2B330052-3A98-4956-985F-1AF6040698B0-1080-00000306637D883A.jpg)

And now with paint - not perfect, but better:
(http://img.photobucket.com/albums/v467/amstrange1/B511F381-CE19-4E60-966A-76ADB793D018-1080-000003065E1F2740.jpg)

First colour coat on the battery tray. Still needs rubbing down, probably another coat, and then lacquer:
(http://img.photobucket.com/albums/v467/amstrange1/D120CDAE-83D2-403B-BB2E-A0A0517BDB71-1080-0000030658773B78.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on November 15, 2012, 12:31:14 am
Still shocked by all of this. Don't make recommendations easily, I genuinely can't get over how bad all of this is. Especially given that I'm still delighted with mine.  :-\
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: POLOMON on November 15, 2012, 09:29:32 am
Oh wow! well at least you know its done properly now rather than leaving it only for rust to come back with the leaky seams!

 Good job lads :-)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on November 15, 2012, 11:27:13 am
Alex - I know you made the recommendation in good faith, and looking at the high standard of your car helped make my decision as the workmanship on that does appear to be top notch. So please don't feel responsible! Sadly it seems that mine wasn't completed with the same levels of love and attention - the photos speak for themselves.

I'm getting more enthusiastic about it again now, about a month ago I was utterly fed up with it and totally disillusioned. Hoping to finish the repairs by the end of this month, and get the full interior properly back in before Christmas.

Yoof probably deserves more credit for his tidying-up welding than the pictures suggest too. The 'before' photo with the seam sealer stripped back is after I'd ground back the bodyshop's welds, so it was even uglier.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: dubstar on November 15, 2012, 08:04:09 pm
It's looking good pal. You can paint mine in a bit looking at your work - sod the paint shop!!   :)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on November 18, 2012, 05:20:49 pm
Cheers Ross!

I cracked on with things yesterday and rubbed the two areas down before giving them another colour coat and a dose of lacquer. The battery tray looks a lot better now, and the area behind the servo better still - shiny!
(http://img.photobucket.com/albums/v467/amstrange1/685158EE-0875-47D0-9C8C-12FAAA3CA8FF-364-000000D4B793426B.jpg)

There's one bleb in the paint there, but I'll live with it - better than cracked filler any day. Next steps are to remove the masking, clean off any overspray - and then re-treat the underneath of the battery tray. That'll get another coat of vactan for good measure, seam sealer and then paint. Will then also seam seal the top side and whip some paint over that, as well as doing the corner where the strut tower meets the bulkhead.

Don't want to speak too soon, but it seems that getting decent paint makes the job easier. Got some Standox 2-pack stuff from the same supplier the bodyshop used, idea being the colour match should be spot on.

Also spent some time playing with gearboxes. Have an ATV with Quaife LSD rebuilt by JP Race to go in, but something didn't look right. Output flange on the offside looked very different to one from my other 'box...
(http://img.photobucket.com/albums/v467/amstrange1/E6FAC507-03CA-4AB2-AEEF-C700C64366B0-364-000000D4C478A120.jpg)

...JP had stuck the offside on the nearside and vice versa. Maybe an innocent cock-up, but my other JP rebuilt 'box also had the same issue originally. Worth checking if you've had a 'box done by them methinks... Am sure I've got them right now, verified on several other (unrebuilt) 'boxes in my collection.

For reference, the flange on the engine block side of the 'box should be 084 356 D, and the passenger side is 084 355 G.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: djtez on November 22, 2012, 12:22:50 pm
i will check mine for sure this weekend, my box was also done ... and its out the car so handy!

thank you andy
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on November 22, 2012, 05:28:45 pm
No probs! The engine block end should have a very protruding output flange on it, and the other should look almost recessed.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on December 01, 2012, 01:00:14 pm
Started with the seam sealer on the newly repaired battery tray. I'd decided to paint it up first, so that any metal that didn't get fully covered with sealer at least had paint and lacquer on it. Once this has all dried it'll get primer, paint and lacquer again. Probably creating more work for myself, but meh.

(http://img.photobucket.com/albums/v467/amstrange1/56317276-620D-4C7B-946F-8F84BB93844A-2616-00000A8119C2A765.jpg)

Did the underneath too, looking nice and messy - prime aim here is to make sure it's fully sealed and lasts for another 20 years. It'll be hidden behind the dash, so I'm not aiming for pretty!

(http://img.photobucket.com/albums/v467/amstrange1/88BB4213-5A38-4CE7-9B11-4DD129164257-2616-00000A81042F6E77.jpg)

The underside is now primered, painted and lacquered too - will stick up a photo later. The battery tray side is getting seam sealer built up in the corner to level out the battery tray and ensure water doesn't puddle at the front. Taking my time to do that so it builds up a layer at a time.

Also removed the original B pillar trims and fitted brand new VW ones both sides. One side is obsolete, but I managed to get a NOS part from eBay - and the other side is still available through VW Classic Parts. The originals weren't bad, but as I'd got new door seals etc. too it made sense to freshen up all the trim!

(http://img.photobucket.com/albums/v467/amstrange1/F2ECCBFD-0333-4D46-B88D-158E9114060E-2616-00000A80E2F9693B.jpg)

Got the door vinyl trims to fit next - if anyone's got any fitting tips I'd love to hear them please!

(http://img.photobucket.com/albums/v467/amstrange1/AB11D0DA-05FC-45A8-8D1B-6C5CC9FD142F-2616-00000A80DCA41545.jpg)

Also weighed some wheels this morning too. The bathroom scales aren't the last line in weighing accuracy, but they'll do for now!

(http://img.photobucket.com/albums/v467/amstrange1/17FF08B0-8E6D-4F32-91C3-5748F092B806-2616-00000A80FDB59847.jpg)

Results are:

WheelApprox Weight /kg
14x6" Golf Steel8.5
14x6" Compomotive MO7.5 (just under)
14x6" BBS RA7.5 (just over)
185/50 R14 Yokohama A539 (new)  7.5

Thought that was interesting, conventional alloys saving about 1.5kg of unsprung mass per corner - which is useful, but not amazing!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on December 02, 2012, 09:55:39 am
Had treated a few rust spots on the boot floor back in the summer, so primered; painted and lacquered that yesterday.

(http://img.photobucket.com/albums/v467/amstrange1/DB841DF3-0651-4641-8A4D-B3B54DF82464-2616-00000B5E8AC4F0DF.jpg)

Underside of the battery tray now painted too. Looks awful thanks to the scaggy welding and repair patches, not helped by the seam sealer - but it's water tight and welded up solidly now which is better than it was when it left the bodyshop.

(http://img.photobucket.com/albums/v467/amstrange1/1E954D3D-3145-43E1-BA17-E8CF0AD8EB78-2616-00000B5F6257D818.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on December 07, 2012, 09:11:01 pm
Put the DKnight door trim stickers on tonight:
(http://img.photobucket.com/albums/v467/amstrange1/9CE25869-9587-4B2F-BB9C-FC8FE588EA68-3778-00000F5837513D25.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/DA05824B-9201-4C31-AE31-731913B59BFB-3778-00000F58447C9BCB.jpg)

They look pretty good. I would worry about them not perfectly aligning with the B-pillar trims thanks to my application skills, but the originals weren't perfect either - and my new (OEM VAG panel!) door isn't quite milimetre perfect. The first photo is of the original passenger door, unmodified, and you can see that the lower swage line aligns perfectly - but the upper one doesn't. The second photo shows the new OEM driver's side door, which is aligned as a compromise between the two.

For those of you buying these door trims and worring about how to apply them, the vinyl seems to be a really decent thick quality so little air bubbles really aren't a concern. You can be pretty ham fisted and they still fit nicely, air bubbles are easily pushed out.

The rounded edges are for the window surround side, and the 45° edges are for the door edge side. I found it easy to fit if you get the first 5-10mm stuck down at the top door edge, and then work down slowly; peeling the backing paper off as you go and paying attention to how central the vinyl is on the door pillar. Worth noting that the vinyl is slightly stretchy, so you're initial starting point doesn't need to be 100% perfect.

So in summary, DKnight might be an agoraphobic hermit with a microphone head, but his stickers are reet bo - so buy them. ;D
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on December 12, 2012, 10:30:42 pm
Cracked on some more with this at the weekend.

Painted up the driver's footrest thing. Wasn't going to bother, but there were a few bits of surface rust so it got Vactan'd and satin blacked.
(http://img.photobucket.com/albums/v467/amstrange1/D5C79B5E-655A-4075-8DE2-5653A57B72B6-3778-000013ABF100F5D8.jpg)

Now all the painting in that area is done, I could put the servo back into position. Battery tray is still to do, but I'm waiting for some seam sealer there to dry as I've had to level out the corner of it with seam sealer to stop water puddling. Given the recent temps it's taking ages to cure!
(http://img.photobucket.com/albums/v467/amstrange1/840E7D40-D6D3-4892-895F-4AF990DCF365-3778-000013ABF8A418DD.jpg)

Which meant that the pedal box could go back in, along with the steering column. With those done, I put the bulkhead sound deadening back in too (after a bloody good hoover out!). It was tearing in a few places, hence the gaffer tape.
(http://img.photobucket.com/albums/v467/amstrange1/566BAE2B-5729-4109-8575-E48A9A12F053-3778-000013AC163A8D70.jpg)

Bumper iron bolted back on.
(http://img.photobucket.com/albums/v467/amstrange1/483A5CE9-E368-4A90-9245-E118AABC548A-3778-000013AC05F84BB2.jpg)

Secondary door seal bits were a pain to put back on, but only because the double-sided tape I've got is really narrow so it needed lots of strips of tape. Bodyshop had lost a few of the clips, but I'd remembered to nick some off one of the many cars Yoof's broken recently!
(http://img.photobucket.com/albums/v467/amstrange1/DABDE53E-7CC0-4BB4-B198-0FE2D9571CEA-3778-000013AC0F59461B.jpg)

Started putting some of the trim back on. That's after a dose of heatgun too, so thinking I might need to shell out for new trim - or buy shares in Back to Black!
(http://img.photobucket.com/albums/v467/amstrange1/981B3DB0-2E3F-4813-A0A9-0B44920403F1-3778-000013AC1CF12955.jpg)

Powder coated engine mounts got the rubbers re-installed. The rubbers are pretty much brand new, so haven't replaced them. Forgot to take photos of the pikey puller I made to reinstall them - it was basically some 10mm bar with big lumps of metal acting like washers either end and a couple of nuts to tighten it all together. Worked a treat with some silicone spray and didn't damage the powder coating.
(http://img.photobucket.com/albums/v467/amstrange1/15283858-0EAB-4A44-AB43-8484FFC3A79B-3778-000013AC22A18D4F.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/04987BE6-1992-440F-B9C5-477C39BCFCAC-3778-000013AC318A63AE.jpg)

Finally, the tailgate got its badges back - for the second time in the rebuild! When it went back to the bodyshop for the battery tray 're-work'/bodging they repainted the bonnet and tailgate as they had a few blebs in them.
(http://img.photobucket.com/albums/v467/amstrange1/F73A545E-92F2-4F96-A254-2692B588B889-3778-000013AC379B0C3C.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: z3i on December 13, 2012, 08:59:49 pm
Enjoying reading this :) good work there
i did exactly the same with my batter tray. had a 6" by 2" hole!!!!! welded it all up and squirted an entire tube of terason seam sealer in there brushed it around, waited about 2 weeks for it to dry haha. primed, based then lacquered, then pumped an insane amount of cavity wax in there! i dont think it will rust, ever!!!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on January 02, 2013, 10:32:59 pm
So, made some progress on this over Christmas...

Found a random bit:
(http://img.photobucket.com/albums/v467/amstrange1/D28E5E5B-6F2C-4E1D-B0B1-5688D45C6B2D-397-0000010FF8730417.jpg)

Forum geekery identified the location for the missing part in the steering column - so that came apart:
(http://img.photobucket.com/albums/v467/amstrange1/692DF58A-F217-4496-A8B6-AD643C58D7C4-723-00000236251547DA.jpg)

Carpets went in, and I started tidying and re-routing the dash harness. The heater box foam seal was all knackered so I cut some automotive adhesive foam I'd got knocking around to shape and fitted it:
(http://img.photobucket.com/albums/v467/amstrange1/3241144F-8F0F-4B78-BFEB-4039AB452042-723-00000235FF652725.jpg)

Reminded myself to sort a bigger oil cooler, mine's only a 13-row which with a turbo probably isn't enough. I think I've still got a monster one from my Saab 9000 Aero, so will have to dig that out.
(http://img.photobucket.com/albums/v467/amstrange1/8C7F5A19-0BF9-438D-B7C5-CCF9BF890B59-1410-000004E47A33BB4A.jpg)

Powder coated accelerator pedal installed, shite photo but it's nice and shiny!
(http://img.photobucket.com/albums/v467/amstrange1/58BEC9F6-FA68-42C8-8E2D-827F101FB135-1410-000004E4AE834FBF.jpg)

Battery tray got its final colour coat. It's not quite the standard I was hoping for when I asked a bodyshop to sort it, but given the circumstances I'm fairly happy with the outcome. Just hope that it doesn't bloody rust again! Now lacquered too, but no photos.
(http://img.photobucket.com/albums/v467/amstrange1/88D3C0EC-D05C-41B1-9D61-7904CCEBD36F-1410-000004E48728CC19.jpg)

Dug out the speedo cable to fit a new rubber grommet on it as the old one was fucked. Ordered a new grommet, but hadn't really crossed my mind that there's huge crimped-on lumps either end. Heated the new bit up and managed to stretch it over. Cut the old one off. Exciting stuff eh?!
(http://img.photobucket.com/albums/v467/amstrange1/44CA8624-5777-4DAB-BC4D-B1B57230B60D-1410-000004E4C0D767DE.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/C97BD557-B064-4DEF-9046-BF27BF4D6856-1410-000004E4D0EA4E7C.jpg)

After some good swearing, and a few skinned knuckles I got the dashboard back in, heater controls hooked back up and dashboard harness all clipped in. Took the time to tidy up the 'professional' immobiliser installation too. Might take a thief at least 60s to hot wire it now instead of 10s...
(http://img.photobucket.com/albums/v467/amstrange1/D1CC419B-B34D-4999-9F6E-5C30C84E7764-1410-000004E4A21C58D2.jpg)

Have just rebuilt a set of clocks to go in, and then it'll be time to put in the chairs and door cards. Got some decent door membranes from SamG40 to fit too - cheers mate! Hoping to get an ETA from Gaz next week on my coilovers too, then I can crack on with fitting a G40 rear axle; rear discs and my 256mm brake conversion up front.

Now have a firm finish date for the project too, needs to be done by May - when this arrives!
(http://img.photobucket.com/albums/v467/amstrange1/Scan2_zpsf3aa420a.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on January 03, 2013, 12:34:01 am
Looking good! Seeing this and Mark's has made me want to get my interior and bay done. Think I'll be pulling everything out of mine once I've got a garage again, binning the shit bits and tidying everything up. Engine bay can wait a couple more years though.

My alarm installation was terrible at first too, I'm loathed to let another alarm fitter touch it because of the mess the first lot of VSIB-approved monkeys made. Slashed the door membranes, broke bits off the dashboard, lost loads of screws and drilled holes without painting the bare metal afterwards. The shock sensor was cable tied to the wiring loom, loosely. Great when you live next to a bus stop. That was the first clue that it was a bit shonky.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on January 07, 2013, 09:53:27 pm
More progress at the weekend.

Bit of tinworm that'd got missed on the inside of the passenger door - had just given it a dose of rust eater, but it was a bit too deep for that, so got taken back to metal before re-treating.

(http://img.photobucket.com/albums/v467/amstrange1/5238FD6D-E3CF-4963-B6BC-BDD1336106C1-2160-000008444073E349.jpg)

Followed that up with a top coat of colour to protect it. Dropped a bollock and got some overspray on my newly repainted metal carpet strip, so will have to repaint that. ::)

Got the 'refurbed' (ish!) speedo cable installed with new clips into the back of the dash, and new grommet.

(http://img.photobucket.com/albums/v467/amstrange1/AFD47EDF-4384-49A0-8251-6C69EE11136C-2160-000008444A2E08B0.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/99AFAB89-F3A0-47F5-8BA8-06FDB000547B-2160-000008440B24544D.jpg)

Removed the masking from the battery tray area finally. Doesn't look too bad in the end.

(http://img.photobucket.com/albums/v467/amstrange1/FA482255-E7C0-4346-9FD1-1AA43C576D05-2160-00000844003FE814.jpg)

I kept the aerial hole. I know most people don't, but I always liked the fact that my car looked pretty standard - and a whippy ancient aerial adds to the image of poverty-spec shopping car cheapness. So anyway, aerial back in.

(http://img.photobucket.com/albums/v467/amstrange1/D9607D75-D3AB-4212-B8DF-1DAA11E9DDAD-2160-000008442663AB6D.jpg)

Whipped the heater matrix/blower assembly apart to clean it. This bit had been removed whilst the car was painted, but for some reason got left inside whilst the car was sprayed - so it was covered in paint dust etc.

Cleaned the lot including the motor in solvent, and then used electrical contact cleaner on the motor before re-greasing the bearings. Going to need to back-to-black the plastic I think, but worth a try as a new assembly is £165ish! I did order a new matrix though, as hopefully it'll save me a job in the future if/when the originally finally decided to let go.

(http://img.photobucket.com/albums/v467/amstrange1/7F9E1A90-25E0-4E52-9C5B-70CE8626792A-2160-000008449AB8D2D3.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/D63A0282-59D8-44D1-94C9-CF48731A3BE2-2160-0000084454157770.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/50348EF2-62FE-4EC9-ACF8-DD1A3D08923D-2160-00000844A08BB320.jpg)

Re-glued the headlining into place wherever it was coming loose. Bulldog clips easily hold it into place while the Evostick dries and are easy to remove afterwards.

(http://img.photobucket.com/albums/v467/amstrange1/C9B5FC58-E24F-4CCB-B3C0-95FA4BF7A7CD-2160-0000084481DFB342.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/5C42BDB6-C739-40D4-BCD4-BA002851584D-2160-000008447A76B25A.jpg)

Managed to rescue my original door card membranes in the end. A clean up with solvent, touch of tape on a few small tears, and some double-sided tape and they were good to go. Can't seem to buy new ones any more, and I could've just cut up a bin bag - but it'd have been a pain to get the right shapes and cut-outs sorted, so I was pleased how these turned out.

(http://img.photobucket.com/albums/v467/amstrange1/63690147-8A61-46CD-91DA-84AE2C45ACDB-2160-000008448AE85570.jpg)

Door cards on front and rear, and rear chairs in. Leaving the fronts out 'til I've got clutch and throttle cables installed. Makes installation easier and saves them getting dirty!

(http://img.photobucket.com/albums/v467/amstrange1/1EDE2AD2-9E62-4F29-94FB-5C918843D6BB-2160-00000844A9C65663.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/482868CC-C456-40BF-953A-8E3214A3D136-2160-00000844928AADAC.jpg)

Going to be back to doing some oily bits soon, will do cambelt and some other odds n sods on the engine whilst it's out - and hopefully by the time I've done that my new suspension will've arrived.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: PeteG40 on January 07, 2013, 09:59:37 pm
- 1 point - should've painted steering rack mate!

but overall quality looks top.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on January 07, 2013, 10:18:36 pm
Rack's coming out later, Kiz has a powder coated one for sale. ;)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on January 16, 2013, 08:59:10 pm
Tarted up heater unit back in, complete with new matrix and foam seals.

(http://img.photobucket.com/albums/v467/amstrange1/12763662-BEFA-4C45-ABD9-D2F6C53707BD-1166-00000484504C7C7B.jpg)

Front wiper linkage and motor back in too. Didn't feel flush enough to buy a new motor just for the sake of having another new shiny bit.

(http://img.photobucket.com/albums/v467/amstrange1/6283A3C6-5E1C-4894-BE11-F85E5D48A1C5-1166-0000048456C4F50E.jpg)

Door mirrors back on. The bases need some back to black!

(http://img.photobucket.com/albums/v467/amstrange1/95E5975A-68EC-470E-B0C5-DDB8BE57B7D3-1166-000004845D2D3E74.jpg)

Brand new door seals installed. These were fecking expensive for what they are, and a bit of a pain in the arse to fit perfectly - but I got there in the end. I'm hoping that having new seals will cut down on the wind noise!

(http://img.photobucket.com/albums/v467/amstrange1/F72777F1-9986-4801-9A5C-96C85E7F74ED-1166-0000048463D840D9.jpg)

Looking more like a car again - at least inside!

(http://img.photobucket.com/albums/v467/amstrange1/1E0E22D4-8E90-4555-861C-E4C9E692B9E6-1166-000004846C028480.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/7275863A-48D3-4CBD-B0A9-24981BF54A36-1166-0000048481F210C6.jpg)

And a late Christmas present finally arrived. Shame that they've omitted the helper springs I spec'd, but hopefully they'll post those on to me.

(http://img.photobucket.com/albums/v467/amstrange1/0B3EB9A5-2F25-49F5-933B-C647F202FA53-1166-00000484897B6556.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Yoof on January 16, 2013, 09:04:06 pm
Front seats need a clean- too many brown trouser moments on them.

Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: dub-disaster on January 16, 2013, 11:09:49 pm
what spec did you choose for your front collies in the end? i had to fancy around and pay twice to have them remade in the end to get mine spot on the measurements i wanted, they even kept my final drawings i asked for them back but they wouldn't let me have them! be interested to see if there now using my lengths for total body length and piston length as there original design had so little travel in it that a minimum of 275lb springs to stop it riding on the bump stops.Did you spec  these lengths yourself ?

I also had alot of problems getting the springs i wanted they have told me that they don't believe in helper springs they think there a waste of time, but the first set of collies i had went loose on full droop!
hope your gaz are correct first time.
love the work on the car and hope to see it soon.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on January 17, 2013, 08:09:25 pm
I'll take some measurements Antony and PM them to you to compare. I asked for helpers with mine, but didn't get any - so (hopefully!) they're now posting some on to me. My setup clearly would need them to avoid the spring going loose in the seat on full droop. Currently not too impressed with Gaz, but the proof of the pudding will be in the driving!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on January 17, 2013, 09:42:16 pm
I didn't get helper springs with mine, but I got them on a "special deal" so I posed the question but didn't moan much. I have the same issue though, the springs are loose when it's jacked up and the fronts clonk when I'm manoeuvring into spaces.

The fronts on mine are 275lb 7in springs, and they are hard, which I'm alright with, but I'll be interested to see how you get on with them. Quality wise they seem good.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: dub-disaster on January 17, 2013, 10:34:27 pm
Quote from: Andy on January 17, 2013, 08:09:25 pm
I'll take some measurements Antony and PM them to you to compare. I asked for helpers with mine, but didn't get any - so (hopefully!) they're now posting some on to me. My setup clearly would need them to avoid the spring going loose in the seat on full droop. Currently not too impressed with Gaz, but the proof of the pudding will be in the driving!

That would be great Andy ill pm you my drawings with dimensions so you cab measure the same bits I did. i have to say that gaz customer care is shit there is no other way to describe it. They showed no interest in trying to improve on there original design which was clearly flawed as the springs where loose at full droop and there was something along the lines of half an inch of bump travel before you're on the bump stop wick probably had another half inch travel in it.
They where general un co-operative and sent me the wrong springs 3 time in a row hence me now having a collection of springs.
I understand companies like this have little time to do research and development for such a small market but some decent customer care and a little bit of willing never goes amiss!
On the flip side there kit is well made although the dampers they use are only of mediocre quality.
Did you go for the damping adjustables up front or not as you can have the solid heat treated piston from gaz gold used if your not worried about adjustablilty.
On softest setting mine are very reasonable on the road but i haven't done Mich hard corneing or had the geometry set correctly yet.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: P1rik on January 18, 2013, 07:44:05 pm
Where did you get your door seals from ?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on January 18, 2013, 09:54:44 pm
VW Heritage - they were nearly £50 each!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: z3i on January 19, 2013, 10:32:31 am
Enjoying the updates and work :) congratulations with the baby :)
i cant believe how rubbish that bodyshop was!!
im sure you can get a big length of that door aperture seal from heritage for cheaper and then you have to cut it to shape?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on February 10, 2013, 07:31:24 pm
Been plodding on with this slowly. Helper springs arrived from Gaz, so bought some SKF wheel bearings and some new hubs ready to build the struts up. Just need a free Friday afternoon to press the bearings in at work now.

Pulled the rear axle off ready to fit a G40 item with Mk2 Golf rear discs hanging off it. The rear shock bolts were seized to the shock bushes, so ended up cutting the bolts off. Will drill the remnants out at some point as the shockers are still serviceable.

(http://img.photobucket.com/albums/v467/amstrange1/7F150546-2341-4D98-BDF9-C3F9A1D99C4B-5730-000016CA64975BE4_zps32802f00.jpg)

Progress got stalled as I noticed a few scabby bits underneath which really needed attention. I think being in and out of a paint oven a couple of times probably exacerbated things where the stonechip/underseal's going baggy.

(http://img.photobucket.com/albums/v467/amstrange1/2D994B26-6611-4E2B-86D8-A2A922B026C6-5730-000016CA6B782CD8_zpseb9e22ae.jpg)

Anyway, I've hit the lot with a wire brush and Vactaned it. No pictures of it as it stands now, after each session my eyes were full of underseal and rust, so didn't really feel like taking pics! Next job is to seam seal and/or stonechip the appropriate parts.

Removed the rear axle brackets and the fuel pump assembly carrier. After 20+ years and a spate living by the sea before my ownership, these bits looked like they'd been down the bottom of the sea. They got shipped off for blasting and powder coating.

(http://img.photobucket.com/albums/v467/amstrange1/07D2478C-FD5B-4648-97C0-1D44C993E754-5730-000016CA723F6787_zpsdd452f50.jpg)

After:

(http://img.photobucket.com/albums/v467/amstrange1/69FDCB41-909F-4135-ABD9-7E3DD4E56B90-5730-000016CA79C77439_zpsf579df5f.jpg)

The fuel pump carrier looks fairly pitted still, but given that it's £75ish for a new one and special order from VW Classic Parts it'll do as is!

Need to get my finger out to get the arse end back together and throw brakes and suspension back on. Then it's easy street and engine refresh time.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on February 14, 2013, 09:08:14 pm
Had the seam sealer out tonight to sort the underneath at the rear. Have some stonechip to go on the areas that don't need seam sealer, so hopefully it'll help things last a fair bit longer without further attention.

(http://img.photobucket.com/albums/v467/amstrange1/816547E1-7E24-451C-9F64-C344B7E1E21E-5730-000019B6395BDC5F_zps5f960a7a.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/F0D20754-2D06-4FE0-BBB7-A91E3068B154-5730-000019B63032D958_zps18525275.jpg)

Sealed the rear rolled arches up with seam sealer. I was under the impression that the bodyshop were going to do that, but they were still black hammerite as per my efforts 8 or 9 years ago. Presumably another optional part of the job as far as they were concerned.

(http://img.photobucket.com/albums/v467/amstrange1/23B8421C-30D4-4D36-923F-98A5AD8BDC92-5730-000019B6428BBAD2_zpscb099e7c.jpg)

Yellowy brown shite in this picture is Waxoyl rather than tinworm!

(http://img.photobucket.com/albums/v467/amstrange1/5067793B-B32E-40BA-B624-A53EBF6612D7-5730-000019B6BD8BE853_zps58be6846.jpg)

Was feeling pretty chipper after all that, not far off being able to bolt the new rear axle back up and stick the new coilovers on. Whilst I was lying on the floor I thought I spotted a bit of crap stuck to the bottom of the passenger door. It's not dirt though, it's tin worm. Really starting to feel like I paid top dollar for a backstreet spray job.

(http://img.photobucket.com/albums/v467/amstrange1/A0001A86-3935-485D-AFA5-52BB737ABC2E-5730-000019B6278B83FB_zpsa029ff92.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: z3i on February 15, 2013, 07:19:25 am
take
 it back to the bodyshop. you paid hard earned money for a shite job. if
 we had let that roll out the door our customer would have exploded! and
 we would probably respray plus some of thier money back
if you kick up enough fuss they will sort it and its not right!
i think im getting more wound up about this than you! haha
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Yoof on February 15, 2013, 12:46:35 pm
Problem is- the bodyshop don't really give a shit. After rectifying the battery tray with a hammer last time, to solve their initial fuck up- neither of us left being impressed at all, this is a £2k+ job, not a few hundred quid special. The paint is good- but the craftsmanship and care behind it is utterly shocking.

Shame, as previously they've done some good work. I think money back and find someone who is willing to put care into their work.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: z3i on February 15, 2013, 01:37:05 pm
Quote from: Yoof on February 15, 2013, 12:46:35 pm
Problem is- the bodyshop don't really give a shit. After rectifying the battery tray with a hammer last time, to solve their initial fuck up- neither of us left being impressed at all, this is a £2k+ job, not a few hundred quid special. The paint is good- but the craftsmanship and care behind it is utterly shocking.

Shame, as previously they've done some good work. I think money back and find someone who is willing to put care into their work.

£2k plus is serious money! its a shame. yeah, need to find someone with some passion in their work, and working with cars is a hobby not just a job
shame you guys are so far from me :/
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: SamG40 on February 15, 2013, 11:17:18 pm
That's shit.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on February 15, 2013, 11:27:23 pm
It's embarrassing. I couldn't hand something over knowing it was in this state.

I don't get it. Seems like a different bodyshop to the one I've left my car with twice now, who were always careful with it, took their time and went out of their way to help.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: PeteG40 on February 16, 2013, 07:39:52 am
Difference is Alex, andy can tell a few people they are shit. You can tell an industry. I say we all add them on Facebook. Then tag them in Andy's photos. Then when they block one of us for it. Another one tag photos. Until they either have to give up Facebook of give a refund.   Who's up for it?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on February 16, 2013, 10:25:28 pm
The hole in that logic is I didn't have an outlet to write for when my car was painted. I had just finished at Max, and was a year away from my regular slot on PVW. They could've done anything to my car, and I'd have been unable to do a thing about it other than moan on forums and Facebook.

Plus you'd be amazed if you saw some of the work handed back by bodyshops for mag coverage. I've seen welding worse than I'd be able to manage, and I've never welded in my life. I've seen paintwork with runs in it and panel gaps you can get a thumb into. I've seen one car which came back with suspension parts missing and driving aids not hooked up properly. Took me a long time to find a bodyshop I felt I could trust, I've had my fingers burnt before. Eastcote Customs painted two of our project cars and they were both fine.

Don't misread that as defending what's happened here, because this isn't good enough even for a cheap job. I'm just surprised and disappointed it's turned our like this. Disappointed because I've been singing their praises since I got mine back, I feel a bit let down that they've not lived up to that recommendation by a long shot. Ultimately though, I'd be hard pressed to recommend them again based on this. Unless of course they come good and fix it.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on March 07, 2013, 07:10:57 pm
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:
(http://img.photobucket.com/albums/v467/amstrange1/41D37040-DC7B-4AB8-BBDE-68B3773F54DE-3349-00000EE1C0F5136D_zps1cf0dd36.jpg)

Got new hubs and bearings for the Gaz coilovers:
(http://img.photobucket.com/albums/v467/amstrange1/F6CBC105-E1A2-45AA-BF4E-1BE0AD4F7754-3349-00000EE169748403_zpscc3f315a.jpg)

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:
(http://img.photobucket.com/albums/v467/amstrange1/07F1B7AB-A75B-479E-A215-DD3F409E3C94-3349-00000EE18FCB79C1_zpsa42f9bbc.jpg)

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.
(http://img.photobucket.com/albums/v467/amstrange1/12E04F06-89CD-4954-B15B-8AA9F3F81FF0-3349-00000EE17A8D2F8C_zpsba2d9caf.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/AC559DCB-D0C3-447F-983E-C61DFE93E52B-3349-00000EE18199AF65_zpsab259d77.jpg)

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:
(http://img.photobucket.com/albums/v467/amstrange1/63F7F8DD-5899-4AA7-89DB-86F338108A20-3349-00000EE19D3CD726_zpse9ec11ef.jpg)

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.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: mark_crox on March 08, 2013, 11:02:26 pm
Looks goods ... :)
don't blame you about the lines. they where a total pain the the arse on my car.. never want to do them again! But may have to as I'm fitting 2 brake regulators to the rears :(
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on March 17, 2013, 08:20:22 pm
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:

(http://img.photobucket.com/albums/v467/amstrange1/EB0CCE75-6EA2-49AB-A1DB-61889BBED77F-5041-0000160A9097D82B_zpsc66e5683.jpg)

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

(http://img.photobucket.com/albums/v467/amstrange1/71CE4F98-4F85-4ED2-AB54-56C9D8F9B56A-5041-0000160A9C0FECDD_zpse9087750.jpg)

New brake shoes and brake cylinders:

(http://img.photobucket.com/albums/v467/amstrange1/B70A484E-EAF5-4040-9645-7A9D56895396-5041-0000160AACE786F7_zps9cb2e00c.jpg)

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!

(http://img.photobucket.com/albums/v467/amstrange1/D71ACB01-F29A-41D3-8B75-A887AAC3F0D5-5041-0000160AD3F0B22E_zps5092892e.jpg)

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:

(http://img.photobucket.com/albums/v467/amstrange1/932BBA6F-841B-4AED-83DB-6E6B8650956A-5041-0000160AE5F5EEF0_zps6049defe.jpg)

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!

(http://img.photobucket.com/albums/v467/amstrange1/0363E659-FC27-4220-89A4-BB17DB914102-5041-0000160AFD644010_zps0e625930.jpg)

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...

(http://img.photobucket.com/albums/v467/amstrange1/98661B39-B803-495C-9CF7-F9A79DBBECBF-5041-0000160AC4C0DDD0_zps13728fa3.jpg)

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:

(http://img.photobucket.com/albums/v467/amstrange1/D827D2E7-1D93-4CEC-BE3F-6FA731BE8736-5041-0000160ACD768E50_zps8a1052e2.jpg)

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

(http://img.photobucket.com/albums/v467/amstrange1/F8614942-F82E-4BC0-AF5D-5B1753556A21-5041-0000160B032C8E1F_zpsa89b53a0.jpg)

Dismantled the brake fluid reservoir and gave it a clean.

(http://img.photobucket.com/albums/v467/amstrange1/E0989945-D0A5-4401-ADC0-24EF4F5E1C9A-5041-0000160B0996909F_zps7b73f21d.jpg)

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.

(http://img.photobucket.com/albums/v467/amstrange1/62BC4179-7107-4936-8EE3-8664C8B19225-5041-0000160B0F683B89_zpsb890ce84.jpg)

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.

(http://img.photobucket.com/albums/v467/amstrange1/C2C7BA4E-3FFE-4409-9945-147D4039DFE7-5041-0000160AED0A2FC4_zps2ffcbe4e.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on March 17, 2013, 08:24:51 pm
Looking good!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Etches on March 17, 2013, 09:09:40 pm
Great job Andy!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: P1rik on March 17, 2013, 11:12:56 pm
Nice work very clean polo
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on April 01, 2013, 09:55:01 pm
Got the coilovers put on the front.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_1320_zps3a97b8fe.jpg)

Whipped the steering arms and rack off, and fitted a new 22mm master cylinder and the brake fluid reservoir.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_1322_zps3cc043f8.jpg)

Audi caliper carriers for Girling/Lucas 54 calipers, cleaned up and strung up ready for high-temp paint:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_1327_zps6ada591b.jpg)

Rack got stripped down, cleaned and re-greased. Now refitted, along with the steering arms.
(http://img.photobucket.com/albums/v467/amstrange1/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.
(http://img.photobucket.com/albums/v467/amstrange1/43B246B1-6C40-490B-B9F0-8523597BE9E1-8485-000022CB08C868BF_zps31f33913.jpg)

Fitted the front brakes, caliper carriers all painted up. New calipers, Ferodo DS2500 pads and braided lines.
(http://img.photobucket.com/albums/v467/amstrange1/37ECD826-065D-4A27-9BB2-A9DC9270EBD3-8485-000022CB14585179_zpsef14575f.jpg)

New/refurbished Lucas 54 calipers done by TRW.
(http://img.photobucket.com/albums/v467/amstrange1/707B7CC4-5DB9-4BE9-8C4E-F567AE4AC3B8-8485-000022CB1BD55FBB_zps85c83b2c.jpg)

Just got to finish off the hard brake lines at the rear and then it's finally on to the engine!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on April 12, 2013, 08:34:44 pm
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:
(http://img.photobucket.com/albums/v467/amstrange1/6410ED37-B8A0-448C-BEA2-E940F7245419-474-000001C245335252_zpscb6d43e9.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/ED461926-C9E4-4C5E-BA80-E750DF2D3DE0-474-000001C25550866E_zps7181d226.jpg)

Fuel pump assembly was a mess, and the crimped rubber onto the nylon lines was buggered:
(http://img.photobucket.com/albums/v467/amstrange1/7F0DA99B-205B-4EB6-84D3-AF24B0683E30-474-000001C26D58E50F_zps591710e3.jpg)

New powder coated fuel pump bracket went on:
(http://img.photobucket.com/albums/v467/amstrange1/3F237A8E-FA58-47FE-BE39-5C30856EC716-474-000001C2840BF7B2_zps8135c97b.jpg)

Cleaned up pump & accumulator with new filter and new rubber hoses & clips:
(http://img.photobucket.com/albums/v467/amstrange1/3C85AAA3-C9F6-4B03-AA95-89ED24654448-474-000001C292CA4D52_zps3e3a52bb.jpg)

And now installed:
(http://img.photobucket.com/albums/v467/amstrange1/ACF44DE1-7194-4643-8D7C-DEB79FE1A9DD-474-000001C2A5097BDA_zps58cb7306.jpg)

Car's now back on its wheels, and it's time to start on the engine - FINALLY!
(http://img.photobucket.com/albums/v467/amstrange1/A9428E1F-EF1F-4BAF-858B-88D299FC3BB5-474-000001C2B0EB730C_zpsee3ca2ed.jpg)

(http://img.photobucket.com/albums/v467/amstrange1/2D974BC1-DCAA-4A07-AAA1-75802DF6BF81-474-000001C2AAB1DA78_zpsbdaee407.jpg)

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?!
(http://img.photobucket.com/albums/v467/amstrange1/340E28CA-AE79-4AA2-ACB2-29070420BACB-474-000001C2D75051E7_zps7467aee6.jpg)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Etches on April 12, 2013, 09:26:29 pm
Cracking work Andy! The rear end is always full of rust and shite so its nice to see how clean yours is looking now, first time seeing your engine in a while, nice to get back to it I would imagine!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: z3i on April 12, 2013, 10:01:34 pm
Quote from: etches69 on April 12, 2013, 09:26:29 pm
The rear end is always full of rust and shite so its nice to see how clean yours is looking

Giggidy
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Jezza-7 on April 13, 2013, 03:15:42 pm
Looking good mate, gaz coilovers look soo nice. And loving the boxes of parts as well.

Will look amazing when its all back together  :)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: AdzCM on April 13, 2013, 08:38:54 pm
This thing is ridiculously clean  :o
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Yoof on April 14, 2013, 07:10:14 pm
Next level this is now  :-*

Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on April 14, 2013, 09:11:20 pm
Ooft!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on April 18, 2013, 09:50:06 pm
Been a bit busy with other stuff, but went to go and get my tyres put on the refurbed steelies today. 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, and I needed to be in the workshop today... ;D It's a shit machine as it doesn't get much use, but as of tonight I'm now a tyre fitting pro, lol.
(http://img.photobucket.com/albums/v467/amstrange1/37A9900C-9D04-47F8-9A20-54CB62A16EA8-1519-00000620446A78B0_zps28971c58.jpg)

Most pointless "I fitted some tyres" post ever?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on April 19, 2013, 10:46:36 pm
Made some progress tonight with some help from Yoof.

New cambelt and waterpump, and repainted the lower auxiliary belt pulley. Dipstick tube painted in silver engine enamel.
(http://img.photobucket.com/albums/v467/amstrange1/E1B9052D-049D-4921-BD1F-AE7DB5A9E5BA-1519-000006D2842D72CE_zps2f9aab8d.jpg) (http://smg.photobucket.com/user/amstrange1/media/E1B9052D-049D-4921-BD1F-AE7DB5A9E5BA-1519-000006D2842D72CE_zps2f9aab8d.jpg.html)

Powder-coated inlet manifold on, along with injectors etc.
Also fitted the powder-coated Mk2 alloy rocker cover with some freshly painted bolts/washers.
(http://img.photobucket.com/albums/v467/amstrange1/98CE1B03-743F-43BB-91CC-464BD2F64652-1519-000006D27DA3C561_zps92c6f683.jpg) (http://smg.photobucket.com/user/amstrange1/media/98CE1B03-743F-43BB-91CC-464BD2F64652-1519-000006D27DA3C561_zps92c6f683.jpg.html)

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.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Etches on April 20, 2013, 03:32:53 pm
Enjoying the rocker cover Andy, bolts look great on it too. Mine let the side down in comparison, dizzy will do too haha!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on April 20, 2013, 09:12:55 pm
So, rebuilt the dizzy this afternoon. Painted it up yesterday:

(http://img.photobucket.com/albums/v467/amstrange1/D7FF3B71-3167-4D0C-8FDC-F78A13A208F8-1519-000007BB00E31604_zpsec36a4a1.jpg) (http://smg.photobucket.com/user/amstrange1/media/D7FF3B71-3167-4D0C-8FDC-F78A13A208F8-1519-000007BB00E31604_zpsec36a4a1.jpg.html)

Removed the masking:

(http://img.photobucket.com/albums/v467/amstrange1/FBB55ED6-A4EE-446E-B06C-2B25988C10B3-1519-000007BB0D4A5324_zpsf19cf124.jpg) (http://smg.photobucket.com/user/amstrange1/media/FBB55ED6-A4EE-446E-B06C-2B25988C10B3-1519-000007BB0D4A5324_zpsf19cf124.jpg.html)

New VW hall sender installed:

(http://img.photobucket.com/albums/v467/amstrange1/6D510A39-3F0C-42F7-A1B3-F16B83BEB155-1519-000007BB172FD0F6_zpsb927e92b.jpg) (http://smg.photobucket.com/user/amstrange1/media/6D510A39-3F0C-42F7-A1B3-F16B83BEB155-1519-000007BB172FD0F6_zpsb927e92b.jpg.html)

Screws in and paint-penned:

(http://img.photobucket.com/albums/v467/amstrange1/FA777B35-CFE2-4B41-907B-03019DC6D623-1519-000007BB1CCC7A1B_zps6d78cff0.jpg) (http://smg.photobucket.com/user/amstrange1/media/FA777B35-CFE2-4B41-907B-03019DC6D623-1519-000007BB1CCC7A1B_zps6d78cff0.jpg.html)

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

(http://img.photobucket.com/albums/v467/amstrange1/15C887BF-A629-43A2-BF04-334635888CF3-1519-000007BB23294E7C_zps06c2c9c4.jpg) (http://smg.photobucket.com/user/amstrange1/media/15C887BF-A629-43A2-BF04-334635888CF3-1519-000007BB23294E7C_zps06c2c9c4.jpg.html)

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.

(http://img.photobucket.com/albums/v467/amstrange1/63E5542F-C0A6-4ACF-8071-94B78A531941-1519-000007BB28F9244E_zps230d3b52.jpg) (http://smg.photobucket.com/user/amstrange1/media/63E5542F-C0A6-4ACF-8071-94B78A531941-1519-000007BB28F9244E_zps230d3b52.jpg.html)

Re-assembled:

(http://img.photobucket.com/albums/v467/amstrange1/0D71A284-C6C7-44EF-B89F-A01E94C91354-1519-000007BB59C45B9C_zps62c47ed8.jpg) (http://smg.photobucket.com/user/amstrange1/media/0D71A284-C6C7-44EF-B89F-A01E94C91354-1519-000007BB59C45B9C_zps62c47ed8.jpg.html)

New o-rings go on:

(http://img.photobucket.com/albums/v467/amstrange1/81F264E9-27F9-42ED-9179-1FED4805EEE5-1519-000007BB5F24DC7B_zps442d560c.jpg) (http://smg.photobucket.com/user/amstrange1/media/81F264E9-27F9-42ED-9179-1FED4805EEE5-1519-000007BB5F24DC7B_zps442d560c.jpg.html)

(http://img.photobucket.com/albums/v467/amstrange1/082D8CDA-AFC3-4F4A-B490-596782A2477E-1519-000007BB64AA715A_zps1e4e5c62.jpg) (http://smg.photobucket.com/user/amstrange1/media/082D8CDA-AFC3-4F4A-B490-596782A2477E-1519-000007BB64AA715A_zps1e4e5c62.jpg.html)

Done:

(http://img.photobucket.com/albums/v467/amstrange1/74442A75-FFB2-49D4-96EE-3C9C7ADA7DB3-1519-000007BB6A9A6F06_zps54df7615.jpg) (http://smg.photobucket.com/user/amstrange1/media/74442A75-FFB2-49D4-96EE-3C9C7ADA7DB3-1519-000007BB6A9A6F06_zps54df7615.jpg.html)

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

(http://img.photobucket.com/albums/v467/amstrange1/1FA0DFCD-7316-450B-B9AB-65F95CF0B0A5-1519-000007BB74DFC47F_zpsf27053af.jpg) (http://smg.photobucket.com/user/amstrange1/media/1FA0DFCD-7316-450B-B9AB-65F95CF0B0A5-1519-000007BB74DFC47F_zpsf27053af.jpg.html)

New wiring harness for the alternator to go on:

(http://img.photobucket.com/albums/v467/amstrange1/D92A083C-C7C6-4CE5-B37C-E8ED8132AC88-1519-000007BB7A751C09_zps816116a5.jpg) (http://smg.photobucket.com/user/amstrange1/media/D92A083C-C7C6-4CE5-B37C-E8ED8132AC88-1519-000007BB7A751C09_zps816116a5.jpg.html)

Fuel lines back in with fresh clips:

(http://img.photobucket.com/albums/v467/amstrange1/9C0F29E3-FE58-4D26-B9E6-DCFF5485EAA5-1519-000007BB81041365_zpsa19b5048.jpg) (http://smg.photobucket.com/user/amstrange1/media/9C0F29E3-FE58-4D26-B9E6-DCFF5485EAA5-1519-000007BB81041365_zpsa19b5048.jpg.html)

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.

(http://img.photobucket.com/albums/v467/amstrange1/A2257FCC-4AF6-49EE-BB06-FE52E25173FA-1519-000007BB86C4DBD2_zpse11720af.jpg) (http://smg.photobucket.com/user/amstrange1/media/A2257FCC-4AF6-49EE-BB06-FE52E25173FA-1519-000007BB86C4DBD2_zpse11720af.jpg.html)

Getting closer to being able to fill that empty space!

(http://img.photobucket.com/albums/v467/amstrange1/FB84B752-6440-429E-A69D-F5780FD27802-1519-000007BB91B50FD0_zps92707bcd.jpg) (http://smg.photobucket.com/user/amstrange1/media/FB84B752-6440-429E-A69D-F5780FD27802-1519-000007BB91B50FD0_zps92707bcd.jpg.html)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: z3i on April 21, 2013, 06:50:34 am
Where did you get the hall sender kit from? Vw couldnt even give me a part number!! And heritage wernt much use either

so shiny!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: P1rik on April 21, 2013, 04:52:53 pm
Love the care and attention going into this project excellent work
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on April 21, 2013, 05:45:13 pm
I got the hall sender kit from the For Sale section on here, but it should be part number 030 998 065 A - yours for £135ish from VW Heritage!

Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on April 21, 2013, 05:55:58 pm
Pushed it out into the sun earlier whilst I got on with rebuilding the driveshafts and giving them a lick of paint:

(http://img.photobucket.com/albums/v467/amstrange1/64118973-C3D2-4166-AEB1-79BD58861FF3-1519-000008E44B6DCCE9_zpsed508d76.jpg) (http://smg.photobucket.com/user/amstrange1/media/64118973-C3D2-4166-AEB1-79BD58861FF3-1519-000008E44B6DCCE9_zpsed508d76.jpg.html)

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

(http://img.photobucket.com/albums/v467/amstrange1/03F74A89-CDD4-4D2D-A0B6-2BA26D071B78-1519-000008E45161268B_zpsa8ba233b.jpg) (http://smg.photobucket.com/user/amstrange1/media/03F74A89-CDD4-4D2D-A0B6-2BA26D071B78-1519-000008E45161268B_zpsa8ba233b.jpg.html)

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!

(http://img.photobucket.com/albums/v467/amstrange1/7D0CF8FA-E5E3-48D6-A4A3-AE28FD5F2C85-1519-000008E45A39FE68_zps73d27e46.jpg) (http://smg.photobucket.com/user/amstrange1/media/7D0CF8FA-E5E3-48D6-A4A3-AE28FD5F2C85-1519-000008E45A39FE68_zps73d27e46.jpg.html)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: josé on April 22, 2013, 08:58:43 pm
Looking good Andy!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Karlos the jackyl on April 23, 2013, 08:15:40 pm
Nice hall sender  ;)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on May 04, 2013, 10:28:03 pm
Been cracking on with this again.

Dug out a PeteG40 lightened flywheel I've had for years. Comparison with stock one:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5592_zpsd1fdbc1b.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5592_zpsd1fdbc1b.jpg.html)

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.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5593_zpsd660754b.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5593_zpsd660754b.jpg.html)

Engine off the stand for the first time in over a year!
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5594_zps18f4748a.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5594_zps18f4748a.jpg.html)

Clutch and flywheel on:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5599_zps9206a6d1.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5599_zps9206a6d1.jpg.html)

Gearbox bolted on:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5601_zpsacf2ed70.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5601_zpsacf2ed70.jpg.html)

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.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5608Medium_zpsdb603766.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5608Medium_zpsdb603766.jpg.html)

Out in the sun again:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5607Medium_zps8aaa5210.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5607Medium_zps8aaa5210.jpg.html)

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.
(http://img.photobucket.com/albums/v467/amstrange1/AF991AF3-7441-4437-BD6D-2F962E271AB8-1760-0000076740E9A348_zps4ac3247e.jpg) (http://smg.photobucket.com/user/amstrange1/media/AF991AF3-7441-4437-BD6D-2F962E271AB8-1760-0000076740E9A348_zps4ac3247e.jpg.html)

Making some radiator brackets out of ally.
(http://img.photobucket.com/albums/v467/amstrange1/C7B883A1-70B0-4135-B068-CA97EC79D9E5-1760-0000076777B66949_zpsc05d33c5.jpg) (http://smg.photobucket.com/user/amstrange1/media/C7B883A1-70B0-4135-B068-CA97EC79D9E5-1760-0000076777B66949_zpsc05d33c5.jpg.html)

Marking up where to bend the strip.
(http://img.photobucket.com/albums/v467/amstrange1/C5399281-0A9D-4D21-93E4-C6D1EE25396C-1760-000007677170632E_zpsf5f64bb3.jpg) (http://smg.photobucket.com/user/amstrange1/media/C5399281-0A9D-4D21-93E4-C6D1EE25396C-1760-000007677170632E_zpsf5f64bb3.jpg.html)

Lower rad brackets before I trimmed them with some rubber strip from my random box of useful shit.
(http://img.photobucket.com/albums/v467/amstrange1/CF84B9B8-72FA-46F2-AB31-02838F4F22CA-1760-000007677DB15B27_zps0b08260e.jpg) (http://smg.photobucket.com/user/amstrange1/media/CF84B9B8-72FA-46F2-AB31-02838F4F22CA-1760-000007677DB15B27_zps0b08260e.jpg.html)

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.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on May 10, 2013, 10:08:15 pm
Boring update, but got the cooling pack installed properly and it's taken an age:
(http://img.photobucket.com/albums/v467/amstrange1/52334508-FF5E-4660-9138-9099BAE7A74E-2750-00000B7D97A06133_zps68e6c02d.jpg) (http://smg.photobucket.com/user/amstrange1/media/52334508-FF5E-4660-9138-9099BAE7A74E-2750-00000B7D97A06133_zps68e6c02d.jpg.html)

Bottom of the intercooler is bolted directly to the box section radiator bar. The top of it is secured with rubber bobbins:
(http://img.photobucket.com/albums/v467/amstrange1/FBE8AA98-CE21-40D5-AABF-50D1AEEEBAB5-2750-00000B7D847CF1E6_zps3572fc2a.jpg) (http://smg.photobucket.com/user/amstrange1/media/FBE8AA98-CE21-40D5-AABF-50D1AEEEBAB5-2750-00000B7D847CF1E6_zps3572fc2a.jpg.html)

(http://img.photobucket.com/albums/v467/amstrange1/60519B77-A0BE-4FA2-B988-8AAFF2305993-2750-00000B7D8AB33C50_zps37b2927d.jpg) (http://smg.photobucket.com/user/amstrange1/media/60519B77-A0BE-4FA2-B988-8AAFF2305993-2750-00000B7D8AB33C50_zps37b2927d.jpg.html)

It's good and solid, but it needs to be - boost pipe clearances are tight:
(http://img.photobucket.com/albums/v467/amstrange1/B2BCEE7E-BC6C-4401-A002-8C53C7C6A4AF-2750-00000B7D9091111D_zpsf1dae6d6.jpg) (http://smg.photobucket.com/user/amstrange1/media/B2BCEE7E-BC6C-4401-A002-8C53C7C6A4AF-2750-00000B7D9091111D_zpsf1dae6d6.jpg.html)

Mounted a beefy Spal fan. Got a fan mount kit which came with some nice plastic legs, but there were only two of them long enough - so used them on opposite corners and then made up my own brackets for the bottom left and top right mounts. Bottom left is angled aluminium, because I had space to use it and it's pretty rigid yet still light.
(http://img.photobucket.com/albums/v467/amstrange1/8F828C9A-F475-4E1F-BA1A-74EE9F8BA0E6-2750-00000B7DAE814A34_zpsa0600c85.jpg) (http://smg.photobucket.com/user/amstrange1/media/8F828C9A-F475-4E1F-BA1A-74EE9F8BA0E6-2750-00000B7DAE814A34_zpsa0600c85.jpg.html)

Top right doesn't have much clearance at all, so that just got ally strip.
Note how little clearance there is to the turbo water pipe and oil drain...
(http://img.photobucket.com/albums/v467/amstrange1/A5ACF8D9-A470-4B05-B29E-4DC2ABD5B937-2750-00000B7DBC0F956C_zpsc867bd7f.jpg) (http://smg.photobucket.com/user/amstrange1/media/A5ACF8D9-A470-4B05-B29E-4DC2ABD5B937-2750-00000B7DBC0F956C_zpsc867bd7f.jpg.html)

Turbo water pipe got bent into a more appropriate shape. There's now 20mm of clearance between that and the radiator, which is still tight between a dynamic (turbo pipe) and static (radiator) part, but should be enough.
(http://img.photobucket.com/albums/v467/amstrange1/1EBA6AC3-7C68-4C5C-B146-7815DC7EF210-2750-00000B7DC913097C_zpsbba3c02e.jpg) (http://smg.photobucket.com/user/amstrange1/media/1EBA6AC3-7C68-4C5C-B146-7815DC7EF210-2750-00000B7DC913097C_zpsbba3c02e.jpg.html)

Going to get a different oil drain sorted. This one will work, but the clearance I've currently got doesn't fill me with confidence - even though it was far worse with the old setup.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on June 11, 2013, 10:07:12 am
Progress has been a bit slow over the last month or so as this turned up:
(http://img.photobucket.com/albums/v467/amstrange1/49BBDFBD-00BF-4B2E-B940-1183ADEF9081-539-00000175CC1EF26E_zps6c19a2c7.jpg) (http://smg.photobucket.com/user/amstrange1/media/49BBDFBD-00BF-4B2E-B940-1183ADEF9081-539-00000175CC1EF26E_zps6c19a2c7.jpg.html)

Moved the water pipes around on the turbo:
(http://img.photobucket.com/albums/v467/amstrange1/5F37032C-691F-4013-8D99-05BD40B101B4-539-000001757AB65FCE_zps6d62b0cf.jpg) (http://smg.photobucket.com/user/amstrange1/media/5F37032C-691F-4013-8D99-05BD40B101B4-539-000001757AB65FCE_zps6d62b0cf.jpg.html)

Inlet pipework fitted, along with new turbo oil drain visible in the background.
(http://img.photobucket.com/albums/v467/amstrange1/ED3DAD8D-7014-4602-9140-3BE906791FEE-539-000001759C2196FE_zpsb41d0960.jpg) (http://smg.photobucket.com/user/amstrange1/media/ED3DAD8D-7014-4602-9140-3BE906791FEE-539-000001759C2196FE_zpsb41d0960.jpg.html)

Massaged one of the radiator support brackets some more to clear the compressor outlet hose properly:
(http://img.photobucket.com/albums/v467/amstrange1/02906FCA-6D0C-4A60-99EE-1ABE980DADF1-539-00000175AAAE5D71_zps1065b65d.jpg) (http://smg.photobucket.com/user/amstrange1/media/02906FCA-6D0C-4A60-99EE-1ABE980DADF1-539-00000175AAAE5D71_zps1065b65d.jpg.html)

Ended up buying a shiny pipe for the airfilter...
(http://img.photobucket.com/albums/v467/amstrange1/8A956CFF-9BB6-4A8B-88CC-A64B7F2C02E7-539-00000175DED8BB87_zps4a7a553e.jpg) (http://smg.photobucket.com/user/amstrange1/media/8A956CFF-9BB6-4A8B-88CC-A64B7F2C02E7-539-00000175DED8BB87_zps4a7a553e.jpg.html)

...it needed cutting down to size, which meant I needed to re-swage the end of the pipe. You can make a pikey swage tool out of exhaust U-clamps, but as this pipe was 80mm OD I didn't have anything to hand - so did it using a screwdriver; block of wood and a hammer. Results are just about acceptable!
(http://img.photobucket.com/albums/v467/amstrange1/9BDE374D-C79A-4282-A341-7C671C9347A0-539-00000175E7006F7F_zpsb75bf3b5.jpg) (http://smg.photobucket.com/user/amstrange1/media/9BDE374D-C79A-4282-A341-7C671C9347A0-539-00000175E7006F7F_zpsb75bf3b5.jpg.html)

Final result - Audi diesel inlet pipe mated up to the shiny 90° bend, and airfilter stashed in the inner wing.
(http://img.photobucket.com/albums/v467/amstrange1/5E68C6FE-A8B8-4F92-924B-D5E35B901A6B-539-00000175FDE17A40_zps162b744d.jpg) (http://smg.photobucket.com/user/amstrange1/media/5E68C6FE-A8B8-4F92-924B-D5E35B901A6B-539-00000175FDE17A40_zps162b744d.jpg.html)

Turbo oil line spec'd and fitted. P-clipped to the rocker cover bolt to stop it flapping about.
(http://img.photobucket.com/albums/v467/amstrange1/9DD4BED5-20C8-44F7-98F7-EEDC48999402-539-000001760ABA12A1_zps8908513d.jpg) (http://smg.photobucket.com/user/amstrange1/media/9DD4BED5-20C8-44F7-98F7-EEDC48999402-539-000001760ABA12A1_zps8908513d.jpg.html)

Better shot of the bay and turbo pipes etc.
(http://img.photobucket.com/albums/v467/amstrange1/C22ADD8C-1E62-4CAE-AF9B-84A9FE3B086A-539-0000017617E38D4C_zps79ada44a.jpg) (http://smg.photobucket.com/user/amstrange1/media/C22ADD8C-1E62-4CAE-AF9B-84A9FE3B086A-539-0000017617E38D4C_zps79ada44a.jpg.html)

Turbo water feed is taken from an unused port on the ally rad:
(http://img.photobucket.com/albums/v467/amstrange1/02FC7C14-279A-4E5F-9B46-19F36FCE2DC9-539-0000017621EBB7C4_zpsb9a020fe.jpg) (http://smg.photobucket.com/user/amstrange1/media/02FC7C14-279A-4E5F-9B46-19F36FCE2DC9-539-0000017621EBB7C4_zpsb9a020fe.jpg.html)

New coolant expansion tank and cleaned up washer bottle fitted:
(http://img.photobucket.com/albums/v467/amstrange1/A8D6445D-AE0B-48FF-87F2-D21CD8DB6210-539-0000017630097B47_zps205b339f.jpg) (http://smg.photobucket.com/user/amstrange1/media/A8D6445D-AE0B-48FF-87F2-D21CD8DB6210-539-0000017630097B47_zps205b339f.jpg.html)

Sticker updates courtesy of Dan Knight. These are a bit gay, but the tyre pressure and fuel grade ones were just because I could, and the headlamp beam alignment covered a mark in the new paint where the original sticker had been!

Before:
(http://img.photobucket.com/albums/v467/amstrange1/6C597212-8C8E-48D2-AF59-B54B8F633FED-539-00000176527D77B6_zps502b3973.jpg) (http://smg.photobucket.com/user/amstrange1/media/6C597212-8C8E-48D2-AF59-B54B8F633FED-539-00000176527D77B6_zps502b3973.jpg.html)

After:
(http://img.photobucket.com/albums/v467/amstrange1/B926283E-D3CD-4BE7-BF92-F1D5127B94EE-539-00000176596489BA_zps43083465.jpg) (http://smg.photobucket.com/user/amstrange1/media/B926283E-D3CD-4BE7-BF92-F1D5127B94EE-539-00000176596489BA_zps43083465.jpg.html)

Beam alignment:
(http://img.photobucket.com/albums/v467/amstrange1/F2D5F272-944E-483E-8A4D-CDF4134E824E-539-000001766A99B6D4_zps64a29345.jpg) (http://smg.photobucket.com/user/amstrange1/media/F2D5F272-944E-483E-8A4D-CDF4134E824E-539-000001766A99B6D4_zps64a29345.jpg.html)

New bits of trim for the bonnet:
(http://img.photobucket.com/albums/v467/amstrange1/2C16B6D6-FD19-4111-8207-EE5FB582BE04-539-0000017663ED9F7D_zpsb1cb9569.jpg) (http://smg.photobucket.com/user/amstrange1/media/2C16B6D6-FD19-4111-8207-EE5FB582BE04-539-0000017663ED9F7D_zpsb1cb9569.jpg.html)

Fresh lamps fitted:
(http://img.photobucket.com/albums/v467/amstrange1/57DA2184-30B6-4AD2-B882-18ED012A4C8E-539-000001763A1591D7_zpsc8bac6e4.jpg) (http://smg.photobucket.com/user/amstrange1/media/57DA2184-30B6-4AD2-B882-18ED012A4C8E-539-000001763A1591D7_zpsc8bac6e4.jpg.html)

Nearly looking like a car again!
(http://img.photobucket.com/albums/v467/amstrange1/66BC6C0E-ED89-4A01-A6E7-493FBE57C2C2-539-00000176407C7AEF_zpsa2c88fa3.jpg) (http://smg.photobucket.com/user/amstrange1/media/66BC6C0E-ED89-4A01-A6E7-493FBE57C2C2-539-00000176407C7AEF_zpsa2c88fa3.jpg.html)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on June 11, 2013, 11:26:24 am
Looking bloody immaculate mate! 8)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: breadman on June 11, 2013, 07:14:35 pm
Congratulations on the new arrival Andy.
Car is really coming along now, looking superb.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: dub-disaster on June 11, 2013, 09:35:46 pm
Excellent work Andy keep it u looking forward to seeing this in the flesh once its done, have you got a show or date in mind you'd like it done for what have you got left to do ??
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: hayesey on June 19, 2013, 04:26:20 pm
is your baby giving you the finger?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: lance on June 19, 2013, 09:32:22 pm
looks spot on that mate.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on June 19, 2013, 10:09:17 pm
Quote from: hayesey on June 19, 2013, 04:26:20 pm
is your baby giving you the finger?
Yeah! Got her to pose for Uncle Yoof.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on July 07, 2013, 09:27:31 pm
Did possibly the world's slowest oil cooler installation.

Started by making a bracket to mount the cooler matrix:
(http://img.photobucket.com/albums/v467/amstrange1/98B4CC97-02D3-4CE0-B01F-131BDA6E0387-1696-00000595CEC897C9_zps8cfa2b8a.jpg) (http://smg.photobucket.com/user/amstrange1/media/98B4CC97-02D3-4CE0-B01F-131BDA6E0387-1696-00000595CEC897C9_zps8cfa2b8a.jpg.html)

Hung some angled aluminium off the bobbins I used to secure the intercoooler at the top.
(http://img.photobucket.com/albums/v467/amstrange1/782B8C3F-E1FA-4AC4-A2A5-C827C4E7FFD3-1696-00000595E2122431_zps0a3aa63b.jpg) (http://smg.photobucket.com/user/amstrange1/media/782B8C3F-E1FA-4AC4-A2A5-C827C4E7FFD3-1696-00000595E2122431_zps0a3aa63b.jpg.html)

Scalloped out the angled ally so the airflow over the matrix isn't obscured:
(http://img.photobucket.com/albums/v467/amstrange1/CC15B310-D699-4F2F-A1C1-E66728C777D6-1696-00000595EA8531CB_zps11d3d833.jpg) (http://smg.photobucket.com/user/amstrange1/media/CC15B310-D699-4F2F-A1C1-E66728C777D6-1696-00000595EA8531CB_zps11d3d833.jpg.html)

Tapped the ally and stuck bolts in from underneath. Made it easy to stick the matrix on top with washers and nuts without having to get a spanner on the bolt head.
(http://img.photobucket.com/albums/v467/amstrange1/C51E5FD3-A8DF-49BE-8B55-DF544EC3B2FB-1696-00000595FD59BFAA_zpsc1f85ac7.jpg) (http://smg.photobucket.com/user/amstrange1/media/C51E5FD3-A8DF-49BE-8B55-DF544EC3B2FB-1696-00000595FD59BFAA_zpsc1f85ac7.jpg.html)

Pipework routed from take-off plate to matrix. Took me ages to find a route I'm happy with. There's velcro on the edges of the intercooler just in case the hoses rub, and then a couple of P-clips to the bumper iron to stop the pipe flapping.
(http://img.photobucket.com/albums/v467/amstrange1/81A55F87-1491-4149-B424-EB4CCFA7E44F-1696-000005965B3A647C_zps70636aa5.jpg) (http://smg.photobucket.com/user/amstrange1/media/81A55F87-1491-4149-B424-EB4CCFA7E44F-1696-000005965B3A647C_zps70636aa5.jpg.html)

The finished product:
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5647Medium_zps5a4c63c3.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5647Medium_zps5a4c63c3.jpg.html)

Crankcase breather hose routed along the inner wing next to the boost hose.
(http://img.photobucket.com/albums/v467/amstrange1/5D597B00-DD9C-44EC-BDE4-0FADA00B1503-1696-000005960C921697_zpsa62b53e3.jpg) (http://smg.photobucket.com/user/amstrange1/media/5D597B00-DD9C-44EC-BDE4-0FADA00B1503-1696-000005960C921697_zpsa62b53e3.jpg.html)

The hose then pops through the inner wing into the cavity behind the front bumper, where yet more angled aluminium came into play to mount the catch tank. Need to get the catchtank modified to fit a drain plug, but should work well as I've got the fog lamps cut-out, so will be easy enough to drain.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5658Medium_zpsdbeb9192.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5658Medium_zpsdbeb9192.jpg.html)

PPP exhaust system fitted to my turbo downpipe. Put an extra clamp on the downpipe so I could still use the original downpipe bracket hanging off the back of the block.
(http://img.photobucket.com/albums/v467/amstrange1/6B6D7869-1622-4E74-9942-CB631140EFC4-1696-000005962DBA5F08_zps3360758d.jpg) (http://smg.photobucket.com/user/amstrange1/media/6B6D7869-1622-4E74-9942-CB631140EFC4-1696-000005962DBA5F08_zps3360758d.jpg.html)

More aluminium bracket used to hold the airfilter in place. Drilled the end of the filter and stuck a bolt through the end so I could easily secure it to the bracket. My previous arrangement used cable ties, which took about 5% of the time to make fit - but used to pull the turbo inlet hoses around as the filter could still flap about - and had a few split because of it. Hopefully no such issue now.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5646Medium_zpsa1d8c799.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5646Medium_zpsa1d8c799.jpg.html)

Bolted the ECU back in, currently tidying up and re-wrapping the wiring looms.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5659Medium_zps19c599e0.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5659Medium_zps19c599e0.jpg.html)

All new washer hose etc. plumbed back in. Added an inline non-return valve which should hopefully help the washers work a little more quickly.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5660Medium_zps8b29b504.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5660Medium_zps8b29b504.jpg.html)

Whilst trimming the front bumper to fit around all the new front-end additions, I remembered that 2 out of the 3 upper bumper mounting features had snapped off. Whipped out the soldering iron and picked up some bumper trimmings from the floor to use as filler, and plastic welded them back together.
(http://img.photobucket.com/albums/v467/amstrange1/IMG_5663Medium_zpsd5d51525.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5663Medium_zpsd5d51525.jpg.html)

Re-fitted clutch and throttle cables, and various odds n sods including the wipers. It's been taking ages as I've taken to cleaning stuff up and painting things before re-fitting, which really isn't like me!

Filled the engine and gearbox up with oil earlier too, so really just wiring left to do...
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on July 23, 2013, 09:49:12 pm
MOT tomorrow...

Few more bits to do, got the roof gutter trims and door rub strips to re-apply, but they can be done after the MOT. Also got it booked in for a full geometry setup on Thursday - as long as it passes the MOT!

After that I need to re-fit and re-wire the gauges and then spend some time mapping it properly.

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5673Medium_zpsd36c6edc.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5673Medium_zpsd36c6edc.jpg.html)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5676Medium_zps0e7c21d7.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5676Medium_zps0e7c21d7.jpg.html)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5674Medium_zpsa223844e.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5674Medium_zpsa223844e.jpg.html)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5671Medium_zps184852f7.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5671Medium_zps184852f7.jpg.html)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5670Medium_zpse6512f00.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5670Medium_zpse6512f00.jpg.html)

(http://img.photobucket.com/albums/v467/amstrange1/IMG_5669Medium_zpsd8c7e605.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_5669Medium_zpsd8c7e605.jpg.html)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Yoof on July 23, 2013, 09:58:53 pm
Man this looks fecking awesome.

Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: gaz g40 on July 23, 2013, 10:20:51 pm
Two words     Pure stealth!
Looks bloody awesome man!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: breadman on July 23, 2013, 10:52:46 pm
Looking superb Andy, it's a real sleeper.
Good luck with the MOT too.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on July 23, 2013, 10:56:38 pm
Stunning! I love it!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Robin on July 23, 2013, 11:38:31 pm
Looking great there Andy.

You taking it to CoG along with yoof?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: z3i on July 24, 2013, 07:11:57 am
Looks awesome! Ultimate sleeper!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Etches on July 24, 2013, 08:45:33 am
Great job Andy, looks class!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: SamG40 on July 24, 2013, 09:40:29 am
Let us know how the MOT goes.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on July 24, 2013, 10:18:28 am
MOT'd.  ;D

Now off to the tax shop.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: SamG40 on July 24, 2013, 01:03:54 pm
Nice one! Will it be at pod in a few weeks then?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on July 24, 2013, 02:01:16 pm
Possibly! Planning on using it a bit to sort any teething issues with the new setup, so will see how it goes. Should have more confidence in it after taking it to Centre Gravity tomorrow for full geometry setup tomorrow.

(http://img.photobucket.com/albums/v467/amstrange1/IMG_2699Medium_zps904bed1e.jpg) (http://smg.photobucket.com/user/amstrange1/media/IMG_2699Medium_zps904bed1e.jpg.html)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Tav on July 25, 2013, 03:50:28 pm
Bay looks great!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: breadman on July 26, 2013, 06:46:43 pm
You must be extremely pleased with how this has turned out Andy?
Looking at the first pre MOT picture, who would ever think that this was a very quick road car that was also built for track day and 1/4 mile action? ;D
Glad to see you haven't gone for the race look with stripped out the interior and so on, looks so much better for it. Still looks very much like a basic Polo albeit an immaculate one.
Proper sleeper, great work.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on July 26, 2013, 08:44:21 pm
Thanks for all the positive comments!

Just got this back from Centre Gravity after a lengthy geometry setup on both mine and Yoof's Polos. Was an educational trip as well as a productive one. I don't profess to be a chassis expert, so please take the following in that context!

Interestingly, although the damping I'd set on the Gaz coilovers was out by a country mile - and my spring rates are on the hard side, my DIY geometry setup wasn't too ridiculous. String, spirit levels, rulers and measuring tapes can get you to a decent position if you've got a flat surface - though I think some luck and a straight shell also help!

Ride Height
I'd set my ride heights myself, turned out FR and FL were the same to the nearest mm, and RR and RL only 1mm out. Time with a metal rule and coilover C-spanners paid off. The car isn't low, but I'd set the ride height as a compromise between aesthetics and suspension travel - biased towards the latter. Feedback was that suspension travel is good.

Dampers
The car was put on a damper dyno, to check the damper effectiveness. Data from this, coupled with a test drive, enabled CG to significantly alter my randomly-guessed damper settings to something sensible.

Weight
Total car mass, with >3/4 tank of fuel and full washer bottle was 841kg. I have a full interior, no spare wheel, but things like interior rubber mats etc. in the car too. Put it down to half a tank of fuel, and it'd pretty closely match the official G40 weight. Not bad considering massive radiator, intercooler, big heavy exhaust etc. So far so good!

Most places won't touch the rear axle on the Polo, as the computer tells them it's not adjustable. This isn't the opinion of CG thankfully... I'd bolted on a straight-looking G40 rear axle, and aligned the brackets based on the original marks in the underseal. It appears that on a straightish car with a straightish axle that this is a decent place to start.

Rear Axle Before
Camber Left -1°52'
Camber Right -1°29'
Toe Left +0°12'
Toe Right +0°18'
So, it had some negative camber at the back - as most Polos that are straight and have been lowered will have. It wasn't even both sides (remember 60 minutes in a degree, not 100 - so 52' is nearly 1°) but not horrific either.
Toe out is, I believe, desirable to a certain extent on the rear of a FWD track car, as it helps the rear to grip mid-turn and aids turn-in. However, for a road car you don't want the rear to be too lively.
So therefore there was scope to improve...

Rear Axle After
Camber Left -1°29'
Camber Right -1°30'
Toe Left -0°01'
Toe Right +0°07'
As my axle and chassis seemed to be straight, no tweaking on the axle mounts was required - just Eibach shims behind the stub axles.
Rear cambers are now very even, and toe much more appropriate for a road car.

As most geometry setups reference the rear in one way or another, it's important to get this right! Then it was on to the front end - really the whole point of the exercise, as with Stage 3 frame and adjustable TCAs there's a lot more to setup than on a stock Polo.

Now here is where things are interesting, as I'd previously set camber and toe using some borrowed gauges, then taken it all apart and fitted Gaz coilovers, but I kept the TCA and compression strut lengths the same. This meant that on rebuild I had a starting point.

All I'd done on the rebuild was leave the TCAs as they were (I no longer had a decent way of measuring camber), measure the wheelbase to set compression struts (a crude way of setting castor) and got out the string and measuring stick to attempt to set the toe roughly parallel. The results were surprising!

Front Axle Before
Castor Left +2°15'
Castor Right +2°17'
Camber Left -1°23'
Camber Right -1°18'
Toe Left +0°16'
Toe Right +0°16'
Positive castor of around 2 degrees is what we're aiming for, so the 'setting wheelbase' method I'd used seemed to be acceptable here!
Camber is presumably a product of the TCAs staying the same length from when I borrowed kit to set it up last time - and a dose of luck. This amount of camber is not bad for a road car either.
Toe was set to toe-in, though I was aiming for parallel. Not bad for the old fashioned 'string method' though. Definitely some luck in getting it equal both sides.

So the aim was for improvements, but bearing in mind changing any one parameter affects the others, this is a highly iterative process - and hence time consuming. The objective was to keep similar camber and castor to what I had, but had a touch of toe-out. Adding this toe-out aids turn-in, but also is supposed to assist traction, as under acceleration the front wheels have a tendency to toe-in on a FWD car - so a bit of static toe-out means your wheels end up closer to parallel when you put your foot down.

Front Axle After
Castor Left +2°15'
Castor Right +2°06'
Camber Left -1°22'
Camber Right -1°25'
Toe Left -0°09'
Toe Right -0°09'
These might not seem like drastic changes, but they involved cutting down one of the TCAs to get the right amount of adjustment, so weren't done in 5 minutes - and required adjusting all aspects of the front end, not just the steering arm!

So, nice numbers - but ultimately this is all bollocks if it doesn't drive very well. The test drive was an eye opener.

Conclusions
I need to do some miles to decide whether spring rates need softening up, but the work done to arrive at the current damper settings took the car from utter shite to tolerable. Now this is a toy car, so tolerable ride comfort might be acceptable if the handling benefits are there...

Now, I've gone from a soggy FK kit with no ARB to 325lb/200lb front/rear springs with no ARB - so it's no shock that body roll is massively improved. Damper settings were critical to making the car driveable with these spring rates though. If I can live with the ride quality, then I won't be bothering with an ARB - roll is much much much better now.

Conveying how the car now feels to drive is difficult, as this is more subjective and less science. Turn-in is improved - but was okay before from what I remember - better now though. Mid-corner stability and traction are greatly improved, and the rear end likes to follow you round a bend now instead of staying put. This is a big improvement for a FWD car.

I'm going to see how I get on with the front toe-out, as I've always had it set parallel before - so need to get some miles on to review this. I like the turn-in improvement it brings, and certainly traction is better, but I still need to get used to the slightly more active steering you get as a result. No bother though, CG will happily tweak if required in the future.

Before the setup I could throw the car around, but not with the confidence that the chassis balance now inspires. This surprised me, as I've owned this Polo for 13 years, so know it pretty well. It's still no sportscar, but it's an awful lot better than a 20+ year old shopping trolley ought to be! I now need to put miles on the car, and contemplate further tweaks to optimise.

Three words probably sum up what I think this exercise achieved - confidence, balance and control.

Review will follow in due course from Yoof once he's had his car back out on track. His setup was more involved due to track orientated nature of the car, additional adjustability, and what's presumed to be consequences of his Oulton crash on the rear of the car.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Robin on July 26, 2013, 09:39:46 pm
Good stuff Andy. Chris certainly knows his shit and I am tempted on taking the polo to him for a session - just got to save some pennies to do so as I know he isn't cheap!!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on July 26, 2013, 10:10:25 pm
Interesting stuff. It'll be interesting to see how you get on with it.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on July 26, 2013, 10:14:01 pm
Mine was 828kg with a half tank of fuel, by the way, so fairly similar given we both have full interiors and factoring in the lighter square back shell offset by the intercooler etc on yours.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: z3i on July 26, 2013, 10:31:14 pm
wow! thats a seriously harsh front spring rate! must be harsh to drive on the roads!
Just looked cg up and they use the stuff we use at work to align cars, kinematic diagnosis system 2. BMW approved. bloody good system!!
sometimes a little twitchy but dam good!

what were you saying about adjusment on the rear? do you mean where the rear axle is bolts? are the holes slightly elongated? and are the shims just those plastic bits?
car is so dam cool!!
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on July 27, 2013, 07:40:37 am
@Taylor: It's nowhere near as harsh as I expected - no worse than Yoof's cup car setup which is ~50lb softer at the front and ~30lb softer at rear. It was horrible until the damping was adjusted though. Going to see how I get on with it.

On the rear axle the brackets mounting it to the body have slightly slotted holes, so there is scope for adjustment as standard. On Yoof's car these got slotted further to get the alignment required. Getting this right is key to making sure the car doesn't crab around, and that the rear beam is perpendicular to the direction of travel - giving even handling characteristics.

Shims are bits of plastic put behind the stub axles for fine adjustment. Same as the scene boys use to get 999° of negative camber so they fit their wicked sick 15" wide BBS XYZ123s in the arches.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: z3i on July 27, 2013, 10:36:47 am
Oh really? Wish id gone a bit harder, decided on 250lb springs front for my gaz coilies.
may swap them out for some harder ones in the future and get cg to set my damping up, their services looks spot on!

ah! Thats brilliant about the rear axle :) i always thought it was fixed and mines slightly out, so i can have a play at work

yeah my rear camber is negative 1.5, yours is 1.3 so will be investing in some shims.
haha yeah! So dam true! Though their shims are more like cheese wedges to get the very desired horizontal camber

thanks for that info mate :) will put it to good use when i get mine on the kds ramp
Cheers for putting your readings up, have something to compare mine too
if you dont mind me asking, how was the damper testing and setting up at cg?
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Alex on July 27, 2013, 04:11:33 pm
Those slotted holes on the rear axle - could they be used to correct a leaning car?

Stuck record, I know.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Jimmy B on September 11, 2013, 10:46:08 am
Looks perfect Andy - I'm very impressed with the build, nice to see us oldskoolers sticking with the old Polo base.

I move back from Germany soon. I'm hoping to lower my PY running gear into my white MK2 when I get back.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on September 11, 2013, 08:01:08 pm
Quote from: Alex on July 27, 2013, 04:11:33 pm
Those slotted holes on the rear axle - could they be used to correct a leaning car?

Stuck record, I know.
Only just spotted this! Possibly could - if yours is leaning a bit because the axle is on the piss.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: z3i on March 14, 2014, 07:51:51 pm
Hi mate, read through this and could only find your front spring rates, what have you got on the rear and how long?

having trouble with my suspension, got alot of body roll with a stage 2 sub 250lb front 180 rear

how do your spring rates behave on the road? is it crashy and squittery? i want less body roll but without the bouncing around through corners. trying to get the right rates for what i want

thanks dude :)
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: Andy on March 14, 2014, 08:09:39 pm
I'd play with your damping. I dropped to 275lb front and 160lb rear for a bit more compliance, I have no front ARB (Stage 3 frame) and would say that body roll is fine.
Title: Re: Turbo Squareback - History & Rebuild Thread
Post by: z3i on March 14, 2014, 08:16:28 pm
Oh really? That's interesting! Ok I will do. I have found that if I turn the damping up any more it just bounces around like mad, I've reached a point where I can go no further before it becomes a god awful ride
Thanks mate :)