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Discussion Starter · #201 ·
Thank you. Your comments much appreciated . Few more photographs. The drive shafts are built up and ready to fit . Effectively they are new but at nothing like the cost of new ones, as the individual inner and outer joints are not that expensive. I bought two pairs which come complete with absolutely everything including the cv joint grease and it cost about £110 . Even get the new outer bolts and they are over a fiver a pop .
I have also done a bit more on the handbrake calipers. Pistons now reassembled and installed with new seals and dust boots . If I do not include the paint , these calipers will have cost £35 for the pair to fully rebuild, with another £9 for the pad shims and £25 for the pads , given that they came with the rear suspension from the tdi as a bonus
 

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Discussion Starter · #202 ·
Brembos now complete apart from pads and a hydraulic pipe . A bit frustrated wit the finish on these , but they are acceptable.When I painted the handbrake calipers I accidentally used slightly less harder than I should have done. The results are really good. The paint flattened out nicely and left a good finish, For the Brembos , I used the correct ratio, left it to stand for 10 minutes and then used it. It began to go 'off' too fast and left a less even finish. However, once installed behind some wheels that is not going to show, but it is irritating
 

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Good work as always Andy. Renewed shafts really look like new ones :D

Cracking price on rear calipers that's for sure!

I really think that the pride and joy of being a car enthusiast is in DIY jobs and you Andy, definitely are taking the whole DIY thing with adding your touches, on the next level!
 

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Discussion Starter · #204 ·
Cheers. I think I am probably being a bit over ambitious with the rear brake modifications as they have led me down an 'even more fabrication ' route which may or may not work. I will post a couple of pictures tomorrow so all can see what I am up to and where I have got to so far. Lovely dry sunny day here today so a nice day to work outside with the angle grinder and associated cutting tools on a workmate . Really cold mind but it saves making a mess in the garage . I also managed a quick 'essential journey ' in the R32 , just as far as the local recycling centre . I am sooo pleased with the seats. They are really nice to sit in . You too will absolutely love yours . And yours will be a breeze to fit ! Do not forget , if yours is a 2006 model, you will probably need some 4.7ohm 1 watt resistors and the yellow connectors with the orange clip. Unless you can get to a breakers yard and find any old Mk5 golf or golf variant with the yellow/ orange connector and cut it off with about 10cm of the leads .That makes life really easy and dead cheap .
 

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Discussion Starter · #205 ·
And the results of a prototype rear lower wishbone. It solves two problems, neither of which need to be solved this way, if at all. The first is that my Ohlins coil springs are 65mm I.d and do not locate terribly well in the dustbin sized spring pan. The second is my big rear brake upgrade and adaptor modification, which involves making use of the damper mounting to offer a third location for the adaptor. The damper could still attach to the hub, albeit via a spacer , this way the damper bolts to the lower arm ( rather like the mk7 golf ) but has to rotate 90 degrees because the arm rotates in an arc about its inner mounting point, whereas the hub moves more or less in a vertical plane ( to minimise camber change under suspension deflection. ) .

Anyway, the photographs tell the story. I might try another prototype in tube . That choice makes inner and outer bush mounting easier but spring pan location ( and damper ) harder . Or maybe not.
 

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Discussion Starter · #206 ·
And then there were two. Not quite sure if these arms will end up underneath a Mk5 golf or on top of the scrap metal bin . Dimensionally, they are the same as an O.E arm. I think that the damper mount will work, although I do need to try one for size just to check .If all is well, it does make my modified brake adaptor much easier both to make and to fit.
 

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Discussion Starter · #207 ·
And then there were two. Not quite sure if these arms will end up underneath a Mk5 golf or on top of the scrap metal bin . Dimensionally, they are the same as an O.E arm. I think that the damper mount will work, although I do need to try one for size just to check .If all is well, it does make my modified brake adaptor much easier both to make and to fit.
 

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Discussion Starter · #208 ·
Diff oil seals arrived this morning and we offered a new home almost immediately . One rebuilt diff later ....... The plan is to simply swap over my Haldex when I drop my diff out and had a nice clean rebuilt one ready to go back in, together with driveshafts .
 

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Diff oil seals arrived this morning and we offered a new home almost immediately . One rebuilt diff later ....... The plan is to simply swap over my Haldex when I drop my diff out and had a nice clean rebuilt one ready to go back in, together with driveshafts .
I lost track of if you have a new haldex already?

They have a tendency to go pop due to water ingress/damage but there is a company that will refurb and improve them to protect against it happening, might be worth considering.
 

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Discussion Starter · #210 ·
Nope. The one that came with the diff is completely unknown. The one on my car has a genuine service history and 58000 miles under its belt, so all I had planned to do is to clean it , remove it , pop it on the rebuilt diff and fill it with fresh oil and a clean filter .
 

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Discussion Starter · #211 ·
As a break from making brake caliper adaptors , I thought I would fit my newly arrived Polar FIS ( Many thanks to Illegal r32 who made all this happen for me... much appreciated ) . Anyway, firmware update duly done , I though I would spend a happy ten minutes removing the panel beneath the pedals and plugging in the Polar . An hour later I came to the conclusion that despite removing said panel, Un clipping the relay box and standing on my head in the footwell, there was now way on this earth that my hand was going to get anywhere near the plug on the canbus gateway , let alone unplug it and plug the Polar in place.
Fortunately this wonderful forum rode to my rescue in the form of a post from some time ago from someone who had met the same problem. Solution is to remove the wiper arms, plastic scuttle panel, windscreen wiper motor and drive and an access panel . Beneath lurks the Canbus gateway . Now knocked off for tea, so battery disconnect in the morning, quick plug swap and I will be one Polar Fis to the good.
 

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Discussion Starter · #212 ·
Round 2. Fitted really easily. The only hard bit is fiddling the wiper motor gear back into place. Oh, and the scuttle panel. A cracking upgrade. Really nice to have temperatures, pressures, speed etc all digitally displayed and all controlled via the steering wheel. Really neat upgrade I would recommend to anyone
 

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Discussion Starter · #213 ·
Right. Warm glow of the Polar Fis has not worn off, but back to the rear brakes. The next step in this labyrinthine journey is the brackets that hold the Tdi calipers. I had to make new ones as these calipers are smaller than the R32 ones. Several hours with the pillar drill, hacksaw and files and one pair of brackets appeared. Not quite as elegant as the Epytec ones for the R32 calipers , but at £9.34 for two pieces of aluminium plate 120x100x15mm ,not quite as expensive either .
 

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Discussion Starter · #215 ·
It certainly did . Mrs Wright got flowers and chocolates but I think that the car got the better deal! Anyway, bespoke rear brake hoses from Epytec arrived this morning. Beautifully made and absolutely ideal. Just waiting for one more item and the rear ended strip and rebuild is set to go .
 

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Discussion Starter · #216 ·
Final roll of the dice with these wishbones. Prototype one went in the bin I cocked up the spring pan height , setting the base of coil spring too high to leave me any adjustment . Prototype two had more promise. It fitted, it had the damper mounting and the spring seat would still have left me with another 15mm of lowering potential if needed. Snag was (a) it weighed 1.5kg more than the o.e arm and (
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it looked as if it was designed to be in the middle of a field being towed by a Massey Ferguson . So that hit the bin. The latest iteration still needs a little coil spring centring ring in the middle of the pan and the damper mount, but as , at the moment it is 0.5 kg lighter than the o.e arm, a bit of a result. It also does not look quite so agricultural and , once powder coated , might even look half decent . However, VW probably spent a lot of time and effort designing the wishbone to take the axial and vertical loads and cost 50p to make . They used 2.2mm thick steel , and the wishbone is primarily a pressing with a top welded in place . I, on the other hand,used 50x30x3mm box steel , fired up my pocket calculator and did some beam strength calculations, primarily in bending and torsion , which is all well and good but with a fold and weld in the middle , half the beam stiffness is lost. Mind you , at just over 1000kg load per mm of deflection and a pin joint failure at 6000kg( when the bolted joint at the hub end gives in ) , perhaps it will do .In the meantime, I have nearly finished my modified caliper adaptors which retain the damper mount on the hub, so prototype three is definitely the last one and is also probably destined for the scrap bin .
 

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Discussion Starter · #217 ·
Time for an update .Brake adaptor and hub modification complete , so powder coating is the next stop. The photos below are my attempt to show and explain what the original Epytec adaptors looked like and how my modified ones look . Also finished the lower wishbones so I will have a choice of mounting the dampers back on the hub, clamping the adaptor, or mounting them on the wishbone. I will do a trial fit and decide when I am rebuilding .
Anyway, why re eingineer the adaptor when the Epytec one would work well and be more that sufficient for the task?
Answer. The Epytec adaptor is mounted via the two 14mm bolts that originally held the o.e caliper . Nothing wrong with that , except that now the braking force is on the opposite side of the disc, and the disc diameter has increased from 310 to 356mm , so that the torque applied via the caliper and through the adaptor will have increased by at least a factor of 5, and that assumes that the Brembo caliper applies the same braking force as the o.e slider . On top of that , the caliper centre of force application is offset axially something like 50mm from its bolt location , so upon braking, the forces try to twist the adaptor both around the axle line ( clockwise rotation ) and anti-clockwise longitudinally towards the car centre line . Ok. It is made of 15mm steel plate but only located at one extreme by two bolts. It will flex. That is life ( Isaac is never wrong , well, not when it comes to mechanical forces on everyday objects ) .

So, the Andy Wright adaptor is in alloy but bolted in three places , the third one doubling up as the damper location ( or not depending on the decision in the opening paragraph ) . Further , the two steel 'pillar' spacers I have replaced with a single ally spacer which gives a much more positive seating for the caliper on the adaptor and it better placed to resist the twisting moments .
 

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Discussion Starter · #218 ·
Managed to 'mock up' the offside rear brake setup today. Looks as if everything works, even the tdi rear brake calipers( although the one in the picture is upside down ) , so my brackets seem to work, but the calipers in the correct location and allow the use of the modified brake caliper adaptor . I will check the other side, just in case ........, but then a trip to the powder coaters seems to be in order.
 

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Discussion Starter · #219 ·
And just in case anyone is wondering why I have gone to the faff of modifying the tdi calipers to fit , well two reasons. The first is that they came free of charge along with a diff, frame , arms etc and the hubs , the latter being the only bits I really wanted and the second is that when I bought the car last June the rear brakes were not brilliant, so I bought some nice two piece rotors and some rebuilt calipers . As I will be using the tdi ones as my handbrake , I will be able to sell the R32 calipers and 2 piece rotors ( and the Hel brake hoses ) as a package as it make a nice upgrade for lesser Golfs .
 

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Discussion Starter · #220 ·
An update. Bits back from the powder coaters and I guess the pictures tell most of the story. The trailing arms, anti roll bar, drop links and Ohlins springs and dampers are still,on the car and will be re used. The trailing arms are already powder coated in the same grey, and the ARB is a Superpro item in blue. With new bolts, the wheel,bearings will get re used as they are only 8 months old . A new brake line to make and a slight modification to the brackets that Verkline supply to support the brake hoses, as they do not fit the Epytec hoses very well.
I had hoped to do this job during lockdown, so I am not quite sure now when I will actually crack on and strip out the back end. It will take the car off the road for a while, just at the point when I really want to use it much more regularly. ( not least getting me and my bike to my weekly cycling club time trials and circuit races . )
 

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