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Discussion Starter · #281 ·
Yep. Easy to upgrade to rose joints at a later stage and both the lower rear arms and the toe bars are easy to make . Just make sure you use CDS tubing and half decent rose joints . ( the really high quality Aurora ones are £60-£100 a pop so no, I did not get them !
 

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Discussion Starter · #283 ·
As a sidetrack, the rear upper strut brace work has progressed, at least as far as making and mounting the upper and lower mounting brackets . The upper ones are clamped to the seat back brackets via a base plate of 6mm steel, a top clamp of 27mmx25mm aluminium with grooves machined in to suit the hoop like nature of the seat back brackets .The actual bar mount is then some 3mm steel welded to the base plate and through bolted through the top . The lower ones are all steel affairs .Very conveniently ,VW thought to put 4 captive nuts 85mm apart vertically and 36mm apart horizontally, right at the base of the inner wing and almost vertically below the seat back bracket, two,of which hold a chrome flip up handle for locating luggage straps (?) . Anyway , rock solid and no welding torch required to be taken to the shell, which is a bit of a bonus . I have made the upper bar with adjuster but not welded it up and still to make are the two bracing bars that will link the upper bar with the inner wheel arch at boot floor level. .
And if you have followed all that , you have probably lost the will to live . Oh, yes, I did have to very slightly cut away a small section of the plastic trim. Once the brace is in place and the parcel shelf resting where it should, it will not be not be noticeable .
And, just in case you have forgotten, battery box modifications finished and new battery installed ( but not connected ) Wheel Tire Automotive tire Vehicle Bicycle tire
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Discussion Starter · #285 ·
Back to the action underneath . Trial fitted the rear 4 pot callipers . Everything seemed o.k so I hooked up the brake pipes and hoses. Two very minor snags. The first is that the bespoke Verkline arb drop links mounted on the Verkline trailing arms are really pretty except when the bastards hit the sodding brake line on full suspension deflection. The other minors snag is my bespoke brake hoses from Epytec that cost slightly more then the GDP of a small country fit wonderfully except where they foul the inside edge of the wheel. Fortunately there was neither paraffin nor matches to hand as I was about ready to torch the &@##@&& . Anyway. Couple of hours out on my bike and things are better, but only slightly . Day off and I will consider the strategy on Monday .Photo to follow when I can bring myself the capture the crime digitally .
 

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Discussion Starter · #287 ·
Bit of progress. Steel lines cut and new fittings and flares made( bit awkward in situ) . One new line made to the nearside but still the offside to do , which is the piece that goes across the car. Anyway, re - routed lines, new brackets and now the hoses are o.k and the brake lines ( well one so far) does not get hit by the ARB drop link . Automotive lighting Hood Automotive tire Motor vehicle Automotive design
 

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Discussion Starter · #288 ·
New lines now installed and the middle section of the exhaust back . Not checked the lines for leaks yet, so that will be a job for the weekend when I hook up the callipers , bleed and hope. I have a really nice brake pipe flaring tool ( vice mounted ) that makes excellent flares SAE) and realised after I had put the lines together that the fittings I had were all DIN . The difference is subtle ( back,of the SAE flare is convex, the DIN is flat ) but as the lines are cupronickel , I think I will be o.k . The more tricky one is the fitting on the steel line as the steel is less forgiving . Bit of a schoolboy error really but I live in hope.
 

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Discussion Starter · #289 ·
Exhaust and rear number back in place this afternoon. ‘Speedycables ‘ in South Wales have suffered some staff shortages so my bespoke handbrake cables ,
promised for last Thursday will be made next Tuesday . Rear turret braces now finished and painted, so I will drop those in tomorrow and photograph
 

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Discussion Starter · #292 ·
More progress as I hope my crappy pictures show. I ended up making my own brake hoses as the Epytec ones, nice as they are , did not fit into my alloy calliper well. ( Not Epytec fault really: the calliper is designed to take a banjo bolt fitting which I should have spotted months ago ) . Anyway, one side now done . The handbrake cable is not quite what I wanted , but the ones I ordered 7 weeks ago still show no sign of appearing so I have used the ones I had made when I planned to mount calliper in the trailing position rather than in the o.e leading position . The result is a rather tight curve but it seems to work o.k and is well clear of rotating bits . Tire Wheel Automotive tire Tread Motor vehicle
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Discussion Starter · #293 ·
Final stages at long last . Now happy with the handbrake cable routing. I needed to make new handbrake levers ( the ones that fit on the calliper ) as I was not entirely happy with the angle of the inner cable when the brake was applied but all looks well now. Just need to drop it onto its wheels, set the ride height and then get it all set up ( toe, camber etc ) Wood Automotive tire Font Tree Gas
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Discussion Starter · #294 ·
Unbelievably , ran into another small snag. The front coilovers are now AST. Fitted very nicely except that the ARB drop link collar fouled the inner rim of the wheel. With some effort , I have managed to get it low down on the damper tube and out of the way , but now my Superpro drop links are too long . Replacements on their way from AST , but a real nuisance . Should have left the Ohlins on and sold the AST fronts. Nearly there .
 

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I've missed quite a lot but now I am getting more active on the forum again and the first thing after a long time I had to do, was to check this thread 😊

I see you've done a lot of work Andy. A lot of high quality work. As I see this build is turning completely into "track car" direction. Undercarriage is modified heavily and I have a question here. How is the drive now, after all these mods, compared to let's say OEM car with coilovers?

Are you after all these modifications considering any engine upgrades (maybe turbo or compressor)?
 

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Discussion Starter · #296 ·
Very good questions. It first turned a wheel last night , just a couple of hundred metres . I will try to get it booked in for wheel alignment and camber /toe adjustment today or tomorrow, and then report on how it feels. As the spring rates are exactly as before , I do not expect the ride to feel any stiffer, and my very first impression on the tarmac was no real increase in noise or vibration, but that was at 20 mph . Full report to follow .
 

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Discussion Starter · #297 ·
Oh. Engine . Really undecided about what to do and which direction of travel here . Second hand engines cost upwards of £1000 as a starting point for a rebuild , so combining that with forced induction, and the total cost could get very high. Just upgrading mine with a Supercharger would need a budget of around £7k , so lost to think about and research here .
 

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Discussion Starter · #298 ·
Right . After extensive road testing ( well, 3 miles ) the conclusion is ......... hard to tell. Road noise and vibration is no more or less than it was before . If anything, the rear is more compliant than before and the front identical ( so far, but the car has not been used in anger ) . The rear brakes feel o.k , though the handbrake is not great . The pads need to bed in of course but I suspect that, even in the longer term ,it will not be as effective as the o.e one , as by design, it does not have the same mechanical advantage . However, as long as it gets through an MOT , it is not critical to me .
 

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Discussion Starter · #299 ·
And 30 miles later .... Ride absolutely fine. Road noise ditto( any increase is more likely a consequence of my rear seats being in my loft rather than my car) .Brakes are excellent though the pedal is still rather soft ( frustrating as , with the engine off and no servo, the pedal feels rock solid ) . The snag is the handbrake which, as it stands, would not pass an MOT . It really does need to bed in properly before real evaluation but I fear I will need a plan ‘b’ , which is a nuisance .
Happy Christmas to all my readers, both of you .
 
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