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Whilst I was fitting
the bushes, Louise said she would remove the soundproofing form the
ceiling... Taking care not to use anything that would damage the roof
externally, like an angle grinder
, she used a 6" steel rule and hairdryer to remove the insulation
Meanwhile, I refitted the front slam panel, lower valance, bumper, chin spoiler
and grille.
I need to get hold of the metal panel that sits at the bottom of the
grille, and above the bumper, visit to scrap yard required I reckon....
I've had to re-solder many of the connectors for the headlamps /
indicators as they are slightly different / damaged on the loom. I've got
the dipped beam and nearside main beam and indicators working.
That afternoon, Louise
finished her mammoth task of removing the soundproofing, she managed to
remove of 2KG worth...Hairdryer and scraper did the trick, slow and
steady. It needed to warm up before it would `peel` off
Afterwareds, a scrub with white spirit and job done
After finishing the brakes
and fitting the rear exhaust silencer, I moved onto the rear coilovers.
Catherine helped remove the wheels
I didn't take any photos of the removal and fitting of the coilovers...
This is the new coilover fitted to the wheel hub and rear beam
The topmounts were new and the rubber didnt have much `give`. I couldnt
get the top nut to start screwing onto the thread.
I came up with a solution.
Using a 17mm Ring spanner to turn the nut, I used a long socket to rest on
the nut, putting some weight onto the T bar pressed the rubber down,
allowing me to turn the ring spanner and screw the nut onto the thread.
I replaced both rear wheel bearings. I'd changed them when I bought the
car, but one had started `rumbling` at Easter, I don't think I'd tightened
it enough, so it seemed sensible to change both now, then I`ve got new
bearings all round.
Louise then adjusted the coil over springs to a starting mid-point.
Had a couple of issues, the
first time I drove down the drive, I couldnt engage reverse and had to
push it back . Much to Louises amusement...
The linkage needed adjusting, I did that and now I can select reverse, 1st
and 2nd. I cant tell if I can get the other gears until I get it on the
road. The brakes felt a little spongy, so there must still be some air, I
can easily bleed that out. The front is too high and the rear too low, but
I can easily adjust that
Unfortunately, the temp warning light started flashing, I dont know why,
it was OK the other day when I tested the engine, so I`m hoping its a
loose connection somewhere. I know the engine isnt overheating, I`d only
just started it !
Tomorrow I hope to adjust the coilovers to level the car, re- bleed the
brakes and start fitting the cage!
I`m actually believing that it will be finished by the end of THIS
weekend, I am really pleased with how its gone the last few days, tomorrow
evening and i`ll have a good feel for how its looking for being ready.
Costs so far
£2,361.91 spent on Old
golf, so carry that over. I haven't added costs for ferry getting my golf
back and tow bar fitting...
£350.00 to buy new Golf
£80 in Petrol fetching Shell (ish)
£27 Windage tray
£100 For new wheel bearings, lower ball joints and track rod ends.
£20 in misc bits (brake fluid, radiator hose etc)
£50 Polybushes
£575 Coilovers
Total Spent on NEW Golf
£ 1202.00
Grand combined approximate total.
£ 3563.00
May 17th
Fitted the plates to bolt
the roll cage to today. Took as long as I expected and had a few issues
with the welder where it worked then the gas flow cut out, so I had to
grind out and reweld parts, which make it look untidy
Anyway, thats my excuses out of the way
... I only took sequence photos for this one plate, so even though the
others look neater, I`ve posted this one so you can see the start >
finish on that one plate.
When I`d cut the old door bars off, part was still welded to the cage
Had to grind that off, which seemed to take ages...
All gone
Wedged the cage into position using blocks of wood so I could measure up
for the plate
Measured and marked new plate
Cut the plate using a saw I'd borrowed, its brilliant, cuts like it was
timber
Marked where to bend the plate
Bent the plate using a vice and large hammer
Put a 45degree edge on the plate to get a good deep weld
Put the plate in position
However, the edge isn't
square, so marked out the profile using a sheet of paper
transferred the profile to the metal and cut to suit, put the plate into
position and tack welded it
Started welding along the rear edge, then along all edges, grinding out
bad weld and re-welding where necessary (which was a pain...)
Cleaned using wire brush
Sprayed with primer
Sprayed with metallic blue (i`ll spray the whole cage this colour before
fitting)
All 4 plates are in position, cage is bolted in ready to make the door
bars tomorrow. I'll then remove the cage, spray it, refit it and then weld
in the door bars, spraying the weld area afterwards. The camera makes the
welding look worse than it is, I admit is isn't the prettiest I've ever
done, but there is good penetration and I'm happy with the strength.
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