Another Wreck, another Race Car.....

[Peter Jones]

Watch this space.

Pete

[Jarred]

I have a feeling I know what's coming...


:biggrin:

[GoLfMan]

ohhh i wanna see piccies :D

[Preen59]

Ahh very very nice. Woo! :biggrin:

[DubSteve]

Pete I am watching but all I can here is the sound of your air horns from Sydney :D

[Preen59]

http://caseman.files.wordpress.com/2007/09/quagmire-38651.jpg

Giggety!

[Tim]

another teaser thread...

[Peter Jones]

Delivered late last night in the rain. The ideal race car project car.

It's a '76 2 door Swallow Tail.

Pre-emission, rust free, no intrusion bars and it's not so original that you feel guilty racing it.

The rear beaver panel has been replaced at some stage with a late model one but the car is otherwise a swallow tail.

The White Golf is nearly finished, I've gone about as far as I can with it while keeping it street reg'ed. I plan to keep gaing track experience in it while I build this car into a dedicated track car over the next year or so.

The first step will be to seam weld it and have a cage built.

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320471-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320472-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320473-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320474-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320475-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320476-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320477-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320479-2.jpg

Pete

[Golf Loon]

Put the swallowtail bonnet aside mate ;)
Other than that a good base.

[Water Boy]

Yeah Pete dont bang up that bonnet... :biggrin:

This will be fun building it up and im sure we will be around weekly as recent visits for bits and advice exchanging :biggrin:

[TassieGTi]

Put the swallowtail bonnet aside mate ;)
Other than that a good base.

Why ?
Every 76er has got one.
I've got plenty how many do you want.
Will trade for a GLS one anytime.

[Jarred]

Looks good Pete. Will have to pop round soon to check it out.

I also have a few spare 3 doors bits if you need, and plenty of spare time to help out too ;)

[Peter Jones]

The bonnet's already claimed - As part of the deal for the car I have to replace some of the parts that the previous owner wanted to donate to his project.

It's all good though, I have found 2 MK 1s nearby with the parts I need.

Pete

[GoLfMan]

if ya need those wheels come get em mate :)

[Oneofthegreats]

Why ?
Every 76er has got one.
I've got plenty how many do you want.
Will trade for a GLS one anytime.

Sorry. Not all 76's got the swallow tail bonnet.

They were all mixed matched.

You could have a normal 76 with all the other swallow tail part's except the bonnet or bever panel.

Or you could have a normal 76 with none of the swallow tail part's on it.

I think the only common part on all the 76er's were the chrome door handles!

VW Oz just put together the car's with what ever part's VW sent them, which were both left over panel's & the next year's panels

[Golf Loon]

VW Oz just put together the car's with what ever part's VW sent them, which were both left over panel's & the next year's panels

Yeah thats right Tim, the 76sers were bitzas as VW empied the wharehouses.

I have a swallowtail bonnet or two also, but they dont make em anymore.

[gtimk5]

I dont think I ever saw an Aussie 76er with the raised section along the front of the bonnet as on the 77on imported models. The problem with them was owners pushing the bonnets closed rather than just dropping them. Without the rodged section they suffered from dents and bends.
I was an apprentice when the first golfs were released in Australia and bought my first one in 1977.
Showing my age eh !!!!!!!!!
Andrew :)

[Young Timer]

Looks like Bill's old motor?

[Peter Jones]

Looks like Bill's old motor?

Yep, Don't think he ever had this one on the road though.

[Peter Jones]

Looks like I spoke too soon about the rust, but then it wouldn't be a 76 without rust would it?

Passenger floor is pretty bad, I vacuumed a couple of holes into it:duh:

I'll weld in a new floor section I think. I'll need a mig welder for the seam welding anyway....

Pete

[TassieGTi]

32 years is a long time to collect moisture and the 76s weren't sealed very well but hey a mig welder is a great investment.Use plenty of POR 15 and it will never rust again.

[Preen59]

\I'll weld in a new floor section I think. I'll need a mig welder for the seam welding anyway....

Pete

Much easier to use a TIG or oxy and fuse the 2 panels together. You don't even have to use filler rod and its very neat. :)

[Peter Jones]

Much easier to use a TIG or oxy and fuse the 2 panels together. You don't even have to use filler rod and its very neat. :)

Hmmmmm, I can do that! That's how I did the shock towers in the white car.

I think I was just looking for an excuse to buy a new toy.:)

1" welds 1.5" apart is the go IIRC.

Pete

[gldgti]

heh - we fuse all day long at work - and it never occurred to me to do it on the shock towers either. thanks preeny.

still, a mig is handy for other stuff.

FYI pete - i just bought a 200amp ebay one (might pick it up today) and will let you know how it goes once i get a chance to use it (next week).

car looks promising - love that blue - such a happy colour!

[mollins]

looks like a good starting point. might be a good start for class racing due to light doors and pre emissions!

looking forward to some more of your vw magic..

[Preen59]

heh - we fuse all day long at work - and it never occurred to me to do it on the shock towers either. thanks preeny.

still, a mig is handy for other stuff.

FYI pete - i just bought a 200amp ebay one (might pick it up today) and will let you know how it goes once i get a chance to use it (next week).

car looks promising - love that blue - such a happy colour!

Also a good idea to stitch weld the centre floor brace too. These are all things i am yet to do, though! haha.

By all means buy a MIG, Pete, they're bloody fantastic machines and make everything so much easier and faster. Aydan- Tell me how the Ebay special goes! If they're good, i'm gonna snap one up too.

[Peter Jones]

Yeah I'm kinda curious about those $200 jobs too.
I've got a BOC account so gas isn't an issue, I'd prefer to run gas sheilded.Never really heard any raves about running gasless. Isn't that just a small gauge arc welder then?

I set up 15amp sockets in my garage for the compressor and arc welder so I'm good to go power wise.

There seems to be a big jump in price on the MIGs. Crap for $100 , awesome for $1000 and stuff all in between. It'll be interesting to see how the $200 ebay units work out.

Pete

[Preen59]

Yeah I'm kinda curious about those $200 jobs too.
I've got a BOC account so gas isn't an issue, I'd prefer to run gas sheilded.Never really heard any raves about running gasless. Isn't that just a small gauge arc welder then?

I set up 15amp sockets in my garage for the compressor and arc welder so I'm good to go power wise.

There seems to be a big jump in price on the MIGs. Crap for $100 , awesome for $1000 and stuff all in between. It'll be interesting to see how the $200 ebay units work out.

Pete

I was thinking of buying a 350 amp 3 phase (We have 3 phase at the workshop.. :D) MIG with a detachable (4 wheel drive) wire feeder.. But i just couldn't bring myself to find a way of justifying it...

You're right.. There's really no good mid range stuff. If you want to spend upwards of $1000, you're better off spending a bit more and getting a really good machine with a copper transformer and really good electrical control.

Gasless is crap. Throws mega spatter too.

[Peter Jones]

I was thinking of buying a 350 amp 3 phase (We have 3 phase at the workshop.. :D) MIG with a detachable (4 wheel drive) wire feeder.. But i just couldn't bring myself to find a way of justifying it...

You're right.. There's really no good mid range stuff. If you want to spend upwards of $1000, you're better off spending a bit more and getting a really good machine with a copper transformer and really good electrical control.

Gasless is crap. Throws mega spatter too.

Yeah, mate of mine has a $15,000 3 phase TIG welder he does cylinder heads with. Damm cool, if you turn it right up you can blow a falcon straight 6 head clean in half:biggrin: I used to repair his antique TIG before he got the new one. The old one was an old commweld piewarmer with a mechanical vibrator and stand alone water cooling for the torch. Loads of laughs!

I'd like a TransMig but I can't justify the price.

Pete

[gldgti]

Yeah I'm kinda curious about those $200 jobs too.
I've got a BOC account so gas isn't an issue, I'd prefer to run gas sheilded.Never really heard any raves about running gasless. Isn't that just a small gauge arc welder then?

I set up 15amp sockets in my garage for the compressor and arc welder so I'm good to go power wise.

There seems to be a big jump in price on the MIGs. Crap for $100 , awesome for $1000 and stuff all in between. It'll be interesting to see how the $200 ebay units work out.

Pete

they ebay one i got runs gas or gasless - i was never going to be sold on gasless only - haha. its only 15% duty cycle at 185A (we'll see) but since most of the time i'll be using it at sub 100A. hopefully pick it up from work this arvo. (thats right, i'm not at work - uni, hehe)

the one i got has a 12 month warranty and satisfaction/money back guarantee, from a store with good history, so i think i'm pretty safe.... the model i bought have been going for around 4-500 bucks, i managed to get it for $360 + $50 p+h.

anyway - sorry, this is way off topic - but i will definately do a good write up for you guys when i use it.

[AUC-05L]

my mate has the cheap ebays special mig. aside from a few niggly things like the wire feed jaming (fixed now) its been good. excellent for welding panels which is what he uses it for.....i'll be getting one eventually.

[Peter Jones]

Cleaned the car up a bit over the weekend.

The passenger floor is pretty bad, i'm going to have to replace most of it.

Welded up a few of the trim holes.

Those tar mats came off pretty easily with a heat gun.

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320500-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320502-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320503-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320504-2.jpg

Pete

[Peter Jones]

I'm a bit concerned with the passenger side sill channel by the base of the A pillar, I'm going to have to make that very strong again because a leg of the cage will end up there somewhere.

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320505-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320506-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320507-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320509-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320510-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320511-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320512-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/11/P1320513-2.jpg

Pete

[Jarred]

rusty. yum.

Got your work cut out, that's for sure.

With that corner, I'm sure a nice little bit of over engineering will do the trick! :D

[Golf Loon]

Thats not so bad Pete, I have seen worse.
You`ll be right.

[Peter Jones]

Thats not so bad Pete, I have seen worse.
You`ll be right.

Yeah, Driver's side is OK that'll clean up with sandblasting.

Passenger side will come up ok too, just needs some new metal.

That seam accross the firewall looks worse than it is. It's perforated in a couple of spots but mostly it's surface stuff that will clean up OK.

I'll be seam welding the car so it's got to go to the sand blasters in anyway to chase out all the seam sealer. I'll get them to hit the rust hard.

Need to make some progress on the beetle though so this might take a back seat for a bit. I'm allowing a year to prep it, the beetle's been going for 2 years now:duh:. It's about time I focused on getting the beetle back on it's wheels. (The beetle is a 59 and it has less rust than this '76 Golf!)

Pete

[DubSteve]

Awesome work Pete, can't wait to see you tear it up :D

[gldgti]

sounds like a good plan pete, certainly look forward to seeing your hadiwork in years to come.

[DVR68U]

yeah they used very good steel in the old beetles , ive got a few at my house to ;)
cheers brenton

[Peter Jones]

Picked up a donor car tonight, a '76 2 door. It has all the bits I'm missing and is too rusty to fix. Pics tomorrow.

Pete

[Preen59]

Picked up a donor car tonight, a '76 2 door. It has all the bits I'm missing and is too rusty to fix. Pics tomorrow.

Pete

Anything can be fixed! Just depends on whether you want to spend the time and money! :)

Love to see some more pics.

[static1800]

Hope it isnt a swallowtail!! if so don't dare scrap :(

[Peter Jones]

Hope it isnt a swallowtail!! if so don't dare scrap :(

You know I didn't actually look:duh: It does have a swallow tail bonnet though.

I've only been told that the rust is terminal I haven't investigated it much myself yet. The "too rusty" assesment did come from a repected auto engineer though (Bill M). It's been stored in the open for more than 5 years. We were pretty busy just doing the trailer thing tonight to spend much time playing with it.

I'll bug bomb it before I go pulling out the interior though, it's a spider's paradise in there.

Pete

[Preen59]

Make sure you bug bomb it outside! Dad made that mistake with a karmann ghia years ago.. There was a black outline around the car in the shed! haha.

[Peter Jones]

Here's a pic to keep you all guessing for the moment.

My friends 4wd has a rear facing camera so I got to watch the golf all the way home:biggrin:

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/IMAGE_266-1.jpg

Pete

[Peter Jones]

You can sleep easy fellas,:countsheep: it's NOT a swallow tail, I just went and checked.

(Never thought I'd find a use for that smiley)

Pete

[Geoffrey Hale]

Hey Pete good to see you've got the bits to continue the blue car project.
Have you got the other one back from the dyno yet ....Cheers Geoff

[Jarred]

I've noticed you've been a bit absent of late Pete.

This explains it I spose - up to no good again!

so that's 1 Beetle. 2 4 door golfs, 2 2 door golfs, and 1 passat? and a BMW? I really didn't remember your garage or driveway being that big! j:

[Golf Loon]

He`s been busy making a multi story car park at his house :).

[Peter Jones]

Just crazy busy/stressed at work. Lots of functions this time of year too, weekends and weekdays. I'm on holidays from next week, then I'll be back into it.

White Golf comes back on Friday, it'll be on the dyno again all day Thursday.

Plans for a monster carport are underway!

Pete

[velly_16v_cab]

lol...love the photo from the 4x4 :biggrin: :biggrin:

[Peter Jones]

Donor car shots. I had a quick look at the rust situation, it's pretty bad. Bad enough for me not to lose sleep over cutting it up. Always a shame to take another one out of circulation but some must die so that others may live.

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320566-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320567-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320568-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320570-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320571-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2008/12/P1320572-1.jpg

(I'm pretty sure I need 100% of the parts too, I'll let you all know if there's anything left over.)

Pete

[Jarred]

well at least its' a martini olive golf you're scrapping:D

Might lost sleep if it was a better colour! j: haha

[GoLfMan]

Jarred and I scrapped a rusty Martini Olive 2 door aswell this year!!!

as you said, scrap one so that another may live :)

will come over soon and scope the scene out j:

[16v_kid]

i like this thread....subscribed

keep it up.

cheers

[Water Boy]

Im keen for some updates due to the return from the US :biggrin:

[Peter Jones]

Im keen for some updates due to the return from the US :biggrin:

Hopefully the bits I bought in the US will be at the docks for collection by the end of the week. Once it's here I'll right up the import process. It's complicated but can be done.

If you're good I might even show you what I bought! :nana:

Pete

[Peter Jones]

Picked up my excess baggage from the wharves today.

It's going to take few days to sort through it all but here's some high lights of what in store for the race car.

Brakes first.

Rears are Std MK3 EBC rotors
Fronts are 256mm Vented 16v Scirocco. EBC again.
I got 2 pairs of discs just in case.

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040235-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040236-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040220-1.jpg

Not sure if I'll use these yet, but useful to have in the cupboard.

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040231-2.jpg

22mm Master cylinder

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040202-2.jpg

Rears


http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040201-2.jpg

In amongst the other stuff is all the wheel bearings to go with this lot too.

Pete

[Peter Jones]

New front arms are only US$25 ea!

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040209-1.jpg

I've also got ball joints and two complte sets of urethane mounts. (They were on sale! :biggrin: )

One set shown here.

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P10402381-2.jpg

Pete

[Peter Jones]

This should be enough stuff to fully rebuild 2 020 5 speed boxes.

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P10402411-1.jpg

ARP Diff bolts.

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040216-1.jpg

Peloquin diff

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040219-2.jpg

and for the other box a Wavetrac diff!

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P10402491-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P10402501-1.jpg

3.94 R&P

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P10402521-2.jpg

Pete

[Water Boy]

Owh :eek:

What more can one ask for :biggrin:

[Peter Jones]

And a few other random bits.

This should cover the next few oil changes.

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040245-1.jpg

Big Duck-Bill spoiler in here.

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040243-1.jpg

Assorted sparkling plugs

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040244-2.jpg

Leads
http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040225-1.jpg

This is just in case a replica of my Golf breaks down in 1956

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040211-2.jpg

The moral of this lesson is don't take your credit cards to America:biggrin:

Pete

[Preen59]

Looking the goods there pete! :)

[Peter Jones]

Almost forgot, there's an EMPI MK1 shifter for the project too!..


http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040197-2.jpg

Pete

[16v_kid]

WOW, pete

nice parts.

very nice.


keep it up

[Jarred]

hahah

cool as Pete. i bet that's not even the half of it too. Will have to drop buy soon again!

Might buy one of those big tubs too for storage if you don't use them. :bluesbro:

[WABIT]

whooaahh! man! didnt even see this thread untill now!

great build mate looking good

dom

[thestu]

This should be enough stuff to fully rebuild 2 020 5 speed boxes.

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P10402411-1.jpg

ARP Diff bolts.

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040216-1.jpg

Peloquin diff

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P1040219-2.jpg

and for the other box a Wavetrac diff!

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P10402491-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P10402501-1.jpg

3.94 R&P

http://www.vwwatercooled.com.au/forums/images/imported/2009/06/P10402521-1.jpg

Pete

BEST!!! GOOD JOB PETE!!!!

make use of that 5 speed :D

[GOLFBALLS]

Whoa Pete! Just goin thru this thread now too.

I have a '76 3-door identical to yours. Same colour blue, same interior, same early bonnet with non swallowtail rear (factory). It has the old forward leaning 1100 or 1300 motor - i'll check which one.

I'll make a sunday cruiser out of it and put the EV k-jet motor from my old mk2 GTI in it.

Looking good though! Got pics of the rust in the olive one?

[Peter Jones]

Minor Progress, an extractor system from the UK, via Roccodingo in Perth, via Phillip Island and finally in my shed.

(Might make it to Orange too if Preeny beats me to the 16v build)

It's an Ashley 4 into 1 system to put a 16v motor into a MK1 RHD.

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1340154-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1340155-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/03/P1340156-1.jpg

Pete

[Preen59]

Niiiiiice. :cool:

[roccodingo]

Yours should be in the container leaving in the next week Chris, will be down Caterham next tuesday to make sure.....along with a pile of other goodies...

Roccodingo ( Via blighty ) :cool:

[Peter Jones]

Small change in direction here, I'm now planning to use 16v MK2 hubs for the bigger wheel bearings, ball joint and more easily obtainable calipers etc.

MK 2 steering arms are in a lower position too meaning I shouldn't have to flip the steering rods over.

Pete

[roccodingo]

MK 2 steering arms are in a lower position too meaning I shouldn't have to flip the steering rods over.

Pete

From memory the f/end geometry will be ok if your using ball joint extensions as well I think Pete...

[Peter Jones]

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1080128-1.jpg

[Jace]

Small asian boy you're going to teach to weld and assemble MK1s?

[Preen59]

Front apron? :)

[morgs]

Floor? Cage tubing? 600hp front mount intercooler?
Tease!

[Jarred]

I'm curious!

[Peter Jones]

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340315-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340316-1.jpg

[Jarred]

Teaser!

I knew I should have dropped by today! :P

[roccodingo]

Press or hoist ?????

[Peter Jones]

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340320-1.jpg

[Jace]

Chose to not make your own? That ought to make things easier. :)

[Peter Jones]

Chose to not make your own? That ought to make things easier. :)

Yep, I could have built one but as I'm always short of time this was a much quicker option. I'll be able to use it on the beetle too and they keep their resale value.

[Jarred]

rotissary!

yay, this means some major progress can get under way!

[Peter Jones]

Here's some pics of the "AutoTwirler" as the assembly instructions call it.

I was hoping to get the car up on it this weekend, but it was delivered missing one wheel (it's on it's way now) and the cross pieces are a little short to pick up the bumper locations.

I'll make new cross beams, it's just a 1.2m length of 3mm 50x50 RHS with some holes drilled in it.

I drilled the arms for the MK1 bumper iron mounts and welded nuts to the back of the tube so it just bolts up like a bumper.

Bumpers usually mount with M8 bolts, I've upped it to 12mm for this application.

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340318-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340325-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340323-1.jpg

[Jarred]

so does it jack it up and flip it?

is the other side identical as well?

[Peter Jones]

Some progress.

After way too long we extracted the blue golf from the pile of rubble that had grown around it since we had it out last.

It's over on the other side of my garage now so I can get some work done on it.

Today -



Removed wiring from engine bay
Removed rain tray
Removed battery tray
Removed brake booster and linkages.
Removed tar matting from rain tray area.
Removed wiper mechanism.
Removed windscreen
Removed front guards
Pulled some other stuff out too....

All looking pretty good so far, only a few minor rust spots under the matel I removed and a very good windscreen area.

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1080134-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1080133-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1080132-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1080131-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1080130-1.jpg

[Peter Jones]

so does it jack it up and flip it?

is the other side identical as well?

Yep can lift 2000lbs so you could lift a golf with the motor still in it! :-)

Both ends are the same and you can rotate it and lock it at any angle.

I'll be seam welding this so it'll save me a lot of grief getting into all the areas.

[Jace]

Rain tray was totally rusted out?
It'll be great for you to look back on this in a few months and think what an ugly, rusty ****hole it was when you started. :)

[GoLfMan]

nice Pete! REALLY looking forward to progress on this one :)

[roccodingo]

An excellent tool Pete, and your right, buying one definately saves time and energy.

You will pretty well be able to do all the welding in the optimum position, well worth the investment.

[Peter Jones]

Bought some steel today, drilled some holes in it and painted it orange.

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340335-1.jpg

Bolted it up.

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340336-1.jpg

and up she goes.


http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340342-1.jpg


Tomorrow I'll pull the suspension out and have a go at flipping it over :-)

[Jace]

Colour matching skills are lacking... :D

[Jarred]

It's not Red! is this a new direction Pete? i doubt it! hahah

can't wait to see it's guts!

[16v_kid]

I must imagine how helpful the spit roast is when it comes to full restorations.

Good work Pete, will be looking forward to see the final product.

[Peter Jones]

Wheeeeeeeeeeeeeeee!

http://www.vwwatercooled.org.au/[img]http://www.vwwatercooled.com.au/forums/images/imported/2010/09/12672pu-1.jpghttp://www.vwwatercooled.com.au/forums/images/imported/2010/09/12672pu-1.jpg



http://www.vwwatercooled.com.au/forums/images/imported/2010/09/2ilyqad-1.jpg

[Valver.]

Nice!! That'll help no end for most jobs!!

[Preen59]

Very nice!

[Peter Jones]

Ssshhh! He's sleeping......

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1080195-1.jpg

[GOLFBALLS]

Very cool. As long as thats the only 'rolling' that car does!

[Peter Jones]

As I get nearer to getting the cage in I need to make some decisions about where things go in the cabin. To do that I need the hardware.

With the dollar so strong at the moment it was time to go shopping.

Pedal set is OBP with 0.750" cylinders for the Clutch and rear and a 0.625 for the front brakes.

Clutch slave cylinder is by CNC brakes, I'll continue running the 020 boxes for now so I'll need this to pull up the clutch lever. I need to go hydraulic as my knee is shot and won't take the abuse any more.


http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340347-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340348-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340349-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340350-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340352-1.jpg

Wanted to sort the wipers too as I might take a bar across the scuttle in lieu of a strut brace bar. This is a storm wipers single wiper kit, I'll be adapting a MK3 wiper motor to a MK1 frame and then applying the single wiper conversion. It'll be mounted dead centre and parked upright.

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340353-1.jpg

By sheer luck I managed to pick up a bargain steering wheel on the weekend too.

It's a suede 350mm MOMO Deep Dish Volatne wheel. Here it is mated up to a matching MOMO hub I scored months ago for $10 off e-bay.

http://www.vwwatercooled.com.au/forums/images/imported/2010/09/P1340354-1.jpg

Just a few last little things to do to the shell before the paint comes off and the seam welding begins.

[Jarred]

Woot! some nice goodies there Pete!

If you're around this weekend, I might pop buy and have a gander, helping my brother moving into his new place, which isn't far from you!

[Volksee77]

Man you have some serious golfs on the go Pete, makes me want to go out to the farm and start building my other rally car and my genuine GTi........................................but now the moment has passed :-) How's the wavetrac going compared to the peloquin mate as with the dollar like this i'm buying one or the other. Since you are the only guy on here using both which is the better of the two?

[Peter Jones]

I haven't actually got the Peloquin into a box yet. Every time I've come close I've had some other gear box issue to sort first.

Right now for example, my Wavetrac equipped box is stuck in third.

I'm very happy with the Wavetrac though, I'm wondering if the Peolquin won't be a step backwards.

I almost need to find a third close ratio box to build up so I can finally get both diffs set up and just alternate between the boxes.

At the moment whenever I pull the wavetrac box out I have to put my spare box in which means I never get around to putting the diff in the spare box.

One of these days I'll just bite the bullet and figure out how to build these boxes my self.

[Peter Jones]

Had a play with the single wiper kit today.

Going to use a MK3 wiper motor on a cut down MK1 frame.

Here's where I got to today, still need to work out a stay for it.

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340355-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340356-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340357-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340358-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340359-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340360-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340361-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340362-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340363-2.jpg

[Jarred]

good work Pete!

[GoLfMan]

love it Pete! This is going to be great!

[Peter Jones]

Starting to get my head around the more esoteric stuff like "where do all the wires and pipes go?".

Bit pre-emptive but there's some stuff that needs figuring out up front.

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/Racecarschematic2low1-2.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2010/10/Racecarschematiclow-2.jpg

The hydraulics are a bit of a brain teaser there's going to be a mix of metric brake fittings, imperial brake fittings, imperial pipe fittings and imperial aircraft fittings!

[Peter Jones]

I'm not normally one for needless decoration, but I couldn't resist a VW Motor Sport Horn Button for my new Momo wheel.:-)

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340368-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340367-2.jpg

[Jarred]

It suits!

(lengthening message)

[Peter Jones]

Another minor, seat related item today.

I've had a bit of lower back ache after races because my spine gets quite curved into the race seat.

It really needed some lumbar support so I looked up the manufacturers catalogue and they had just the thing.

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340372-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340376-1.jpg

[Preen59]

Nice work, Pete. :)

Nothing like Lumbar support. Kidney support is also good, if you can get them (and you need it).

[Volksee77]

Where did you find that horn button pete, very horn indeed

[Peter Jones]

Where did you find that horn button pete, very horn indeed

E-Bay Germany!

[Peter Jones]

Bit more movement.

The car is booked in for paint removal next weekend.

It'll take me all year if I try and do it so it's off to the pros to get it all done at once.

Getting onto the trailer was pretty straight forward, the rotisserie will actually pass right over the trailer if you take out the spreader bar.

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340387-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340386-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340382-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340381-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340378-2.jpg

[GoLfMan]

nice Pete :D

[Peter Jones]

Ball joint extenders arrived in the mail today.

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1340395-3.jpg

[Jarred]

NICE!

from pmw (or who ever it was?)

[Peter Jones]

NICE!

from pmw (or who ever it was?)

Chap in the UK making them.


VOLKSWAGEN LOWER BALL JOINT EXTENDER.
FOR ALL MODELS USING 19mm BALL JOINT.17mm CAN BE MACHINED.
FITS PINCH CLAMP ON STOCK VW UPRIGHT,AND STOCK BALL JOINT SHANK.
RETURNS LOWER CONTROL ARM TO PROPER ANGLE TO IMPROVE FRONT SUSPENSION GEOMETRY
ON CARS THAT HAVE BEEN LOWERED.
LOWER BALL JOINT EXTENDER ARE CNC MACHINED FROM EN19/T SAME AS 4140/4142 STEEL.
THEY ARE THEN HEAT TREATED VACUUM STRESS RELIEVED.
EXTENDER DROPS BALL JOINT 50mm ON 19mm and 45mm on 17mm.

[Peter Jones]

Dropped the shell and panels off for paint stripping today.

It's getting tanked, the process will take about a week and it will remove all the paint, bog, seam sealer, glue and body deadener all in one go.

The body goes in a caustic tank which then gets heated up and stays in there for about a week.

The loose panels go in the same tank, but go into a de-rusting solution too as a second step.

Off for a bath.

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1080630-2.jpg

Left the roof bows in until the last minute.

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1080632-2.jpg

Ever wondered where the centre of gravity is on a 2 door shell?

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1080634-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1080635-2.jpg

Bath time!

http://www.vwwatercooled.com.au/forums/images/imported/2010/10/P1080636-2.jpg

With cup day next week it'll probably be bout 2 weeks before I get the car back completely naked, in bare metal.

The goal is to get the rust repairs done the minute it gets back and get all the seam welding done asap so I can work on the bare metal before I have to undercoat it.

Once that's done it'll be off to the roll cage shop.

There's pros and cons to chemical stripping vs media blasting. This isn't for everyone and not something you'd want to do to a street or show car.

I should end up with the lightest possible starting point for a racing body shell.

[Water Boy]

What class you planning on running in Pete?

[Peter Jones]

What class you planning on running in Pete?

Probably just going to stick with sprints and hill climbs. Nothing where there's much in the way of any special requirements.

The cage will be built to suit any class though in case things change in the future.

[Water Boy]

Probably just going to stick with sprints and hill climbs. Nothing where there's much in the way of any special requirements.

The cage will be built to suit any class though in case things change in the future.

Just I noticed you removed the rain tray so no Improved Prodiction.

[Peter Jones]

Just I noticed you removed the rain tray so no Improved Prodiction.

Hadn't really considered running improved production. I can always stick a rain tray back in there if the mood takes me later on.

[Jarred]

fun fun fun!

i'll have invite myself over when you start doing some welding! see if I can absorb some more infomation and technique!

[roccodingo]

Looks good pete, marty the guy that bought the cars over for Phillip island historics runs a hot caustic tank, still yet to plumb up a phosphating tank to treat the shell after the caustic. LMK how much there going to charge you as i was considering sending a few shells to a mob near wodonga.

Paint Removal (http://www.recoat.com.au/index.php?option=com_content&view=article&id=4&Itemid=5)

And the reaal treatment UK style
Paint Stripping, Rust and Underseal Removal for Cars and Industry by Surface Processing Limited (http://www.surfaceprocessing.co.uk/)

Biggest issue is to neutralise the caustic and the phosphate before paint application.

[Peter Jones]

Just got the news that the car will be ready for collection either Monday or Tuesday.

I've tee'd up some help to do the rust repairs to the floor and A pillar during the week and then it's off to Brown Davis on Friday for a rollcage.

In other news, the brakes arrived today. With the dollar so strong the timing was good to bring these in.

These are Corrado G60 twin pot calipers and will bolt straight up to the 16v MK2 hubs I'm going to use. The calipers are enormous!

http://www.vwwatercooled.org.au/[img]http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0046-2.jpghttp://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0046-2.jpg

Here's a pad compared to the pads I run now (16v Scirocco.)

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0047-2.jpg

280mm Discs to suit.

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0045-2.jpg

[AusScare]

What wheels have you got planned to fit those brakes? Are they GAP discs?

[Peter Jones]

Wheels will have to be at least 15" to clear. I have a set of Corrado steel wheels that will work but there's a lot of other considerations before I settle on which wheels I'll finally use.

I didn't get these discs from GAP but GAP do sell this size. GermanAutoParts.com (http://www.germanautoparts.com/Volkswagen/Corrado/Brake/72/1)

[Peter Jones]

Here's a side by side shot of a G60 calliper next to a MK2 16v calliper. (The MK2 calliper is the same as MK3)

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0049-2.jpg

[Jarred]

they're some big calipers! IF they dont stop her, I don't know what will!

[Jace]

This is awesome. Brown-Davis are renowned for their bolt-in MX5 rollbars. :)

[Volksee77]

Just got the news that the car will be ready for collection either Monday or Tuesday.

I've tee'd up some help to do the rust repairs to the floor and A pillar during the week and then it's off to Brown Davis on Friday for a rollcage.

In other news, the brakes arrived today. With the dollar so strong the timing was good to bring these in.

These are Corrado G60 twin pot calipers and will bolt straight up to the 16v MK2 hubs I'm going to use. The calipers are enormous!

http://www.vwwatercooled.com.au/forums/http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0046-2.jpg

Where did you get those calipers from Pete? very nice bit of kit

[Peter Jones]

These are brand new from Bahn Brenner but it is possible to find them second hand if you scour the universe.

Search eBay for "Girling 60"

They were fitted to some of the more powerful Audi 80 & 90s.

They're a bolt on upgrade for a MK3 but there's some work to do to get them onto a MK1.

There are adaptor brackets for these to bolt up to MK1 hub MMP >> Braking (http://www.momentummotorparts.com/store/braking.asp)

I'm using MK2 16v hubs (so long as I can adapt them ok) the brackets above are plan B.

[Peter Jones]

Just got the word that the car is ready for collection from the paint strippers this Saturday.

[Dub Toffee]

NICE, whats better strippers (Paint) or soda blasters? i got a shell i want to strip / blast

[Peter Jones]

NICE, whats better strippers (Paint) or soda blasters? i got a shell i want to strip / blast

Depends, Both have pros and cons.

Chemical stripping removes everything including all the stuff inside the cavities. Can be tricky to get all of the caustic solution out of the cavities which can cause paint to bubble down the track.

Media blasting won't remove all of the paint everywhere and there's a risk of distorting the panels. Very hard/expensive to remove body deadener using media blasting.

Chemical stripping doesn't remove rust in itself, many places offer a second cleaning process to remove rust.

Both methods cost about the same.

Mine's a race car so future paint issues don't bother me as much as getting all the body deadener and seam sealer out of it.

[Peter Jones]

Picked up the car and panels today.

There's less rust in it than I expected and the shell is really straight.


http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0081-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0082-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0083-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0084-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0085-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0086-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0090-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0091-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/IMAG0094-2.jpg

[Jarred]

looks good! better get that welder out!

[Dub Toffee]

THAT looks Magic!! :-) it is singing "I go the magic in me" I love the look of bare metal.

[gldgti]

Pete, looking at those pics of both the brakes and the shell gives me inspiration. Thanks mate, keep up the good work.

[roccodingo]

E mail sent with some welding info Pete.

Shell looks good but get the phosphate onto it quick !!!

[Peter Jones]

E mail sent with some welding info Pete.

Shell looks good but get the phosphate onto it quick !!!

Cheers Grant,

Was up late last night cleaning and etch priming panels like crazy :-) Got the email thanks, I'll respond soon. Back to primer now, pics to follow.

[GoLfMan]

looks great Pete! Really is a straight shell!

[Peter Jones]

It's been a busy couple of days.

Got all the loose panels cleaned up and etch primed late last night.

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1090309-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1090310-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1090319-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340434-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340436-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340440-2.jpg
This is the seam sealer/adhesive from around the underside of the bonnet. The dip didn't disolve it but it picked out pretty easily. The rust above was where water had gotten under the sealer.

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340441-2.jpg

[Peter Jones]

We tackled the passenger side floor today. Not a trivial task.

Before shots.

I took out the seat mounts as I'll be welding in lower ones for the race seats.

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340442-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340443-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340444-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340445-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340446-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340447-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340448-2.jpg

[Peter Jones]

There's three separate patches around the base of the A pillar all of which need replacing as well as the entire floor and part of the sill.

In no particular order here's the removal of old metal and the prep of the new piece.

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340453-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340458-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340459-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340461-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340463-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340464-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340465-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340466-2.jpg

That's where we left that for the moment, there's jus a bit more trimming to do now before fitting the repair piece.

The repair piece came from Jarred's old Yellow MK1.

[Peter Jones]

Manage to find a bit of time after dinner to get into a bit of seam welding.

The concept here is to stitch rather than laying down a continuous weld to allow some flex and prevent the body from tearing itself apart.

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340470-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340471-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340472-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340474-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340475-2.jpg

There's a lot more welding to come!

[Jarred]

Welds are looking good!

Glad to see some good has come from old yellow :)

[Peter Jones]

Got more seam welding done on the underside tonight.

Before.
http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1090339-2.jpg

After

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340482-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340483-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340484-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340486-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340487-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340488-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/11/P1340489-2.jpg

[Jarred]

looking good,

how many hours so far? Or not even bothering to count?

[Peter Jones]

looking good,

how many hours so far? Or not even bothering to count?

About 6 hours on the seam welding so far and about 16 (2 people x 8 hours) on the rust repairs.

Another 5 hours or so prepping and painting the loose panels.

[GoLfMan]

not mucking around Pete! Great work!

[GOLFBALLS]

This really is awesome!
It's like a tutorial.
I've got basically identical work to do on both my mk1 shells

[Peter Jones]

Marathon effort this weekend.

There's more photos, but I didn't take a lot I was pretty flat out.

We got the floor in on Saturday, it was a very big job and took all day. I finished up a couple more rust repairs too.

Sunday I finished off some of the welding, cut in a few new pieces here and there.

COuldn't leave it in bare metal any longer and it's booked in for a roll cage this friday so it had to get etch primed at the least.

Major wash down with phosphoric, water then prepsol before blowing a light coat of etch over it.

Here's some pics in no particular order, the magpie keeps wanting to help and will steal your chips if you leave them out.

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340497-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340498-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340499-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340500-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340516-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340518-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340526-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340533-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340541-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340548-1.jpg

Tired now. Have to get it rolling again before Friday, the cage shop need it on its own wheels, few more late nights yet.

[Preen59]

That's unreal. What sort of money are we talking to get a body dipped like that? It came back amazing!!!

Well done, Pete!!

[Peter Jones]

All up the stripping cost $1500 for the shell and all the panels as well as the repair piece.

Body only would have been $1200.

Comparable to blasting price wise, but blasting won't get the underbody tar stuff off.

I just didn't have the time to sand/scrape it back manually, I'd still be sanding by this time next year.

[Jarred]

Can I be of any assistance Pete? I'm free monday and wednesday nights?

[Preen59]

All up the stripping cost $1500 for the shell and all the panels as well as the repair piece.

Body only would have been $1200.

Comparable to blasting price wise, but blasting won't get the underbody tar stuff off.

I just didn't have the time to sand/scrape it back manually, I'd still be sanding by this time next year.

Well worth it, mate. What a top job. And you're doing everything properly, which i always like to see.

Great stuff dude. I'm seriously in awe. :)

[Peter Jones]

Cheers Chris,.

Jodie was sneaking about with a video camera while I was spraying.

For those who like to watch.......


http://www.youtube.com/watch?v=9oC3GSiCGGQ

By the way, that's an insanely easy way to spray a roof.

The interior was pretty easy too because I could spray the interior roof with the car upside down. :-)

[Preen59]

Pretty to watch, mate. :)

[Peter Jones]

Started bolting in the basics to make it roll.

Cleaned up a steering box and column.

Going to have to box out a recess for the pedal box to slide forward.

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340551-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340552-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340554-1.jpg

Once it's back with the roll cage all this stuff comes straight off again and it goes back up on the rotisserie for the rest of the panel work.

[Peter Jones]

With some help from Jarred during the week and Geoff Hale today the car is now at Brown Davis awaiting a roll over protection structure.

Here's some before pictures, the after pictures will come in about a week or two when I get the car back.

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340560-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340561-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340563-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340564-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340565-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1340566-1.jpg

[Jarred]

Glad I could help out the other night!

looking forward to seeing what they come up with!

[Peter Jones]

It's back!

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1090441-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1090442-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1090443-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1090444-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1090449-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1090452-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1090454-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1090455-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1090456-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1090459-1.jpg

[Peter Jones]

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1090460-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1090461-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2010/12/P1090462-1.jpg

[Jarred]

Looking good Pete!

If that wont work, I don't know what will!

[Peter Jones]

Yeah, I'm very happy with the way it turned out.

A few comments on the design.

I wanted to keep it all as light as possible which is why the single diagonals in the roof, hoop and rear stays.

Weight is also the reason for the driver side getting full double intrusion bars and the passenger side is a basic single bar.

It's a single occupant setup for track work, you'd use a more comprehensive setup for rallying.

The boxes that the rear hoop is sitting on have a compression member inside them to prevent that box from being crushed in an accident.

It's an interesting science, all the pieces of the cage do different things, some parts are for safety, some are for rigidity and the main function of the rear horizontal bar is to hold the seatbelts up.

[Preen59]

Very neat cage, Pete. I like it.

Like anything, there's more to it than is visually recognisable. :)

[GoLfMan]

nice Pete! Good to see it progressing so fast! Next the Engine?

[Peter Jones]

nice Pete! Good to see it progressing so fast! Next the Engine?

Engine is last.
Lots of bodywork first then suspension and brakes.

Much wiring too.

[Dub Toffee]

Nice work with the cage! theirs nothing like Fresh MK1 :-)

[Preen59]

There's nothing like Fresh MK1 :-)

That's taking over the bukkake sig.. spelling corrected. :P

[Peter Jones]

OK. Been quiet for the last week, painted the bedroom and installed some stainless steel balustrading.

Back to the cars now :-)

The golf is back up on the rotisserie now and the suspension is back out.

Just getting back into some rust repairs now.

First up is a tricky bit, firewall.
There's actually 3 panels that meet at the seam across the firewall.

The lowest of the panels is the main bulkhead which has an upturned flange on which the next two panels sit. The bulkhead panel is quite thick being a structural member of the car.

This is a panel I'm fabricating to replace the firewall above the seam. I made the bends with a cheap bender ($60) from the local tool place.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340573-1.jpg

This is the section that the piece above is to replace.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340574-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340576-1.jpg

The wheel well came out yesterday. More on that later.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340578-1.jpg

Spot welds cleaned up

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340579-1.jpg

New piece held in temporarily for rough trimming.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340581-1.jpg

From the inside.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340583-1.jpg

At this point I've got to make and install the lower repair piece before I can do any more with the upper section.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340584-1.jpg

Before it gets cut out a new piece needs to be shaped. Here's piece 2 with another flange bent onto it.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340585-1.jpg

[Peter Jones]

Marking up.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340587-1.jpg

Rough trim of new piece.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340588-1.jpg

Clamp in new piece.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340589-1.jpg

Beat the snot out of it with assorted hammers.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340591-1.jpg

Here's the two pieces upper and lower so you can see them taking shape.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340595-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340596-1.jpg

Marked for cut out.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340600-1.jpg

Remove lower section

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340601-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340603-1.jpg

Trial fit looks good enough to proceed.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340604-1.jpg

[Peter Jones]

From the engine bay side

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340605-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340607-1.jpg

Easier to punch holes than try and drill sheet metal.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340608-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340609-1.jpg

Lower repair panel in place

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340610-1.jpg

Clamped.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340611-1.jpg

Spotted back to the flange.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340612-1.jpg

Tacked,

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340613-1.jpg

and welded!

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340615-1.jpg

Bit of a tidy up with the grinder.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340617-1.jpg

[Peter Jones]

Tomorrow I'll finish shaping and attach the upper piece.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340619-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340620-1.jpg

[Jarred]

Looking good Pete!

[Preen59]

Nice work, dude. Really cool to see how you're going about it.

Panel work is one thing I have NO idea about. The only sheet metal work I do is prototype parts (mostly stainless) and I make my own jigs and tooling for that. No much is transferable unfortunately..

[Dub Toffee]

wow, Gota be proud of that metal work, Thats a bit more than just banging a bit of flat plate in where no one will see it. Good job

[Peter Jones]

Just purchased an ABF motor and a 02A gearbox. Unfortunately they come with a Seat Toledo attached. :-)

Pics of the donor car tomorrow.

[Preen59]

Just purchased an ABF motor and a 02A gearbox. Unfortunately they come with a Seat Toledo attached. :-)

Pics of the donor car tomorrow.

I smell horsepower... :D

[Peter Jones]

I smell horsepower... :D

I drove it today, it's certainly got potential.

The race car's a long way off built yet. Might install the motor and box stock for a R&D shake down run or two. Might even use the EFI initially just to see how the combo goes and see where I should focus on developing.

[Preen59]

Nice work, mate. Is it registered?

I have no experience with the ABFs, but from research, they seem to be quite responsive to modification. I guess it's the usual deal.. Making pretty good HP is easy, making more than everyone else.. That's where it gets tricky. :)

[roccodingo]

Chasing some SEAT parts myself Pete when you get around to breaking it...

[Jarred]

Nice one Pete

[Peter Jones]

Nice work, mate. Is it registered?

I have no experience with the ABFs, but from research, they seem to be quite responsive to modification. I guess it's the usual deal.. Making pretty good HP is easy, making more than everyone else.. That's where it gets tricky. :)

Only just de-registered this week.

ABFs make 150 HP stock. I reckon thats a pretty good starting point to upgrade from.

The Toledo claims the following specs 110 kW (150 PS; 148 bhp) @ 6,000 180 N·m (133 ft·lbf) @ 4,800

Another reason I went for the ABF is that aftermarket support is huge and there's heaps of information and experience out there

[peedman]

Nice pickup, these abfs are getting around these days!

Ive got a tip for you unique to the toledo. Get rid of the stupid long cable that attaches to the remote speedo sensor and buy a vr6 one and plug it straight to the gearbox to save some space!

[Peter Jones]

Slowy working my way across the fire wall plugging up holes.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340642-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340643-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340644-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340645-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340646-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1340647-2.jpg

[Preen59]

Nice work, Pete. I'm interested to see how you run all your lines, wires and cables.. :)

[Peter Jones]

Yeah, so am I :-)

Everything will be exposed because it's a race car and there's nothing to hide it under.

Brake lines will exit the cabin through the stock holes, remembering that the master cylinder will be inside the cabin. The line to the rear will travel along the tunnel and split in the centre of the car to each side.

Fluid reservoirs will be up in the rain tray area in front of the driver and have braided lines coming down inside the firewall to the pedal box.

Lines will be secured to the body using P clips with rubber inserts and sealed rivets.

Fuel line to remain under car but will be new pipe of suitable diameter.

Wiring will go wherever it has to. I'll be making the loom from scratch and keeping the weight down.

The only lights on the car will will brake lights and a rain light so all of that will wiring will be minimal.

I'm thinking I can can keep weight and complexity down if I go for a digital dash rather than individual instruments.

In any case my wiring skills are above average so I don't anticipate any issues. I've wired up much more complicated stuff.

[Dub Toffee]

That pluging hole business is my least favorite job bet youl be happy when the nitty gritty bodywork is done and your putting on nice smooth lines of paint :-) what do you think of that special glue you can use to glue metal behind the holes to plug them instead of welding them up?

[Peter Jones]

I'll probably be using that in a few places where I want to leave an option open to run something later.

The spare wheel filler will probably be glued in if I use a fibreglass panel for that.

I've also got "Blaze Brake" fire retardant mastic for sealing the firewall where the roll cage passes through it.

[Peter Jones]

Picture of donor motor just 'cos.

http://www.vwwatercooled.com.au/forums/images/imported/2011/01/P1090834-2.jpg

[Preen59]

What's the plan for the donk, stan?

[Peter Jones]

What's the plan for the donk, stan?

Ask me at SEDF. I've got lots of ideas but it'll be a while before it even comes out of the Seat.

It will be rebuilt of course.

[Preen59]

Ask me at SEDF. I've got lots of ideas but it'll be a while before it even comes out of the Seat.

It will be rebuilt of course.

No worries, mate. :)

[gldgti]

In any case my wiring skills are above average so I don't anticipate any issues. I've wired up much more complicated stuff.

So modest Pete! We know the truth.

Your plan sounds marvallous, will you have the car weighed when the time comes to see how all your efforts have paid off?

[gldgti]

I've also got "Blaze Brake" fire retardant mastic for sealing the firewall where the roll cage passes through it.

Are you allowed to weld the firewall to the rollcage where it passes through? Just curious.

[Peter Jones]

Are you allowed to weld the firewall to the rollcage where it passes through? Just curious.

I don't think so. I never really checked.

In any case I can't modify this cage now or it loses it's CAMS certification.

[Umai Naa!!]

Are you allowed to weld the firewall to the rollcage where it passes through? Just curious.

Short answer is no. Not exactly sure why, though.

Keep up the good work, Pete.

[Jarred]

havn't heard from Pete in a while??

Surely he must be finished by now?

[Peter Jones]

Still pottering away.

Nearly all of the metal repair is done. I have a friend coming over on the weekend to help me straighten out the boot floor and re-skin a door.

I keep finding more brackets to remove and clean up.

Hopefully not too far away from some mock fit ups and undercoating properly.

Still awaiting transport from the UK for the fibreglass bits. Should be under way soon.

Other parts are accumulating.

Work has been taking a lot of my time as I'm coordinating a big tender at the moment.

[Peter Jones]

Re skinned the Drivers door today. The one on it needed the bottom 4 inches replaced due to rust.

Process is straight forward, cut the old one off, weld on the new one.

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340655-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340656-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340657-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340658-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340660-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340661-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340662-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340663-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340664-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340665-1.jpg

[Peter Jones]

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340668-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340669-1.jpg

Got the rear floor straightened out and the strength back in it too. The seam welding can continue now.

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340667-1.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340671-1.jpg

[Dub Toffee]

this will be mental!! top job on the bodywork effort! Are you a panel beater Pete or just acquired the skills over the years?

[Peter Jones]

I have a good friend who is a contract panel beater, he specialises in resto work. Dennis helps me out when I'm out of my depth.

The welding is all mine though.

[Jarred]

Process is straight forward, cut the old one off, weld on the new one.


Yea, I'm sure it was that easy! j:

Didn't realise the floor was damaged? or was that just because you removed the wheel well?

[Peter Jones]

The car has had a rear collision at some stage in it's life, the floor in the rear was quite wavy. It hadn't been too well straightened out when they replaced the rear panel.

This is where Dennis had to help me out, the metal was very stretched and it took more expertise than I've got to pull it all back into place.

We actually deepened some of the swage lines to pull it in and the lip around the tyre well was squared up too to give back it's strength.

One area was quite buckled and had to be shrunk with the oxy before it would lie flat.

The wheel well will be replaced with a flat panel, maybe aluminium with a cross fold or maybe a fibreglass one from performance trim.

The floor is pretty thin in places from rust, welding it was a delicate job and it'll take a fair bit of hi-fill to make it look right for paint.

[Peter Jones]

Still welding away. Nearly got around all the seams now.

Starting to get into some of the mods.

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340689-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340690-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340691-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340693-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340694-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340695-1.jpg

[Valver.]

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340693-1.jpg

Lovely attention to detail with this one!! :D

On another note: sorry I haven't been in touch re those head studs. Will be away until next Tuesday, but can call in Saturday/Sunday week if this will suit? :)

[Jarred]

i was just thinking about this project on the weekend!

Glad you're still doing it!

[Peter Jones]

Lovely attention to detail with this one!! :D

On another note: sorry I haven't been in touch re those head studs. Will be away until next Tuesday, but can call in Saturday/Sunday week if this will suit? :)

Cheers, yeah I'll be about, just give me a call and make sure I'm home.

[dubmc]

great stuff pete! this is one of my favourite threads on here, keep it coming!

[Peter Jones]

Did some more work on the rear apron today.

With the spare wheel well gone I needed to make a new brace for the rear apron as well as finishing off the second row of speed holes.

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340709-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340712-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340713-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340714-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340717-2.jpg

[roccodingo]

coming along nicely Pete, holes are looking the biz for sure !!

[Volksee77]

looking very nice and professional there Peter, what are you using to pull those holes through

[roccodingo]

looking very nice and professional there Peter, what are you using to pull those holes through

One of these :D

http://www.vwwatercooled.com.au/forums/images/imported/2011/03/P1340694-1.jpg

[Preen59]

Way cool, Pete.

Don't throw all those bits out.. I'd like to see how much it all weighs when you're finished. :D

[Peter Jones]

Don't throw all those bits out.. I'd like to see how much it all weighs when you're finished. :D

I'm kinda curious too.

I've been collecting all the metal I remove, I'll weigh it all up at some stage and let you know.

Ultimately of course I'll weigh the finished car.

[Peter Jones]

looking very nice and professional there Peter, what are you using to pull those holes through

As Grant pointed out the gadget is pictured earlier in the thread.

The device is a combined punch and flare. It's quite vestatile and can be used to punch a hole, flare an existing hole or punch and flare simultaneously.

They come in a range of sizes from 1 1/2" through to 2 5/8". These holes are 1 1/2" but the diameter of the flared section is about 2".

Here's a link to the manufacturers site. You can buy them off e-bay or places like Summit racing.

Allstar Performance - racing and high performance car parts, accessories and specialty tools. (http://www.allstarperformance.com/product.htm?prod=1001http://www.allstarperformance.com/product.htm?prod=1001)

Summit Racing (http://www.summitracing.com/)

As well as removing weight, flaring the edges of the hole stiffens the panel, making it quite rigid.

My reasoning behind perforating the rear apron was to reduce drag, With the wheel well gone it's just hanging in the breeze.

I could have removed the apron entirely but I wanted to keep the shape of the car.

[Dimitri]

really nice work so far!

[Preen59]

Yes I notice a lot of people cut the apron off the Mk1s in full race trim.


I'm kinda curious too.

I've been collecting all the metal I remove, I'll weigh it all up at some stage and let you know.

Ultimately of course I'll weigh the finished car.

Yeah, weighing the finished product is the ultimate goal I guess.. But it is definitely interesting to know how much you got out of removing metal from it. :)

[Peter Jones]

Moving a bit slowly this weekend, I slept badly and have put my neck out. Google tells me the condition is Torticollis and that I'll just have to tough it out for a couple of days 'till it sorts itself out.

Anyway... I did manage to get a little more work done during the week and perforated the C pillars. Mostly for looks I guess, that's not a lot of weight saving :-)

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340722-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340723-2.jpg

[dubmc]

just a question pete, i know ive this on many race cars, but what impact does it have on structural integrity if any?

[Peter Jones]

Depends which bits you remove.

In a Golf anything behind the rear shock towers is only there to hold the tail lights up. (From a racing perspective)

Flanging the holes can actually add to the rigidity of the panel whilst removing weight.

[Peter Jones]

With the dollar so strong at the moment I've been doing a bit of shopping.

Finally bit the bullet on sway bars and opted for the lightweight hollow ones from Autotech.

Autotech Sport Tuning: Swaybars (http://www.autotech.com/category/swaybars.html?fromcat=mk1-rabbit)

Light weight means lighter race car and less postage :-), they're only about 10kg.

Front is 25mm and rear is 28mm.


http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340730-1.jpg

Front bar uses stock mounts and I was able to get a kit with nearly all of the brackets new.

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340732-1.jpg

Rear bar uses stock mounts on the beam and custom mounts on the shock tower.

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340734-1.jpg

[Jarred]

choice! Good work.

[Peter Jones]

Camber tops arrived today. These are seriously well made things!

Straight forward fit up too will easily get -2.5° of camber without modifying the towers apart from drilling the 4 mounting holes.

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340735-2.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340736-2.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340737-2.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340738-2.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340739-2.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340740-2.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340741-2.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340742-2.jpg


http://www.vwwatercooled.com.au/forums/images/imported/2011/04/P1340744-2.jpg

I dropped off the struts for rebuilding today too. They've gone to Top Performance, they'll pull them apart and take a look at the valving and spring rates, work out the best setup and rebuild them.

If you hadn't guessed it already, I bought these Koni Coil Overs off Dom.

http://www.vwwatercooled.com.au/forums/images/imported/2011/04/IMG_0160-2.jpg

[Jace]

Awesome ingredients in this recipe. Going to make one well baked delicious racecar!

[morgs]

Any adjustability on those sways? You home over Easter? Will pop in for look if ok.

Morgs

[Preen59]

I bet those strut tops weren't cheap... But worth every cent.

Nice work as always, Mr Jones.

[Peter Jones]

Not cheap at all but much better quality than others at similar prices.

The integrated spring perch helps get the most travel out of the shock.

An interesting feature is the bearing system, the spherical bearing isn't taking any axial load.


The central bearing on GC camber/caster plates is a proprietary bearing, and is made specifically for Ground Control by a US manufacturer. The load rating is 30,500 pounds, and only supports the side load of the shaft. The center bearing DOES NOT support the weight of the car, which is an original and exclusive GC feature. Therfore the load rating of the GC center bearing is incredibly overbuilt for the intended use.

The seperate bearing for the actual weight of the car, at the top of the spring, is a needle bearing that is specifically designed and manufactured in the US for axial load. This bearing, which has no other purpose than to support the weight of the car is also very overbuilt by design. The AXIAL load rating of this bearing is 12,100 pounds.

[Peter Jones]

Any adjustability on those sways? You home over Easter? Will pop in for look if ok.

Morgs

No adjustment on the sway bars. I'll be home over most of Easter except for Sunday when I'll be running at Sandown.

Pop over during the day, I'll be in the driveway :-)

[GOLFBALLS]

Such good reading! This is the most motivating thread on here at the mo!

[Peter Jones]

Progress has been a bit slow of late, work's been keeping me busy and I've had plumbing repairs to get sorted at home.

Here's another couple pieces of the puzzle just arrived today from SCCH via TPR Engineering.

Electric water pump adapter for the ABF and a rear toe stabiliser kit.

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/P1340795-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/P1340796-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/P1340797-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/P1340799-1.jpg

There's more parts on the way, but you'll have to wait to see those.

Meanwhile I'm continuing to make progress on the seam welding and rust repairs, it's nearly all done now.

Hope to start priming it soon.

[Jarred]

I'll have to come past once exams are done!

Will be good to see more progress as always!

[Valver.]

Ooh, very nice bits, and great to see some progress :D I'll be very interested in how the rear setup pans out, so looking forward to your review. Results from others in the UK with similar setups seem to be very good :)

Seeing this thread again has reminded me about your head studs, which I'd completely forgotten (!!!). If you still want them, PM your address (not sure I still have it) and I'll express them out tomorrow!!!

[Peter Jones]

PM sent.

The tricky bit with the rear toe rods will be to get them to play nice with the rear sway bar. I think they'll end up in about the same place on the beam and at the shocks.

I'm going to have to customise the mounts for both I think.

[Preen59]

Glad to see it all arrived in good order, Pete! :)

Can't wait to see more..

[Peter Jones]

Thanks for organising those bits Chris.

The water pump is going to be interesting, I'll end up with a unique solution for the alternator I think.

Definitely won't be anywhere near the stock position.

[Preen59]

Thanks for organising those bits Chris.

The water pump is going to be interesting, I'll end up with a unique solution for the alternator I think.

Definitely won't be anywhere near the stock position.

Not a problem at all, Pete! :)

Yes I'll be interested to see what you come up with..

[dubmc]

i'm just trying to figure out how thsoe rear toe rods work? i'm guessing they work in conjunction with the sway bar to stop movement in the rear beam? These would be common in a car with independent rear suspension?

[Peter Jones]

They stop camber & toe in changes in the rear axles under heavy corner loads by preventing the trailing arms from twisting.

Southern California Cylinder Heads (http://scch-heads.com/viewpart.php?id=43)

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/complete20kit20on20beam201201a20logo111-1.jpg


The VW rear torsion beam is a fast and effective way to get the rear of these front wheel drive cars rolling,unfortunately when subjected to sever lateral g forces it has a tendency of flexing inward or outward causing unwanted toe changes in the rear end of the car which leads to a more unpredictable driving environment.

A young italian Mechanical engineering student who was using his Golf MkI to compete in local racing events realized the unwanted effects of the tow changes in the rear of his car, After some thought he came up with a simple yet effective solution to fix this problem. Thus was born the rear torsion beam toe stabilizer bar!

SCCH is proud to now offer the SCCH/Cavedoni Mk I Rear Beam Toe Stabilizer Kit.
The Toe rods are constructed out of 6061 aluminum, while the drop towers use 1/8" steel before they are TIG welded together. In addition SCCH uses only the finest PTFE lined rod ends seal it washers and hardware to hold the kit together.

NOTE: Some welding is required to install the SCCH/Cavedoni Rear Beam Toe stabilizer kit to your car and the modification is permanent.SCCH recommends you consult a certified welder for this application.

[dubmc]

They stop camber & toe in changes in the rear axles under heavy corner loads by preventing the trailing arms from twisting.

Southern California Cylinder Heads (http://scch-heads.com/viewpart.php?id=43)

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/complete20kit20on20beam201201a20logo111-1.jpg

ah k yeah nice...geese mine handles extremely well with gti sway bars & vw motosport strut braces...this is just going to be something else! i can't imagine what it would be like, keep it up pete! a serious race car this will be

[alex g]

Wow haven't stopped in for a while , looking awesome.
Great work Pete.

[Preen59]

The tie rods only really need to be fitted if you have enough grip to bend the rear arms in during cornering.. On an everydayer or a weekend warrior car like mine will be I doubt they'd make much difference. :)

[Peter Jones]

More parts of the puzzle have arrived over the last couple of days. A lot of long term planning is starting to come together.

Head studs for the ABF from Valver. Bit premature for these yet, I'm trying to keep my focus on the body work, but they became available so I grabbed the opportunity.

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/P1340800-1.jpg

Sparco steering wheel quick disconnect. Need this to figure out seat and control placement in the cabin. I'll need to get the seat mounts sorted soon as I'm rapidly approaching undercoat stage.

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/P1340801-1.jpg

And a big box from Performance trim. :banana:

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/P1340802-1.jpg

These guys do a nice job of packaging.

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/P1340803-1.jpg

Door cards, only 600 grams each.

I'm required to have door cards as a safety measure, this seemed a reasonable solution.

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/P1340806-1.jpg

Fibreglass front guards, 1.6kg compared to 4kg for an unpainted steel one.

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/P1340807-1.jpg

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/P1340808-1.jpg

Spare wheel plug 800grams

http://www.vwwatercooled.com.au/forums/images/imported/2011/06/P1340814-1.jpg

More fibreglass is coming, it's on a boat somewhere in the Suez canal at the moment.