mrj
Posted a lot
Posts: 1,662
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May 30, 2011 15:39:14 GMT
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today was a good day, so i went to the workshop and started to weld ... i sandblasted the welds as preparation for lead loading ;D this is the stuff, that is applied before loading : done ... lead loading is not really necessary here, but i want to practise it .... that is ok for me... on with the primer; i will sand it down a little bit and then the tornado red will be applied ... next : the front wing ... i found a huge rust hole last year and just put on a panel, as i wanted to replace the wing anyway ... now, i have to new wings but no budget for having them painted at the moment . But i have a scrap wing, which i could use for the lower area ... thin disc + grinder = quick result .... and more rust at the sill, but no holes ... sandblasted and grinded down ... primer added ... trial fitting of the lower piece... yes... and welded in ... no award winning welds, but more than enough for me... primer added, too ...now the left side at the rear will be done tomorrow, then i will put on some tornado red .... and also tomorrow the first parts should arrive ...
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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yesterday i had time to do the left side; it was a bit worse than the right : the inner panel was rusty, too... and inside the wheel arch welding was also necessary ... rust cut out... panels made... and welded in ... i forgot to take pics of the inner panel ... lead loaded ... and primered ... this is my favourite treatment after welding; sealant out of the tin, you can apply it with a brush .... maybe i have to put on a bit of filler here before painting... we'll see ... next on the list : new suspension, stay tuned...
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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top work!
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E36 328 Touring
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mrj
Posted a lot
Posts: 1,662
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Jun 23, 2011 11:21:03 GMT
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thanks ! today we have another bank holiday and as an extra bonus the wife and the son are on holidays until sunday, so it would be rude not to go in the workshop.... to finish the metal work, some paint was put on yesterday... you still see some marks under the paint, but with me fillering it it would have been worse, anyway, this will be covered by the GTI stripes... like christmas, all the new shiney parts... brake hoses, rear axle bushes ... engine mounts, hand brake cable ... bushes for the subframe and the wishbones .... rear brakes and vented discs for the front ... and the best purchase, a new rad. As my car has aircondition, it has quite a large rad, that is normally pretty rare and expensive, someone was clearing new old stock on ebay and it was mine for 29 Euros ... ;D rear shocks and filters ....also i bought a lot of new bolts for all the parts i'll be replacing .... all the stuff on the table was in total less than 250 Euros, so you really can't complain .... the rear wheel cylinders had both one bolt missing ... didn't look too bad, but i want it new .... i started to remove the rear axle, you can change the bushes with the axle in the car, but it is not a nice job; as i'll be replacing the brake hoses and lines anyway, it is easier with the axle out ... these are the original bushes, so after 24 years and 300.000 km it was necessary ... as you can see, the bolt won't go out, as they fit it like that from the factory and it stops at the edge of the sill. One might be tempted to bolt of the mount from the body, but that ends up with sheared bolts and a lot of trouble, as they are welded to the body... so i took the grinder, cut off the head and pushed the bolt the other way out ...new bolts were included in the new kit ... that would have certainly failed the TÜV .... i cut off the brake hoses for better access, they are much better to remove when the axle is out .... the condition of the brake line is frightening shocks also came out, those are BOGE gas shocks and approx 10 years old. I'll be replacing them with a set of Kayabas i found on ebay.... now the best resolution would to sandblast and powder coat the rear axle, but as i do not have the time to wait a couple of days to get the axle back, i will take the wire brush and some chassis paint, it is not a concours d'elegance project ;D But, last week i had the same job to do on another car, and the owner wanted it to last forever; so here are some pics how it could look : well, but with a little time it will look similar ..... more later ...
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Jun 23, 2011 19:37:15 GMT
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i removed the bushes later this afternoon, hell they were really seized solid : you have to hammer them out .... after that i took the wire brush on the grinder and cleaned the axle and put on some chassis paint : no need to put on primer before, it is paint&primer .... in the previous post i mentioned about one bolt missing at the rear cylinders; now this is strange; i have ordered a set of cylinders from the same supplier for the other car, and i received different cylinders : they only have one bolt Haven't seen that before, especially as the backing plates have two holes, i must find out about that later ...
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Jun 24, 2011 20:22:14 GMT
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i have found out about the wheel cylinder; the alloys ones are produced with one hole since a couple of years ago, so it doesn't make sense but it seems correct... well, back to the interesting stuff: this is the tool i used for fitting the bushes .... it is normally a Renault tool, i had some tubes from a tool for replacing wheel bearings, together it works good ... it went smooth, last time it took a lot longer, as i didn't have that tool... the beam went back in the car, new shocks were fitted and the backplate of the brake was painted with zinc primer and black afterwards ... then the engine was secured with some ratchet straps .... and the front subframe came out ... if you compare the engine mounts, it is almost shocking...the new ones are at least 15mm higher, so i am really looking forward to the final result, the car must drive better than new ... tomorrow i'll take care for the brake lines , i hate that job, but is has to be done. Maybe i'll manage to change all the parts at the subframe, too.
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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Looking good Jürgen, are you bringing the Passat to Lobbach?
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mrj
Posted a lot
Posts: 1,662
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Looking good Jürgen, are you bringing the Passat to Lobbach? yes, of course, it is the only car i can actually drive ... the bus ? Well... ;D
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Jun 25, 2011 19:26:06 GMT
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i wanted to go to a show today, so did not have much time, but the front subframe should be done today, so that the paint could dry; first the wishbones : i must bore you again with Passat specific details, and i am sure i have mentioned that before, but anyway : the Passat has two slightly different front suspensions; it is all about with or without power steering. Cars with PAS have different wishbones, struts and swaybars . My Passat didn't have PAS from factory, the previous owner just fitted the steering box and the pump; the wishbones bushes are reinforced with metal, so they should live longer, they also have only one lip, so are easier too fit, too . Out with the soft bushes : i took a saw and cut off the lip: and with the hammer they came out easily ... and in with the new ones : one lip, metal sorround, done ... subframe was as easy, out with the hammer, in with the "special" tool i used for the rear bushes ... after the new bushes were in, i remived the visible rust and painted the subframe with chassis paint . Big plans for tomorrow : all back in , replace the brake lines, bleed the system, i really should be finished monday....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Jun 26, 2011 20:16:50 GMT
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subframe complete and ready to get back into the car ... but i found out, that the rear subframe bushes don't fit, they went in too easily, and they almost fall out ... so i'll be buying them local tomorrow, along with some more brake lines. I hate brakelines,as you can see here : this is from the front, i totally rounded the nut, though i had a special tool for that, i just cut it off in the end. One of my most favourite jobs is replacing them in the engine bay with no space ... no problems with the rear brakes ... also bought the clips for the lines, that will get extra bonus points at the TÜV station new discs at the front, too ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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Jun 27, 2011 20:39:23 GMT
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i was pretty busy today, and i hate replacing brake lines it was not so bad at the rear.... but at the front, it is best done, when the engine bay is empty ... i replaced in total 6 lines and all the 4 hoses, should be enough for the next 20 years ... borrowed the Volvo from the neighbours this morning and went to the local motor factors and bought the correct subframe bushes; they didn't fall in, i had to pull them in with a threaded bar, so they will stay in ... one more thing for today was replacing the radiator; also bought a new fan switch , here you can see the weird V-belt arrangement, i bought that new, too ... in... i also replaced the coolant pipe from the rad to the expansion tank; another - job will be to replace the heater valve .....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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Jun 27, 2011 21:12:12 GMT
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Impressive as always Jurgen.
Looks good.
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mrj
Posted a lot
Posts: 1,662
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Jun 29, 2011 10:37:16 GMT
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heatwave over here, lucky the workshop is very cool today i wanted to investigate the idle; as it wouldn't pass the emission test, so i pulled the injectors : they are not bolted in, they are being hold in a plastic insert in the head .... i had a scrapped golf engine in the wirkshop which a mate bought for 1 Euro on ebay, mileage was half as much as the Passat, so i used the injectors from that engine. On the legt the "new" ones, on the right the Passat ones... on the left you can see a rubber ring, which acts as a gasket, i also replaced this gasket. When those rings get old, they start to leak. The easier the injectors come out, the more worn they are. When they were in, the idle was better, but still not ok , then i found this : the huge rubber part between throttle body and airflowmeter was torn; it is no longer available from VW, i used the better one from my blue Passat ... this is what it looks like; the metal net is used to prevent backfiring ... oops ... guess its time for some brake cleaner ;D The lower piece of the air flowmeter is moving up and down and moves the link to the fuel distributor.It is a clever design and reliable, but seizes easily if the car is laid up for more than 12 months .... that looks better ... with the rubber back on, idle was spot on as i had to take out the battery to replace the rubber part, i realised, that the red cable for the amp was clamped between the body and the spring cap i properly bolted it to the dome and fitted a cable tie ... TÜV looks also after such things .... the Golf engine had a red cam cover , so i had to take it ... then i replaced the heater valve; it is somewhere down there . You can't see it ? Neither could i, it was a horrible job to replace, especially with those stupid hose clamps , which were fitted the other way round, almost no access ... last job was an engine flush and some fresh oil.... should be ready now for the next 300k kms Fitted the rear bumper, tigthened all the bolts , so tomorrow first test drive and a proper clean is on the cards....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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mrj
Posted a lot
Posts: 1,662
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today i went to the TÜV station and here is the result : ;D dated back to May, as TÜV was due in May, but no advisories, which is unusual for a 24 year old car ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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nofrills
Posted a lot
my wings are made of Steeeeeeeel!!!
Posts: 1,243
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Awesome Buddy, really pleased after all the hard work!
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mrj
Posted a lot
Posts: 1,662
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after driving a couple of kilometers, the Passat was "ok", but still had some issues i didn't like and had to adress : - very soft brake pedal - clunking noise from the front brakes - squeaking noise from front suspension (like an old couch ) - idle was way to high and fuel consumption went up... the brakes : i replaced the new handbrake cable, as it was a very cheap pattern part, i bought a proper one at the local parts shop... that actually allowed the self adjusters of the rear brakes to work, pedal was fantastic, done . Noise from the front brakes: also replaced the pads by proper ones, the other ones were sliding around in the caliper the idle : replaced the injectors again with another set i had, also found a leaking air hose and replaced that too; now i have the same old lumpy idle as i always had with this car... done ;D the noise from the suspension : i suspected the dome bearings, they were not that old (2 years) but Passats obviously eats them very quickly, so i bought some quality heavy duty ones . They are not that expensive, but replacing them means taking out the front struts including messing around with all those bolts (30mm nut at the driveshaft tightened up with 300 Nms ) ... but i had an idea : fit this first ... with a compressed spring you can open the top mount : you need a special nut for the dome bearing ... on the left the old one, on the right the HD part... there is a difference ? ;D the bearing itself also sits higher ... well, after that the noise was still there , but the steering is a bit more precise and i have A1 brakes... i think the noise might be coming from the bumpstop, i'll investigate that at a later point, i am happy for now ....
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- 1971 VW 1600 TL Fastback - 1978 Passat GLS Variant - 1980 Audi 100 5E - 1981 VW aircooled panel van (sold) - 1983 VW Jetta Mk.I - 1984 VW Polo Coupé - 1984 VW Passat hatchback - 1987 VW Passat Variant - 1987 VW Passat hatchback - 1988 VW T25
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