I've been a naughty boy...

Discussion in 'Show Us Your Bit On The Side' started by theBusmonkey, May 17, 2015.

  1. 1st July we will be at Leicester racecourse doing the vintage carnival. back that evening though.
     
    theBusmonkey likes this.
  2. theBusmonkey

    theBusmonkey Sponsor

    Cool, we'll be down at the farm so maybe if you fancy camping over...?
    The Dickys may be attending as well depending on diary commitments, we'll see closer to the day eh?
     
  3. Looks like im doing my cockney impression there! Gor blimey guvnor!
     
    theBusmonkey likes this.
  4. Good work there Neil. Very patient approach paid off! Well impressed.
     
  5. theBusmonkey

    theBusmonkey Sponsor

    We took Big G to Wales last weekend and here's a short vid some of you may be interested in.
    17 vehicles in total attended.
    Mainly T3 syncro's, but also a T4 syncro, a couple of T5 4 Motions, an Amarok and a V10 Touareg.
    Enjoy...:thumbsup:
     
    Iain McAvoy, philntfc, Gnasha and 6 others like this.
  6. Merlin Cat

    Merlin Cat Moderator

    Fab! You look like extras waiting to be in a modern day Game of Thrones :)

    The T25 pick up was no slouch was he!
     
    theBusmonkey likes this.
  7. JamesLey

    JamesLey Sponsor

    Love it! This makes me want my Baja even more now.
     
    theBusmonkey likes this.
  8. davidoft

    davidoft Sponsor

    No pots and pans in a pick up
     
    theBusmonkey and Merlin Cat like this.
  9. MorkC68

    MorkC68 Administrator

    brilliant! :D
     
    theBusmonkey likes this.
  10. theBusmonkey

    theBusmonkey Sponsor

    So we've had a few years of fun with G, and it's time to repay in the form of a spruce up.
    The original WBX has been reliable and a pleasure, but just lacking in power on the rough stuff.
    The decision has been decided to go from petrol to diesel in the form of a 1.9TDi.
    Before that, theres a tonne of bodywork and, well coz life's short, we're going all out and modifying suspension and re-modeling the interior.
    The engines out, and it's my task to rebuild the transaxle, uprate the CV joints and refurbish one of the rear bearing carriers.
    This will enable the engine to be fitted and commissioned before other work is undertaken.
     
  11. theBusmonkey

    theBusmonkey Sponsor

    Today's job has been to finish the axles and get them ready for the pallet back to Scotland.
    I'm uprating the CV joints to allow for more articulation, necessary as the new springs will provide a small lift and I don't want the geometry too far from stock.
    The new,, non standard, boots come with sleeves to increase the OD of the axle.
    IMG_20210806_142016_compress28.jpg

    I'm fortunate with the workshop as this onerous task is made much easier if you can support the axles vertically to press on the joints.
    IMG_20210817_121550_compress98.jpg

    Boot slid up to give access to the inside of the joint
    IMG_20210817_124209_compress55.jpg

    And the gloop packed in
    IMG_20210817_122214_compress80.jpg

    Slap the boot onto the joint and it keeps them from attempting to spit their balls all over the place. Flip, play, pause, repeat...:rolleyes:
    IMG_20210817_123057_compress22.jpg

    On to the bench for new bolts (slightly longer as the Porsche joints are a bit wider than std, new spreaders and new Schnoor washers.
    IMG_20210817_150522_compress8.jpg

    Threads cleaned of grease and protected from crap ingress.
    IMG_20210817_150807_compress93.jpg

    Ready for shipping
    IMG_20210817_151409_compress44.jpg
     
    Last edited: Aug 17, 2021
  12. theBusmonkey

    theBusmonkey Sponsor

    Next task this week is the transaxle.
    I'm re-gearing to compensate for the change in power delivery from the TDi, and to allow the fitment of larger diameter tyres.
    I've been collecting bits for ages. All new bearings, synchronisers, new 2nd, 3rd, 4th, reverse and gelande gears and a new crown and pinion.
    4th gear is unusual as it's a straight cut gear.
    Long distance cruising in 4th with standard helical gears exposes a couple of well documented weaknesses with the 094 trans.
    Straight cut gears eliminate axial loading on the shafts, which causes bearing displacement, but at the cost of a bit of noise.
    This fine tooth 4th should minimise that. We'll see how that works out in 18 months or so when I strip it all apart to see what we can see...

    The puzzle laid out
    IMG_20210815_105939_compress73.jpg

    Metal caged bearings throughout
    IMG_20210815_105520_compress23.jpg

    GT Gears 3rd and straight cut 4th
    IMG_20210815_105525_compress4.jpg

    Main shaft stack built
    IMG_20210816_140025_compress88.jpg

    Tomorrow sees the pinion shaft built and hopefully the cases thrown together..
     
    Mattlad, Merlin Cat1, Dicky and 7 others like this.
  13. That 4th is going to be loud, I suspect.
     
  14. theBusmonkey

    theBusmonkey Sponsor

    Apparently not so much. The early coarse toothed gears from GT were. This is one of the new profile 'street cut' sets that go some way to reducing the frequency of the mesh.
    We'll see. Someone's got to have a go or we'll never know.:cool:
    Some folk love loud exhausts, I'm going to love the sound of no axial displacement I hope:confused:
    There's a lot of sound insulation going in when the van comes back...:rolleyes:
     
    F_Pantos likes this.
  15. It's a great effort, I have nothing but admiration, and perhaps a little envy ;)

    I have a "suitable" street box in the Bug, not straight cut, I may add, tho 1st is straight, and, wow that is loud. Nevertheless, after a few hours, it gets wearing! Go for a "joy ride" and you don't notice it, but two hours on an m-way and the ear plugs go in.

    It's a fair point about sound proofing, I reckon some of my noise is from the extra mounts that are needed to hold the box steady with a bigger power plant so more noise finds it's way into the cab.
     
    Merlin Cat1 likes this.
  16. family site, no porn allowed, I am slightly aroused by that fine toothed straight cut 4th......
     
  17. theBusmonkey

    theBusmonkey Sponsor

    All done, and about to be loaded into the pallet for its journey to the frozen wasteland that is Scotland.
    I'm not going to lie, it fought me. Some protracted discussion with US
    suppliers and pointers on how to manage a manufacturing defect without suffering further delays has resulted in a set up I'm really happy with.
    Well, on the bench that is and so far as the dti's and micrometers tell me, but the proof will be when it starts going round and round!

    Diff lock with stainless components. The vacuum unit will be left off until fitting into the chassis to save damage..
    IMG_20210907_162522_compress66.jpg

    Bell housing refurb with RJES reinforced clutch fork, Weddle PTFE impregnated bushes, new seals and INA release bearing guide sleeve around the new TDi input shaft..



    IMG_20210907_162543_compress8.jpg

    Handling it you start to appreciate some of the stresses these components are under at engine rpm.
    That dual mass flywheel and clutch assembly weighs a tonne.. IMG_20210907_164808_compress85.jpg

    And the finished article. It'll be in the hands of the transport company tomorrow.
    Not at all nervous...:eek:
    IMG_20210907_162937_compress1.jpg
     
  18. theBusmonkey

    theBusmonkey Sponsor

    Yep, it's a ball-ache!
    It adds hours to the process so my advice to customers is either waxoyl or a blast of underseal just to protect the already corroded alloy!
    However, I needed to do it in order to be able to price it accordingly.
    Paint is smoke and mirrors ;)

    Note, bay boxes, esp the dry state ones, are usually in way better condition than the vast majority of T3s. Sometimes they are so badly gone as to be unusable. VW taking cost out of components as the move to front wheel drive drew closer...
     
    Merlin Cat1, Dicky and F_Pantos like this.
  19. HFR!
     
    Mrs Busmonkey likes this.

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