Building a race car -hopefully! Help may be required

I have just payed for my membership for VWDRC for 2011!!!!!!!!!!!!!!!!!!!!!

shadydaz wrote:

I have just payed for my membership for VWDRC for 2011!!!!!!!!!!!!!!!!!!!!!

Good man!

It's been a hard day at work so far...

OK, so have managed a couple of hours at the old girl over the festive period so get to indulge you guys with more crappy fotos, horray!

Here is my progress:

Finally got the rear beam off to leave her propped up like this...


While I was scratching around down there I found this on the rear sill...


and on inspection of the beam there was this...


and upon stripping the beam found that these...

were only fit for one place as BER.

I have wire brushed the beam by hand ready to go at it with the powertools. The handbrake cables were brand new so saved them for later.

Getting the rear beam off inspired me to get the last few bits off the car.

Fuel tank out...


Then the fuel filler pipe which was rotten went, inner arhes good though...

And the filler hole inpected, one of the screws had to be drilled but this is getting chopped and smoothed anyway...


No need for this anymore!


Steering column, rack and pedal box out along with rear mount and fuel lines


100% stripped. The floorpan is greasy but in pretty good nick.

Started with the cutter...




Half way through cutting the old rear panel off discovered that there were actually two valances glued together on there!



This almighty pikey-likey bodge left the floor in a poor state too.




It looks like I am going to have to chop out the lat 2 inches of floor and weld a new patch in.

Also still got some tidying up to do around the chassis members/rear wings before can stick a new one on...




The RHS looks worse than it is and the LHS is worse than it looks!!!!!!!

With this in mind got onto frosts and ordered some gear to assist me with this major bodywork.

Big order going into Quiffs too shortly for the new panels (rear arches too!!)

The front of the car is solid, the back is crust. DOH

Also got a set of Polys on the way to start building up the suspension again as can work on refurbing the small peices around this major stuff. Bit stuck on which set of coilovers to get. Want in car adjustables, any one got any ideas?

Thanks for looking!

Daz.

What box is better?

A 02A or an 02J for racing. 'Twill be getting a Diff and clutch upgrades either way.

Cheers!!

Another small update.

I got my box of Looms out of the loft the other day as will need to get my head around how to plumb this old girl back together. First up was the rear valance loom...







Wiring checked, cleaned and tidied up a treat. Will get getting some heat shrink this week to finish it off.

Got some goodies form Frost's with a bit of discount curtosy of this club of course!



Can now start welding and painting chassis.

Also bit of a landmark day today as the very first BRAND NEW PARTS arrived...



Well chuffed with that!

Also went on a bit of a mission with sorting out all the parts that had been stripped of her. Ended up doing this with some degreaser...


Went through that cycle four times!!

Then after hand drying did this...


And was left with these which need rubbed down for paint...


OCD anyone???

shadydaz wrote:

What box is better?

A 02A or an 02J for racing. 'Twill be getting a Diff and clutch upgrades either way.

Cheers!!

From memory the 02J has a shorter final drive, something around 4.25 on the EBD coded gearboxes off the mk4 20 vt's and the like. The later ones were slightly taller something around 3.3 - 3.8. I deally something like and EBD would be better suited to you for track use depending on the circuit.. They can be converted to cable too

o2j uses an electronic speedo pickup, so wouldnt work with normal binnacle, but then in a race car you probably wont be worried about a speedo. if you are, you will need to use mk3 golf or ibiza abf clocks, or an aftermarket dash (although most aftermarket dashes use a completely different sort of pickup anyway)

if you use an o2j, you will need the matching tower, an o2a one wont fit

o2j has solid shift bushes as standard so thats a plus, but presumably you would be running a proper motorsport shift tower so its almost irrelevant

Apparently lsds for o2js are way more expensive, but i havent really looked

theres lots of aftermarket gearkits available for o2as, but not many for o2js

o2j looks a bit nicer too

I know of a ENJ coded 02J for sale for with 68k on it.

whittle wrote:

o2j uses an electronic speedo pickup, so wouldnt work with normal binnacle, but then in a race car you probably wont be worried about a speedo. if you are, you will need to use mk3 golf or ibiza abf clocks, or an aftermarket dash (although most aftermarket dashes use a completely different sort of pickup anyway)

if you use an o2j, you will need the matching tower, an o2a one wont fit

o2j has solid shift bushes as standard so thats a plus, but presumably you would be running a proper motorsport shift tower so its almost irrelevant

Apparently lsds for o2js are way more expensive, but i havent really looked

theres lots of aftermarket gearkits available for o2as, but not many for o2js

o2j looks a bit nicer too

I'm sure you can take out the electronic pickup and just use a normal speedo cable, so normal clocks will work. And it's easy enough to bolt a cable shifter in if you're doing this much work.

Lupton_20vt wrote:

I know of a ENJ coded 02J for sale for with 68k on it.

LOL, thought your last post wa going somewhere!

PM me a price please buddie.

There is currently this on ebay, it is already converted to cable change which (without any prior research) may hook up to a shift tower easier. I amm very tempted!

http://cgi.ebay.co.uk/ws/eBayISAPI.dll?ViewItem&item=170578915617&ssPageName=STRK:MEWAX:IT

pm jaques_g60 on here

he has an 02o with a quaife lsd for sale

A wee bit more today before I go back to work tomorrow.

Stripped down these



but some of the bushes are a bit stuck on one. They have been washed and degreased ready for refurb. Anyone got any ideas what I can use to free off the bushes that are stuck?

This is coming along nicely...



Bit more to do on it yet before its ready for paint though!

Started on that box of bits that I degreased yesterday, sanded down:


Encapsulated here:




...and now sprayed with chassis paint!

Should have worked my way through the box by the end of the week!

Burn the old bushes out

You have a pm...

I have binned the wishbones. After spending a bit of time tonight cleaning one up a bit, they look too far gone to risk it the car once it is together.

New ones on the way soon, along with those other bits too hopefully!

So I had some goodies turn up in the post this week and decided to crak on with as much as time would allow...most of it being pre assembly on refurbed parts!

The handbrake is now refurbed, bagged and tagged ready for later...

Having now decided that I am not doing a rear disc convo I had to sort these out...


This has turned out to be very time consuming as the regulator bolts are as good as welded in. As you can see they need some attention paying to them too! Got them stripped as much as possible (bar regulators) then wire brushed them. Soaked them in rust eater stuff over night and they looked like this;


Then I managed to get one of the regulators off one of the plate so attacked it with the wire drill brushes until it looked like this...

prepped ready for rust encapsulator;

...and painted...

The only other bits I refurbed for the rebuild were these and the little bits that go through them...

Left one is before, right is after!
I have brand new components to rebuild, just need to sort the other backplate out now.

Also I have now finished this...

.. the mounting brackets were also done with most of that box of bits form earlier so this will be pre-assembled during

The new front wishbones turned up during the week also so spent a bit of time sorting them out and had my first attempt at welding 8O as I wanted them seam welded...

Had a practice on the old ones;


Not too bad I guess, so I tried for real and ended up with...
New bits prepped;


and done;



These were rust encapsulated immediatley and each wishbone resprayed with chassis paint ready for assembly.

Wrapped and packed ready for later...


Assembled:



That's all for now folks!!

Good stuff man sureley rear disk conversion is a must for a track car though

mk1g60phill wrote:

Good stuff man sureley rear disk conversion is a must for a track car though

It will only be racing in a straight line!!

wouldnt the rear disc setup perhaps be lighter than drums?