The last update was almost two weeks ago, and while I’d love to say we’ve just been too busy building, that’s not really true. It’s been a quiet two weeks, although a fair amount of research has been done. We’ve been looking into the cooling system and engine mounts.
We’ve also sent the gearbox in to be examined and overhauled, as well as have the front of the input shaft machined. More will follow on this when it’s done, but essentially it will be machined to 10mm diameter, and shortened (that still needs to be measured). Then a bush will be installed in the crank shaft (I believe this is a 15mm OD, 10mm ID bush), which acts as a pilot bearing for the gearbox input shaft.
In terms of actual work done, we’ve largely assembled the suspension parts. It’s amazing how quickly this adds considerable weight to the frame. The chassis used to be relatively easy to pick up, but now it’s quite a beast.
Assembling the suspension resulted in us finding a slight flaw. The front left top mount point for the shock is positioned fractionally too far into the chassis (or the support strut next to it is too far out). This means that although there is plenty of space for the bolt once it’s in, there isn’t enough space to actually get it in. The error doesn’t seem big enough to affect the suspension geometry, but it will need to be treated differently. The best solution we’ve got so far is to use a stud threaded on both ends, with no bolt head. There is enough space to insert the stud, and then it will have to have a nut on each end.
No pictures of the suspension as yet, will either post again or update this one.
In terms of parts, we now have a petrol pump and radiator overflow bottle. The pump is for a BMW E46, and it came from AutoZone (cheapest price). The one from Midas and Goldwagen is over twice the price (twice the quality? Time will tell).
The expansion bottle is for a Golf Mk3. It has a “gas” inlet pipe at the top, and a water expansion line at the bottom. Make sure you get the cap as well, since it comes separately. Once we have full clarity on the plumbing configuration, it will go up on the web.
On paper, the expansion bottle on paper didn’t cost too much. However, the actual purchase turned out quite emotional, expensive and included a trip to the police station. How’s that for an intro…
Essentially what happened is that I was doing the Saturday morning shop, and I figured I’d pop to Goldwagen and try to get the expansion bottle. En route, the traffic light ahead turns red, and I pull up with one car ahead of me. Out the corner of my eye I see movement, and notice that a truck, parked in front of the shops on my left, has his reverse lights on. Suddenly it starts moving – straight towards me. I started hitting the horn, with increasing panic, to indicate my presence. Unperturbed, possibly even encouraged, he keeps coming. The crunching noise and rocking motion of the car felt similar to those moments just after slicing your finger while chopping veggies. You can see it, and you felt the pressure of it, but there isn’t any pain yet. For a moment you think “maybe it didn’t really happen”. Then it starts bleeding.
I got out of my car, utterly speechless. He was very apologetic, and possibly as shocked as me. Eventually all I could say was “do you realise how much I love my car?”. Sigh.
B