Update Feb 25th 2021

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Gearbox issue

It was really nice to drive the car out the garage, however on the test drive it seemed that I had a fault in the gearbox, 2nd gear would not engage when changing from 1st or 3rd. Pulling way in 2nd gear didn't sound "good". 

After several hours messing with the gear selector and gear selector rod unfortunately it seemed that it really was a fault in the gearbox. 

With the car so close to being finished not what I wanted!!!  Engine out time!!!!! 

Engine and gearbox out

Once the engine was out I did notice a small leak from the flywheel seal, a new seal has been fitted, sort of made me feel a bit better about having to take the engine out. It would have needed to come out at some point in order to fix the leak.

Oil from flywheel seal visible in the gearbox case.

The problem in the gearbox has been fixed,  it needed adjustment to the 1st/2nd gear layshaft and reverse gear.

Happy gearbox ready to refit

Engine & gearbox back in the car, quick test drive and 2nd gear now works 😅

IVA Prep

I have gone through my check list of all things relating to the IVA test. Below are a few photographs of the items where the edges need to be "softened".

If anyone wants my check list then let me know, it may not be complete but its a good start

Fixing tab on headlight needs covering

Interior rear view mirror requires rubber edge

Front indicator light requires rubber edge

Door mirror arms require rubber edge

Car overview ready for IVA

I think I have the car ready for IVA, fingers crossed. Booked in for first week of March, just need a dry day!!

Once through the IVA there is still a few jobs to do.

Steering will is for IVA only it will be replaced!

Update - Jan 30th 2021

The interior trim has now been completed and the car has been back in my workshop for a couple of weeks. I will post some final pictures in my February update.

I now have a list of jobs finishing jobs which include preparation for the IVA test, enough to keep me busy during this current Covid lockdown (Jan 2021)

Windscreen wiper arms

Location hole drilled

Here is a job I didn't expect! I popped into the garage to do a couple of easy jobs. Surely bolting on the windscreen wiper arms and blades would be a 5 minute job. After much head scratching it turned out that the arms provided needed modifications.

The first thing required was to drill out the location holes.  

Nearside arm reshaped

The arm on the nearside then needed a bit of reshaping, so out with the Dremel. 

Before

  Then both arms needed the lower bush chopping off..

After

Release 10mm nut &

 refit to desired position

I adjusted the park position of the wipers by undoing the centre bolt on the mechanism and adjusting to the desired position

I also reshaped the end of the wiper arm reversing the angle,

A 5 minute job it was not!!!

Persistent Oil Leak

Oil leaks on the external oil filter pipes and brackets have been a reoccurring problem. I have removed all the components then cleaned  and rebuilt using thread sealer on all joints. Fingers crossed!

 

Turned the engine over and blew the oil filter ring gasket!! :-(

Seemed like the obvious culprit was one or both of the oil pressure release valves. On inspection it seems that both valves are stuck forcing all the oil into the filter. The joys of badly made Chinese parts!! 

Once removed (I'm waiting for a special tool as they are stuck) the exterior of the valves will be checked over and where required hand finished the with fine wet and dry then oiled and refitted. So this job is my current "in progress"

**Update**

Fitted standard VW springs and valves, also fitted new Fram oil filter all seems well...at the moment!

Clutch Adjust

Adjusted the clutch so the movement at the pedal was about 1/2 inch

Brake Adjust

Adjusted the pedal to master cylinder to gibe me an earlier firm pedal.

Windscreen fitted and heated screen wired

The windscreen has been fitted and the wiring connected for the heated screen.

Fog Lights Latch switch

The wiring loom supplied by Chesil didn't take into account the IVA rules relating to the switching on and off of the fog lights. and as such needed some modification. 

The latest IVA revision states that the rear fog light must turn off AND STAY OFF when the headlamps are switched off. That is to say, if the headlamps are switched off then back on again whilst the fog light switch remains in the on position then the rear fog light must NOT turn back on unless the user specifically activates the rear fog light switch.

To allow for this it required “hacking into the previously wired lights and fog light circuitry and adding in a Fog Latch switch. I hate having to go back to redo a job :-(

If anyone wants my diagram on how to wire this let me know

Seat Location Plates

Set of floor plates pre paint

I decided to add additional strength to the floor area where the seas are bolted in. 

I used 4mm steel which I epoxy primed and coated with Raptor paint to match the rest of the floor

In Primer

Raptor Coated.

Plates fitted

Exhaust

Fitted the Sebring tail pipe insert from Vintage Speed

Fitted Sebring tail pipe insert

Next jobs

• Test drive then IVA Prep

Build Hours

Trim Diary #2 - Dec 23rd 2020

Here are a few pictures showing the work completed since the last update.. Very close to being finished now.

🎅 Happy Christmas to everyone and lets hope for a better 2021!!🎅

🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄🎄

Front bonnet complete carrying the same style from the interior

The sill and upright panel by the doors have been filled and sanded to achieve a perfect flat and straight edge, one issue with diamond stitch pattern is that you can see any unevenness in the panel being covered.

Centre tunnel looking good! 

Nearly finished! The seatbelt bracket is temporary only for the IVA test

Trim Diary #1 - Nov 24th 2020

Change of trimmer

I decided to change who I was going to trust to trim the car, Option 1 Sports Cars who did such a good job on the paintwork also have a small trim shop. They have a great eye for detail and only take on one job at a time, unlike a lot of trimmers who jump around between jobs.

The car was dropped off on 20th October, and they have been making good progress, what follows is a  diary of the trim process to date.

30th October

First mock up of a door panel in vinyl with other areas of the car marked out to determine the pattern and layout of the two leather colours and diamond stitching 

The seats I had made are not going to be used and I have decided instead to use the two Mazda MX V seats I have as a start point. The foam seats and back panels will be modified to reduce the overall width then trimmed in line with the rest of the car.

12th November

The rear trim panel that sits around the rear area has now been carefully fabricated in fibreglass and is ready for the final trim. The door panel for the near side has been completed again in fibreglass and foam covered ready for trim (no photo)

The two rear quarters have been trimmed, the centre panel is still in mock up stage in vinyl.

24th November

The original mazda seats have now been reshaped and covered, looking good.

Rear "seat" storage shelf has been completed

 Central tunnel is a work in progress

Update Oct 1st 2020

A few final jobs before it goes back to the paint shop for a little remedial work to a few paint scratches caused build during build, I'm quite pleased that there isn't much.

From the paint shop it's up to the trimmers 1st week in November. So this is probably going to be my last update until I get the car back, hopefully in December (maybe)

Offside rear suspension

The offside rear was just not sitting at a good height, I had maxed out on the adjustment on the spring plates, but it still was not correct. I decided to bite the bullet and strip down the suspension arm, and reset back one spline on the outer torsion bar. Quite a job, but it's done and I now have a good ride height with the adjustment set the same on both sides of the car.

Other jobs

• The front and rear sway bars have been tightened

• Fitted the old VW steering wheel and got the horn working, this will be replaced with my custom wheel after the IVA test

• Added Stickers relating to brake fluid

• Finalised fit on the external oil filter and pipework.
• Refitted final engine tinware
• Completed a full engine run and final check on any leaks etc

Engine will need a final tune and setting up of tappets, but for now its running ok

Interior

The trimmer has provided a visual mockup of the interior, finding the colour carpet I wanted was not easy, then I found it when having a browse around John Lewis! These are just a start point, be interesting to see how it progresses once we start.

Handing over the car to someone else is scary!!! I've warned the trimmer that I am more than a little obsessed with detail,  but I'm not sure he gets how OCD I am!