They sent you a perfectly straight dash bar?!

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GTI-6 & Rallye

Rallye gets sideways in the wet at Snetterton

So got up bright and early this morining and Dave came over and he had a good go at some more of the body work, it really is starting to get there now.

Forgot to take any photos.

I got on with getting the oil cooler and intercooler mounted.

Fist off I refitted the slam panel and rad.

I had to unscrew the loom under the cross member (didnt wanna drill through it )

I then used the spacers supplied with the cooler and the two plates they supply, but the slots are not big enough for the bolts for the intercooler to go though, so had to file them out.



then fitted the cooler



then fitted the bumper to check clearance



the good thing with using the mounting plates supplied, is that there is so much room to move the cooler.

It can be moved 2 inches either side, or six inches backwards,

then the biggest pain in the arse job of the day, fitting the oil cooler.
What a ball ache, so much fiddling but its all fitted now





I used one of the bolts that holds the bumper on to hold the bracket for the left side of the cooler, I thought that was pretty genius



With the cut offs from those 2 fixings I made the supports for the top, they will be welded on, just need to speak to jim as to the best way to do it.





that looks pretty mean like that, but will be getting a badged carbon bonnet from NUR.

and with the rad fitted



I did a little prep work today on a bumper I brought (my idea or mint and other peoples is very different) but its getting there now



and I finsihed off by seam sealing the rear panel





Its starting to take shape now.

I need you to take a look on the best way to weld the brackets to the slam panel. either notch it or not.

Do I need them?

Na they go between the intercooler and the rad dont they?

there is so much room between the rad and the cooler I cant see them being a problem

well i have just read this project thread from start to finish. and all i can say it is going to be a beast when it is finished. excellent work to you both and the knowledge you got to do a project like this .is this going to be ready for fcs?

Nice progress chris, do you have any part no.s for the parts you replaced on the vts rack?

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Team 'unintentional rat look'

ah right, thought you had replaced the gaiter and o-rings etc. nevermind!

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Team 'unintentional rat look'

So the sun was out and had loads of stuff to fit so cracked on with it.

this turned up this week, gave it a polish just because I am a little sad.



.

This is what I started with this morning



The swirl pot didnt come with the holes drilled to mount it, which is a good idea I think

So se about marking them up and getting them drilled



I then thought about how I will connect it all up to the standard pump, so decided to use the other hole that the phase 1 uses. I cut 2 peices of pipe and turned the pump round so the out let face the right way.



they are cable tied together noww, but I forgot to take a pic of that.

I then set about runnig all the braided hose.

This took ages, but I am pretty happy with it.











I then made up possibly the shortest fuel pipe ever.
I have never made aero quip hoses, but to be honest its not that bad.
The one problem I did find was cutting the hose, I tried some tin shears and they f*cked up the braid, I then tried a junior hack saw no go, then a big hack saw and nothing, bit p*ssed off I attacked it with an angle grinder and hey presto perfectly smooth cuts.

I took the fixing apart.



then loosened the braid and fitted the olive



with the trusty rubber lube to push it home

well the swirl pot was 86.10 quid delivered

The pipe is 120 quid, but I need another 2m (could get away with 1m) for the engine of the smaller pipe.

the fuel filters are 13.99 and 12.99.

the weld on ends for the fuel rail are 7 quid each

its about 300 quid so far, and I need to buy the rest of the ends now I know how it will all go and what I need.

Looking good mate, any luck from your uncle with a welder yet?

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R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars

Not yet, been a little hectic with Brian stuck in Cyprus all week, I'll look into it on Monday

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R H Davey Welding Supplies. I sell new and used welding equipment in the Hampshire area. I take on welding jobs in the evenings, ally casting repairs are one of my specialities but I can weld pretty much anything. PM me with your requirements.

Some of my services: (See my for sale threads)
Engine mount/chassis repair
Solid Beam Mounts BACK IN PRODUCTION
Harness bars