[no such user]

Yes, the 02C gearbox dosen’t bolt straight onto a pre 90 propshaft, well it bolts up but it’ll trash the rubber doughnut and the drive flange on the gearbox once you start putting power through it.

the recesses in drive flange are as follows ( as far as I know )

rallye 25mm
passat syncro g60 22mm
90 spec syncro 22mm
pre 90 spec syncro 18mm

So you have an 18mm lug in a 22mm recess & put under load that is going to move about and trash ether the doughnut or the driveflange, so there are 3 options I see,
1) get a passat g60 doughnut and machine the propshaft end down to 18mm or
2) get a piece of steel bar, centerbore it 18mm, the turn the outside diameter down to 22mm then part off 3mm sections. fit the said sections onto the rubber doughnut on the gearbox side and sorted you have a nice tight fit.
3) find and fit ether a 90 speck front propshaft section or whole prop and rear diff

[no such user]

I had a fairly industrious session the night before last.

The heater, dash and dashboard loom are now safely re-located in the car.

The Techtonics cam has also now arrived, which is nice. Apparently the ABF rad is now in at Vee W Services, ready for collection, too.

Spoke to the guy doing the head work earlier today and he’s received it and the flywheel (getting a lightened one) and it should be ready for collection by next Tuesday [:0].

I’ll be collecting the head and flywheel the weekend after this, so the items which will be outstanding are the bits due from Chris, some spacers for the prop that DannyP said I’d need (and he could get sorted, you listening, Danny?). Once this little lot shows up it’s going to be bolted together, really *gulp*.

[no such user]

We’ve decided on a date – 10-11th May.

This is the weekend when there is the fourth round of the GT racing at Nordschleife. That is on the Saturday. On the Sunday the track is open to the public all day. There is also track time either side of the weekend.

Here are the opening times and events over this period, along with school holidays and other events that might get in the way, or cause extra expense, or crowding on the track: http://diamondhell.com/content/view/34/46/

I would suggest everyone organises their own travel and accommodation as necessary. There are plenty of campsites, apartments and hotels around Nurburg and Adenau. http://www.nurburgring.org.uk has plenty of links on it.

[no such user]

If you bolt the engine in using mk1 mounts then the propshaft output flange on the gearbox lines up perfectly with the steering rack, so you have to weld the mk2 subframe in.

[no such user]

If you need a hand, give me a shout.

[no such user]

About what?

[no such user]

Welcome in. How did you find the site?

[no such user]

Only on a nice 5-banger motor, Steve

[:p]

[no such user]

no not yet, still got to clear some space to work on it for the mot and a few eesential tweeks.

will be fitting center section and back box off my old one this weekend allong with the 280mm brakes 15″ alloys and possobly the rear disks and rallye ARB then it’s mot time, after that we shall have to see.

think it’s going to get the megasquirt ecu quite soon even if it’s just going to be looking after ignition later it may get the AGG bottom end thats sat in the shed, then lots of playing before the whole 16v thigs starts again

[no such user]

Completed bracketry to hold microswitches and plug:

Also blanked off the EGR valve hole in the manifold and acquired rather nice packaging from work to ship the head off in.

[no such user]

Yay – have new bottle of Argoshield, so can continue with the second bracket tonight, hopefully!

[no such user]

Further update tonight and good progress – several hours bracketeering in the workshop and the 2E throttle plate housing is almost ready to begin a new life of crime running Bosch Digifant with two microswitches, rather than the potentiometer of the 2E system.

Pictures here: http://diamondhell.com/component/option,com_rsgallery2/Itemid,29/page,inline/id,797/catid,28/limitstart,0/

Need more Argoshield and time.

I gathered together a load of crossflow pictures from VWVortex the other night. These are now here:

http://diamondhell.com/component/option,com_rsgallery2/Itemid,29/catid,27/

[no such user]

….or was that two black pipes….. I get confused….

[no such user]

I don’t think the photos really illustrate the full amount of ballache that has gone into making the exhaust work – I’ve had to lop off one of the legs of the 2 Rallye downpipes and basically move it through 90 degrees from by the side to above the other pipe. As you’ve now seen the space is a real issue in this installation – it’s easy to see why VW didn’t bother with a RHD Rallye or an RHD Golf3 Syncro – it’s simply ridiculously tight!

As Chris has supplied a pressure pump presumably from another Syncro (the pipes fit) I’m quite happy to mail you my old larger-bore pipe, if it will help – but it will give you two blue pipes……

[no such user]

Welcome to the wonderful world of ‘Chris can find it’.

[Author]

Posts