Labor day

today was a good day. Got lots done, made a lot of progress.

I started with the handbrake adjustments. There just has to be a better way of locking up the brake discs than with this delicate cantilever mechanism. At least on this car the mechanism seems like it has not had the shit beat out of it like on the GTi. Hopefully it will hold. Both sides seem to take OK.

I finish up the right side steering pivot.
Cotter pin on the suspension cylinder.
I let the impact wrench bang on the axle nut for a bit.
Wheel on, bolts in.

I work some more on the left side pivot. The flexible connection that delivers HP to the caliper looks all dried up & shitty. I had one in stock from an ebay purchase a long time ago. Fairly easy installation, although the HP line was hard to get threaded in place. I reinstall the ground wiring on the brake pad warning light leads. It got torn off at some point in the prior day's wrestling with driveshafts and control arm links. I reinstalled the vent duct for the disc cooling. The metal on this duct was in good shape, so I did not strip it down & repaint it. It had a consistent layer of grease & I guess that's why there was no corrosion.

I need to get one of those long bolts to anchor the tin back in place. I put the spindle nut on the driveshaft & let the impact wremch rattle away on that for a bit. Reinstalled the original protective cover and new cotter pin.
Cotter pin for the suspension cylinder.

Installed the HVLP return line from the clutch slave cylinder back to the reservoir. I used the existing rilsan as much as possible. The 90 degree turn at the master cylinder was cracked, so I cut it out & I spliced in a section of fuel injection hose.

Also installed the piddle line from the slave cylinder boot/ gator back to the reservoir.


The return line from the clutch also feeds the master cylinder. A was able to use a length of rilsan for this section.

I bundled the steering HVLP dump hose, the brake HVLP dump hose, and the clutch supply hose to traverse the back of the crossmember. I'm not happy with the connections of the two piddle lines from the DIRAVI box. these need a better hose to grab onto the nipple on the diravi box.