Gotch - thanks. Looks to me that cutting it with an angle grinder would be the easiest option. I shall have a ponder for a bit and see what feels right.
Project build 02 plate silver PD150 5 door
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While waiting for the head to come back I got around to fitting the strut brace.
Out with the trusty old angle grinder once again.
![Automotive exterior Gas Bumper Wood Machine]()
The first job cut off the support tabs and then tidy up the remaining parts of the weld with a flap disc.
![Wood Bumper Automotive design Automotive exterior Automotive lighting]()
I spent a while wondering about the cuts so that it would fit the part around and under the bonnet support gas strut and not have to cut all the way through the metal. Sprayed the newly cut areas with gloss black metal paint.
offering it up before drilling the holes
![Hood Automotive fuel system Motor vehicle Automotive tire Automotive exterior]()
Drill ready with some cutting oil. Interestingly I have to send the Milwaukee drill in for some warranty work. the chuck is not as good as the drill. I will replace it with a Rohm chuck in the near future if the Milwaukee replacement is no good.
![Red Drink Gas Liquid Personal care]()
Points marked and drilling the small pilot holes
![Automotive tire Liquid Fluid Tableware Gas]()
Working up slowly to the 8mm size I wanted
![Automotive tire Rim Gas Automotive wheel system Machine tool]()
Some touch up paint in the holes and left to dry. Then put some jacks under the control arms (car is still on stands) and took the weight to lift the car just off the stands and then lowered so just touching to simulate being on the wheels and then offered up the Wurth M8 bolts, washers and lock nuts and tightened it all down.
![Motor vehicle Hood Car Automotive design Automotive exterior]()
I then repeated the cuts, sanding and painting on the other 2 strut braces for the 2 other cars in advance of fitting them.
Out with the trusty old angle grinder once again.
The first job cut off the support tabs and then tidy up the remaining parts of the weld with a flap disc.
I spent a while wondering about the cuts so that it would fit the part around and under the bonnet support gas strut and not have to cut all the way through the metal. Sprayed the newly cut areas with gloss black metal paint.
offering it up before drilling the holes
Drill ready with some cutting oil. Interestingly I have to send the Milwaukee drill in for some warranty work. the chuck is not as good as the drill. I will replace it with a Rohm chuck in the near future if the Milwaukee replacement is no good.
Points marked and drilling the small pilot holes
Working up slowly to the 8mm size I wanted
Some touch up paint in the holes and left to dry. Then put some jacks under the control arms (car is still on stands) and took the weight to lift the car just off the stands and then lowered so just touching to simulate being on the wheels and then offered up the Wurth M8 bolts, washers and lock nuts and tightened it all down.
I then repeated the cuts, sanding and painting on the other 2 strut braces for the 2 other cars in advance of fitting them.
Got the head back this morning.
New billet steel camshaft, new bearings (old ones were in POOR shape), bolts, followers (at least one cam follower had failed), and the camshaft was worn. Some new valve guides and valves were lapped.
I'll be building it back up this week.
![Gas Engineering Font Automotive tire Machine]()
![Rectangle Automotive exterior Automotive design Auto part Font]()
![Automotive tire Camera lens Camera accessory Lens Cameras & optics]()
New billet steel camshaft, new bearings (old ones were in POOR shape), bolts, followers (at least one cam follower had failed), and the camshaft was worn. Some new valve guides and valves were lapped.
I'll be building it back up this week.
Did the timing belt yesterday evening with my pal Ian. Then set injector backlash, and put it all back together this morning with a new rocker cover gasket from Darkside Developments (you may recall the dramas I had on the black PD130 build with an inferior gasket). Managed to fit the engine cover back ith the strut brace. I removed the post that sits on the intake manifold and the cover now just slides under the brace.
Just gave the car a few runs and all seems good. Let her get up to temperature, ran for about 5 miles and then stretched her legs a bit. Pulls really nicely now. Parked up in the garage for now so I can check the floor for any leaks later.
Will need new discs at the front, otherwise thus far am well pleased.
Just gave the car a few runs and all seems good. Let her get up to temperature, ran for about 5 miles and then stretched her legs a bit. Pulls really nicely now. Parked up in the garage for now so I can check the floor for any leaks later.
Will need new discs at the front, otherwise thus far am well pleased.
Something interesting - occasionally the car is giving a puff of blue smoke. Sometimes after an overrun and sometime after pootling along slowly in traffic. Or pulling away having sat idling for a short while at the lights. Never lasts just a noticeable puff - last seen as I reversed up the drive. Any ideas?
Been pondering a vibration I can hear and feel with the engine running. Turns out the clearance is too tight with the cover on and it is making the noise/vibration. Remove it and whilst the engine is a bit louder no vibration.
I am fitting new discs and pads to the front today. I went to do it yesterday and regrettably, as seems to be happening more often these days, our local Euro Car Parts branch sent discs that were too small. I specified 288 mm diameter and received 280 mm diameter.
Discs and pads arrived just before I was due to leave so will be fitted in the morning. The golf did about 150 miles today. The car ran great, other than the puff of blue after each brief stop and there were plenty in Manchester, after a 50-mile motorway run in. I noticed this seemed to be happening less as the day went on and tonight did not see it happen once. Cruised at just below 60 (about 1750 rpm) and got a great indicated economy.
Also noticed that if I clicked the indicator up with cruise control on the motorway when I cancelled it the movement of the indicator stalk cancelled the cruise control off and would not resume. if I pressed the indicator but not clicked up, or clicked up and then slowly carefully pushed it back to rest position cruise control would not be interrupted.
The rear washer was not working. I pulled the back door apart when I got home - there is no liquid arriving at the wiper motor via the hose so I pulled the headlining down at the back and no sign of water. I will investigate at the washer bottle end tomorrow.
Aircon needs re-gassing as well.
Also noticed that if I clicked the indicator up with cruise control on the motorway when I cancelled it the movement of the indicator stalk cancelled the cruise control off and would not resume. if I pressed the indicator but not clicked up, or clicked up and then slowly carefully pushed it back to rest position cruise control would not be interrupted.
The rear washer was not working. I pulled the back door apart when I got home - there is no liquid arriving at the wiper motor via the hose so I pulled the headlining down at the back and no sign of water. I will investigate at the washer bottle end tomorrow.
Aircon needs re-gassing as well.
Removed the rocker cover and added a little silicone seal to the back edge. I replaced the rocker cover gasket with an OEM one from Darkside Developments so that should be OK. It was not leaking badly so if this does not resolve it I will likely just live with it.
Adjusted the outside front door pull handles as well by moving the small plastic toothed end that pulls on the door lock a few teeth towards the outside of the car. Doors open better now.
Adjusted the outside front door pull handles as well by moving the small plastic toothed end that pulls on the door lock a few teeth towards the outside of the car. Doors open better now.
The passenger front door lock mechanism has been playing up -sometimes unlocks and sometimes locks. New lock mechanism was ordered. Also, one of the plastic (nylon?) clips for the window in the same door broke. New one on its way to me.
Cut slots in some washers and have fitted these under the bolts at the back of the valve cover so give a little more nip pressure to the gasket to see if we can sort the oil seep from the back edge. Bit damp today and had to work out in the rain as one of the other cars is in the garage waiting on 3 rebuilt and 1 new injector to come in then I can get the car running again and out of the garage.
Pulled the discs and pads off the front - getting replacements under warranty from Euro Car Parts as these are warped after a few thousand miles.
Also starting to take apart the aircon compressor to change the clutch coil to see if that gets the aircon working. A fiddly job in car without de-gassing the aircon and removing the compressor.
Also starting to take apart the aircon compressor to change the clutch coil to see if that gets the aircon working. A fiddly job in car without de-gassing the aircon and removing the compressor.
Never use euro car just a waste of time of a company everything over priced and someone else has had it before you. My mate bought 2 wheel cylinders for his Octavia both have been tampered with and he was about £22 each took them back yesterday got from my normal car factor that I use
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