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Discussion Starter · #82 · (Edited)
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.

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The first job cut off the support tabs and then tidy up the remaining parts of the weld with a flap disc.

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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

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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.

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Points marked and drilling the small pilot holes

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Working up slowly to the 8mm size I wanted

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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.

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I then repeated the cuts, sanding and painting on the other 2 strut braces for the 2 other cars in advance of fitting them.
 

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Discussion Starter · #83 ·
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.

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Discussion Starter · #84 ·
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.
 

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Discussion Starter · #85 · (Edited)
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?
 

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Discussion Starter · #86 ·
Managed to fit the engine cover back with the strut brace. I removed the post that sits on the intake manifold and the cover now just slides under the brace.
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.
 

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Discussion Starter · #87 ·
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.
 

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Discussion Starter · #88 · (Edited)
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.
 

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Discussion Starter · #89 · (Edited)
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Discs and pads fitted.

The rear washer was the usual suspect in the end. The black barbed plastic hose had parted company with the pipe left side behind the C pillar. All sorted now.
 

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Discussion Starter · #91 ·
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.
 

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Discussion Starter · #92 ·
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.
 

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Discussion Starter · #93 · (Edited)
Fitted the new regulator clips - and decided to inspect the wires as there has been a grinding noise when raising and lowering the window. Discovered the wires are frayed inside the regulator so I have ordered a replacement regulator. Should be here Saturday.
 
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