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Looking good Dave. You're knocking this out pretty quick.
 

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Discussion Starter · #24 ·
My arm is healing, looks like i'll have a cool circle scar.


Had Nate machine some hubs for me, Thanks NATE!



Parts keep rolling in... It's hard for me to NOT do certain things while rebuilding this car. I'd love to have just done the simple engine swap, but this car needed a lot of stuff, lots of deferred maintenance going on. SO if you're going to do it... might as well do it right:





Got jealous of Chris' Catch can... had to get one myself:


Had to get batteries for my caliper and shims as well;



Pressed in the first one to do some test fitting:






Now for some rears, cleaned it up and gave it a lick of paint after this:


Here are most of them:


New vs Old Ball joints



Here are the old rears...



Now, truth be told I dont really care for adapters, but i understand them in some cases. in my case however they are extremely tricky. 1- they are 2 peice and obviously push the wheel WAY OUT. I have a bit of a wheel problem and have several spare sets of wheels floating around, HOWEVER with these adapters, none of my wheels fit, even the ones that i had to use a spacer on to run... 2- the brake rotors were all worn horribly and needed to be replaced, which requires removal of these adapters, the bolts to remove them are seized... 3- A rear wheel bearing was shot and would have had to have them removed anyway for that work. My motto of course is to make things right, this didn't feel right to me, so I changed it all to make it 'right' in my head.

"Corrected:"



And now the wheels i wanted to run fit INSIDE of the fenders... weird concept I know: (17x8.5 BBS CH 003)





And Chris hooked me up with a great looking CQ Seat in black leather:



On a final note. after spending way to much time installing new valves and such on the head i had. (Honestly hell for me would be manually removing and reinstalling valve retainers all day) I talked to Nate and he convinced me to send it to a shop. Should have it back tomorrow, hot tanked, skimmed, new valves and valve seals all installed and ready for action. It was pretty cheap and well worth the peace of mind i get from having it done.

32 Days left...
 

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Discussion Starter · #31 ·
trying to wrap up suspension bits so I can finish the engine part of it.

Finished the final knuckle. Had to go grab this from a friends house, I swear everytime I want to get work done, there are several steps i need to take first. To get this knuckle I had to go to Josh's house and take the WHOLE subframe with upright, brake, rotors, and a wheel 'seized' to it all... So i went and grabbed it all and got the wheel free and continued to strip it all the way down to this:



pressed in a new bearing and the new machined URS4 hub:


It is hard not to spend 10-15 minutes on cleaning when this car has been so unloved for such a long time:



while it doesnt look like much in this picture, notice there is a screw upright next to the pile. it is literally 2" high of stuff i scrapped away:


Lots of new brake lines that will also make their way onto the car:


also removed steering arms and tie rods:


tried to match lengths to keep it semi close so i can at least drive it to get an alignment.


Reason i decided to remove them, this wasn't even the worst one;


New arms all prepped:


new cover for the steering rack installed, gotta say this was more of a pain in the ass than i thought it would be:


Had to actually refer back to the 'good book' to make sure i wasn't going to break something. Needed it out anyway for some torque specs and what have you.



25 Days left...
 

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Discussion Starter · #32 ·
Got some more done:

Chris Brydon machined my valve cover to accept 2.0t Coilpacks:


Prepped the valve cover for some paint:


Primer:


Laying some coats:


Finished:



Installed the head, I was a bit annoyed with my headbolts from FCP Euro:

Spent more time sorting that than i would like to admit.

Head installed:


mock up of timing belt cover, coolant to turbo line:


installed:


little details, injector wire cover:


Received my Euro 3 spoke steering wheel, it smells like 10,000 cigarettes:


New strut mounts(another deferred maintenance item):


Both front axles had split boots and gunk everywhere, rebuilt them:




More updates as they happen, 21 days left!
 

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Discussion Starter · #33 ·
worked a bit more this weekend, finished most of the front suspension.

New control arms with Derlin bushings, new strut bar links, new bearings, new ball joints, new strut mounts, should be pretty well dialed once it is on again.









Also got the timing belt on, with covers and such, looks like i'm going to need a longer PS pump belt, doesn't play well with the AAN cover.



Nate machined a small block off plate for my inlet tube. this inlet tube has been modified and powder coated, I wasn't a fan of the built in HKS BOV that was added to this pipe, so the easiest solution was to have a block off plate added.




Nate also helped move brake lines so i could fit the new brakes. Feels good to have the suspension dialed in and ready for a proper alignment.



Newly rebuilt calipers, all new seals, all new pads, shims, retailers, ect. Along with all the new suspension bits.

17 days left. I hope to start it wednesday, I'm close, need to wrap up a few things with vac and breather lines. But its close. I'll try to get an alignment and new tires mounted by friday and have 2 weeks or so to put some miles on it and iron out any other potential problems that might exist.
 

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Discussion Starter · #35 ·
Small things

Radiator and plumbing is all in:


This is the condition of the old coolant hose fittings:



Got a 'new' old OEM Muffler, cleaned it a bit:




Old and 'new", can't believe this was on there:


Mounted:


Gunna put this in as well, Magnaflow high flow cat, attached to the v-band that matches the downpipe:



Airbox and coolant filled:


Bumper ONish:


Installed HIDs into the projector housings of the RS2 Headlights, i'm pleased with how it turned out:



lights installed:


New tires mounted on the wheels as well:


Thats all for now.

Still Needs:
Exhaust tied together
Alignment
Coolant fully bled
???? Any random problems that could pop up
then just general cleaning and finishing off small 'wants'

8 Days left...
 

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Glad to see you making great progress and keeping up with the schedule:) Have fun in vegas:)
 

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Discussion Starter · #37 ·
K, here is the weekend update:

put her back on all 4 again:




It was able to move under its own power, which is good:


Drove it down to the alignment shop:


I was hoping to drop it off at the exhaust shop after the alignment, however I didn't get the car down to them early enough to make it all happen.

Drove moderately well. Loud, but well. Had a big rattle and clunking sound from the passenger front so when i got it back home i took a look, and it was the strut mount, but it was actually a poorly installed strut mount. So i wrestled the top bolt off and had to reseat the castle nut (that is the part i didn't properly seat), then it all fit back together. the clutch was feeling a bit lazy as well so i tried to bleed it, i ended up covering myself in brake fluid, but it felt better today when i drove it so perhaps my messy approach was still functional.

It is very hard for me to see things dirty and not want to clean them, but the truth is, it takes HOURS upon HOURS to clean everything properly, and due to my tight time table, it isn't the top priority with this build, but i still take time to do some work:


After:


the paint on this car cleans up so nice, i wish i had more time/money to dedicate towards a proper detail.

Made a small converter for the reverse light switch, the harness i have is expecting an 01e, i have an 01a, so i made a quick removable conversion in the event that i upgrade to an 01e, there won't be any cutting or splicing needed.


Got lights on and I'm feeling good about the car:



Still working on a grill solution, not sure how I feel about the B3 hood look, i thought it would have come out better, but now i'm a bit on the fence.



I dropped it off at the exhaust shop this morning.
~4 days left...
 

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IMHO, in contrast with the cream puff it shares the driveway with, yes, that B3 grill just doesn't sit right. Why not just pick up the B4 hood eventually?

Also, it would be nice to get some S2 rears on these coupes. I've been looking for a rear S2 bumper for some time now, where is the market at for these right now?

Looks very nice. I like the new (is it new?) coolant reservoir tank with the pink kool-ade. Small detail but it looks nice. My original tank is faded to hell and I can barely tell there is fluid in it without a maglite up against it.
 

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Discussion Starter · #40 ·
nribs said:
IMHO, in contrast with the cream puff it shares the driveway with, yes, that B3 grill just doesn't sit right. Why not just pick up the B4 hood eventually?

Also, it would be nice to get some S2 rears on these coupes. I've been looking for a rear S2 bumper for some time now, where is the market at for these right now?

Looks very nice. I like the new (is it new?) coolant reservoir tank with the pink kool-ade. Small detail but it looks nice. My original tank is faded to hell and I can barely tell there is fluid in it without a maglite up against it.
Yeah, if a pearl b4 hood pops up locally i'll probably snag it. I'm going to try and make a different grill, it might help it. Sadly the under headlight trim it came with was black and i think that takes away from the overall look as well.

The s2 rear bumpers are affordable, its just the shipping that is costly. and since the s2 rear bumper is also the same as all the other euro coupe rear bumpers, they are plentiful.

Yes its a new reservoir, they are only like 30 bucks or so, worth it.
 
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