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  #241  
Old 11th February 2021, 02:29 PM
MikkiJayne MikkiJayne is offline
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I got it from Hitek Electronics - they had the lowest price and cheapest next-day shipping. They're a Permabond and Henkel (Loctite) dealer so a handy supplier of both ranges.

JBWeld is ok as a general purpose epoxy, but I've never actually checked the data for it to see how strong it is on various substrates or conditions. When I have a specific application I tend to go searching for a product designed for the job. My usual go-to for products like this is Loctite - their 638 retainer will glue slip-fit components together so they never ever come apart. But, 638 doesn't do gap filling so I needed something else and Loctite aren't too strong on the methacrylates for some reason. TA4207 can do small gap filling and is optimised to work on unprepared aluminium so fit the bill perfectly. TA4202 is a general purpose methacrylate but it needs aluminium to be sandblasted to get a decent bond.

There are a few Permabond epoxies (ET500) on Amazon, and the TA4202 methacrylate, but for some reason not the TA4027, hence Hitek.
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  #242  
Old 11th February 2021, 03:41 PM
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Quote:
Originally Posted by MikkiJayne View Post
I got it from Hitek Electronics - they had the lowest price and cheapest next-day shipping. They're a Permabond and Henkel (Loctite) dealer so a handy supplier of both ranges.

JBWeld is ok as a general purpose epoxy, but I've never actually checked the data for it to see how strong it is on various substrates or conditions. When I have a specific application I tend to go searching for a product designed for the job. My usual go-to for products like this is Loctite - their 638 retainer will glue slip-fit components together so they never ever come apart. But, 638 doesn't do gap filling so I needed something else and Loctite aren't too strong on the methacrylates for some reason. TA4207 can do small gap filling and is optimised to work on unprepared aluminium so fit the bill perfectly. TA4202 is a general purpose methacrylate but it needs aluminium to be sandblasted to get a decent bond.

There are a few Permabond epoxies (ET500) on Amazon, and the TA4202 methacrylate, but for some reason not the TA4027, hence Hitek.
Brilliant! Thanks for the detailed explanation. I noticed the ET500 and others but not the one you used. Like you said, sometimes you can't sandblast or prepare some surfaces, this seems to fit the bill perfectly.
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  #243  
Old 11th February 2021, 09:54 PM
MikkiJayne MikkiJayne is offline
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Wiring harness tonight, which took longer than expected because I forgot about the damage to it.

This engine came without coilpacks but I have a few spares from exploded engines



Coilpacks fitted and the wiring harness cleaned up and back in place



The last ever new-old-stock D2 engine harness heat-shielding. Some cars have shielding over the downpipes and some don't. Not sure why. This one had none at all.



Aftermarket shielding on this side



They should all have shielding here but captain carnage left it off and the exhaust heat killed the pvc sleeving



This is the left engine mount connector which has frayed and damaged wiring



This is the speed sender connector which just broke off when I wiggled it.



I've refitted the harness to the engine before mending these connectors so I can make sure I get the lengths and connector orientation correct. Its as easy to work on with the engine on the stand as it is on the bench so I don't lose anything. The damaged wires and sleeving will be replaced, and this section of harness wrapped with more heat shielding material. Hopefully TPS have repair wires in stock so I can still get the engine in over the weekend...
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  #244  
Old 12th February 2021, 09:08 AM
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were these damanged by capt. bodge or chewed up by rats? I've never heard of these sort of animal attacks on cars happen in UK
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  #245  
Old 12th February 2021, 09:50 AM
MikkiJayne MikkiJayne is offline
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I think these have simply become brittle with age tbh - really the only legacy of the car's 320k miles, apart from the sandblasted paint. Captain carnage probably didn't help when he took it apart to swap the engine, and certainly didn't help by leaving off the heat shielding, but that alone didn't kill these connections.

I've had a few things chewed by mice out here in the countryside. My A6's sound deadening has been pilfered to make a nest, and empty acorn shells left in trade That also has a connector boot or two with tooth marks as they seem to like rubber. Oh, and while my mum's Beetle Cabrio is in storage (cos covid) a mouse made a nest in the bonnet sound deadening pad, but I evicted him before he ate any of the wiring.
I replaced the engine harness on Gareth's due to extensive nibbling of wiring and connectors. Thats a repair project for when I need it.
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  #246  
Old 12th February 2021, 05:30 PM
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Sounds like a fair swap, fluff for shells. I think it was Honda USA that produced a loom tape designed to prevent “nibbles” from sneaky little mice, it’s loaded with chilli to dissuade them from chomping wire harnesses.
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  #247  
Old 12th February 2021, 08:41 PM
MikkiJayne MikkiJayne is offline
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I need some of that tape!

50 of wires These would have been much cheaper had I remembered they were needed and ordered them in advance



Cut off the burned and brittle sleeving



Attach the repair wires to the originals with heat-shrink crimps





Wrapped the repaired section in fabric tape



and the covered it up in heat-resistant sleeve



Engine and box back on the subframe



New exhaust manifold hardware

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  #248  
Old 18th February 2021, 05:28 PM
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<casually waiting for more>
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  #249  
Old 18th February 2021, 07:20 PM
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Quote:
Originally Posted by Ronin View Post
<casually waiting for more>
you might be a while unfortunately:

http://forum.a8parts.co.uk/showthread.php?t=16135
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  #250  
Old 24th February 2021, 08:02 PM
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Quote:
The hvac inlet is all back together with new foam and new screws
Is that foam available separately? It is perished on my car.

Thanks for the info about the adhesive! I broke off the bracket for the ignition control modules, and that stuff seems good stuff to fix it.
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