WITW - Barn-find Final Edition

[MikkiJayne]

Subframe today, but I started by glueing the brake hose bracket on so that could be curing. The adhesive has a nominal strength on aluminium of 22N per mm². The bracket has an area of 616mm² which gives 13552N of holding force in ideal conditions, or 1.3 tons. I reckon that should hold a brake hose



New bolts. I've used the D3 toe adjustment bolts as they're only 4mm longer than the D2 ones. I got mk5 Golf camber bolts, but unfortunately they are missing 8mm of thread on the end so aren't quite long enough. The D3 camber bolts are 10mm too long, so I may have to just get the Febest ones.

The two long ones on the right are for the outer toe rod joint, which are from an Amarok, and 5mm longer than the D2 bolts. We probably should have an alternative parts thread where I can list all this...



All assembled







It was about this point where my phone battery died, so no more pics unfortunately. I had to swap the headlight level sensor, and made a new arm for that at the same point. The rear dampers are painted and back in too.

There are a couple of jobs left before putting it back in the car - the diff mount bolts were on back order so those need swapping, new camber bolts as noted, and a few other bits of hardware. I'd also like to get the brakes assembled while its sitting on pallets and nice and easy to get to.

Finally, I need to make some alignment sleeves to line it up with the rear mounting holes, as the tool I made when I did Ricky D's doesn't work with the D3 bushes. Those are 20mm inner diameter, whereas the locating holes are 21mm diameter, so I'll print up some simple sleeves for these. There's no load on them as they are purely used to line it up, and being printed there's no issue leaving them in place.

[S81]

This is really pretty much a full refurbishment,are you looking at 300 plus hrs ?

[Ronin]

Nice touch with the carpet on pallets.
A typical workshop would probably just use 2 transmission stands or something and scratch the subframe.

[strummagnet]

Originally Posted by MikkiJayne

Subframe today, but I started by glueing the brake hose bracket on so that could be curing. The adhesive has a nominal strength on aluminium of 22N per mm². The bracket has an area of 616mm² which gives 13552N of holding force in ideal conditions, or 1.3 tons. I reckon that should hold a brake hose

The time and effort to 'do it right'

I would have just stuck a rivnut in there and bolted it

[tonupkid]

Presumably Rivnuts etc are not aluminium. Is there therefore a potential for galvanic corrosion in future, or does your use of sealant insulate he different metals from each other?

[MikkiJayne]

I have aluminium rivnuts where they are appropriate, and considered one here but I don't have a reference for what's behind this sheet metal so adhesive was the way to go.

Now covered in seam sealer



New fuel filter



The old one was dated 2002 so likely the original



This is the D3 camber bolt which is 10mm longer than it needs to be. Its ugly but it does the job.

[strummagnet]

Originally Posted by MikkiJayne

The old one was dated 2002 so likely the original

Changed at recommended intervals

I wonder what it looks like inside?

[MikkiJayne]

They are usually a bit brown but nothing remarkable. I cut the Murple's filter open, which had 323000 miles on it was just a bit dark. No crud or blockages.

Some progress from last night - rear calipers painted to match the fronts



Printed alignment spacers to line the subframe up with the body. There's no load on these - they are simply there to hold everything in the right place while the bolts are done up.



Subframe complete and ready to go back on. I keep looking at this and wondering whether a Tesla motor would fit in it



Reassembly is the reversal of removal Position it in the right place on the pallet jack and lower the car on to it



Bolted back in





B-roll shot



A few bits to reconnect, but it should be back on its wheels today

[strummagnet]

Originally Posted by MikkiJayne

Subframe complete and ready to go back on. I keep looking at this and wondering whether a Tesla motor would fit in it

An S8 FE-E............ hmmmm call to action for someone I bet

[strummagnet]

Originally Posted by MikkiJayne

Printed alignment spacers to line the subframe up with the body. There's no load on these - they are simply there to hold everything in the right place while the bolts are done up.

Are there alignment spacers used during first assembly? Just curious if the tolerance between the sleeve in the bush and the bolt is to allow for some 'lateral' adjustment to align the front and rear subframes or wheelbase lengths.