My new daily project with a 1.4 TDI

[tchouki85]

 

I installed a SEAT Ibiza type JCZ gearbox and a black Diamond reinforced clutch

[tchouki85]

 

[tigcraft]

How does the JCZ gearbox perform? Maybe I should say how f dad o the ratios compare? 

[tchouki85]

frankly I don't know but I think they are about the same since the gearbox comes from a 1.4tdi like my Lupo

[FraH2o]

14 hours ago, tchouki85 said:

 

I installed a SEAT Ibiza type JCZ gearbox and a black Diamond reinforced clutch

Many thanks for this info! I think i'll search this gearbox.

[tchouki85]

you'll have to make some adjustments to the anchor points but it mounts very well

[FraH2o]

I start with the restoration-refurb of the rear calipers (heritage of my poor burned and dead GTI 😪)

After full Disassemble them, i did a first mechanical rust removal with brushes and drill.

 

I wanted to test the legend of coca cola: i made a 24 hour bath in coca which contains a little percentage of phosphoric acid.
It worked but just only a superficial part of the oxidized layer came off.

 

 

I made another bath for 24h in hydrochloric acid 
I washed with water and lastly quick brushing and finally a quick rinse in ammonia to stop the action of hydrochloric acid which has completely removed the oxidation of iron.

 

I spray a protective layer of silicone spray to avoid new (and rapid) oxidation while I do some tests.

Next steps try the brake group to build the new brake line and test the handbrake cables and start thinking about the size of the rear rims, the wheel arch (the roller fender is ready), and any camber shims.
Once the fitting test and all doubts will be ok and solved, I will  paint the calipers together with the front ones (which will be completely disassembled like the rear ones and wiil be refurbed with new gaskets and new pistons)

[FraH2o]

I started a pre-assembly to forward/check all the connections with the brake line and start having a response on the clearance on the rear axle with future rims

ABS sensor good

I'll be be a slight milling  to accommodate the head of the lower bolt that fixes the caliper holder to the hub

In the meantime, fittings and pipes for the brake line have arrived and all seems to work good

And a quick test to watch  the future clearence anfd work to do on whell arch

I'll wait to check the front axle as well and then I'll think about taking the epytec camber spacers between the bridge and hub.
For the moment even if internal of 5 mm I do not mind the rear. I will evaluate.

Today it remains for me to check the handbrake cables (still golf mk3) and then I will proceed (after having made the tube) to disassemble the front to refurb the calipers also 

 

[cutr1]

Complimenti, sono italiano anche io😀

[tchouki85]

hello

to the top you are still advancing, it's great to follow you, I see that it is you who will create your brake pipes with the fittings that you took a picture of, is it reliable without leaks and able to hold the  brake circuit pressure

do you have a link of your fittings and pipe please

[FraH2o]

On 8/26/2022 at 9:38 PM, tchouki85 said:

hello

to the top you are still advancing, it's great to follow you, I see that it is you who will create your brake pipes with the fittings that you took a picture of, is it reliable without leaks and able to hold the  brake circuit pressure

do you have a link of your fittings and pipe please

Hi tchuki.

I did them by myself and hydraulically tested in the workshop. In the past I have done it for the braking systems of my scooters and for the moment no problem.

For the connectors i went to local brake shop and bought M10 and braided hose but i think is easy to find on the net.

[FraH2o]

I go ahead on with calipers

Also clean the front

 

I thought about making bases out of self-locking (which I have a good extra dose of) and threaded rods.

In this way, painting should be easier

 

and also the overhaul kit for all calipers

And finally an acid green as paint for calipers (99% chosen by the daughter) 😆

And after 2 hours and 2 coats, a 24h of complete drying

 

 

 

 

 

 

[tchouki85]

hello awesome your work of repairing the calipers that you did, I will soon redo those of my golf4 they are double pistons I will have fun I think

[FraH2o]

The reassembly of the braking system is almost finished.
With the sanding pad I made the necessary recess for the head of the lower bolt for the caliper holder bracket.

A quick paint of black and this too solved.

 

 

 I Painted the dust covers, greased everything and mounted the discs.

For the moment I have left the old caps to make the last tightening of the hub bolt with the wheel mounted, once adjusted I will also put the new cap.
To keep in place the new rear brake lines , I took 4 new clips that hold the abs sensor wiring and I reused the original pins.

 

I Reassemble the calipers and connect everything.

The Lupo GTI's brake cables (already at home) are the final step,  just need bleeding, and if there are no surprises, the braking system should also be fine.

 

[FraH2o]

I Also fixed the speech of handbrake ropes

Blue: Drum wolf
Red: Disc wolf
Yellow: Golf mk3 with discs

 

Having the  golf mk3 at home, I tried to see if I could use them but in addition to the difference in length (a 20 cm), the measurement of the sheath and related terminals also varies.

Handbrake cables  lupo gti and problem solved.

Also fixed the clips that stop the cables to the bridge and everything is ok and perfectly functional.

Finally I wanted to test the do-it-yourself bleeding system with a vacuum pump… which proved to be effective and easy to use.
Now I wait for the rear lowered springs and then maybe I move on to the rolling of the fenders.

 

[tchouki85]

it's always a pleasure to read your modifications, once again congratulations

[mk2]

Nice work 👍🏻😀🇬🇧

I've not seen the brake hose kit before. It means it is possible to make your own brake hoses (if originals are not available anymore). 

Where did you buy it? What are the search words? Looks like no swaging machine is needed.

[FraH2o]

On 10/2/2022 at 9:46 PM, mk2 said:

Nice work 👍🏻😀🇬🇧

I've not seen the brake hose kit before. It means it is possible to make your own brake hoses (if originals are not available anymore). 

Where did you buy it? What are the search words? Looks like no swaging machine is needed.

Hi mk2

I made by myself useing braides hose and brake connector bought on local shop....but i think you can find on the net. The connction are M10x1 and not need swaging machine, it's the same method to do brake lines for motorcycle or scooter.

[FraH2o]

Springs has finally returned. They're  warmed and reardened for a total reduction of 60 mm.

 I painted the heated part by first giving the metal primer and iron mica ... I deliberately left half the spring yellow and half the spring gray mica,

 

 

Then the absorber.

Here the comparison of ammo: oem vs coilover (-35mm) and Corsa b (-87mm)

The comparison was made taking as reference the difference in length on the rods.

I then lined the thread of  spring holder to give a minimum of protection.

 

[FraH2o]

I completed the brakebleeding and a fast adjust of the front coilover and finally grounded

[tchouki85]

ohhh the delirium how low, you're not afraid to hit the oil pan

[cutr1]

Nice work mate

[mk2]

It is good. I think we all agree... 👍🏻

[FraH2o]

The oil pan have 70mm of clerance from gorund. Is low but safer than golf that is about 35mm.  I use sump saver for golf that protect sump, gerabox housing and subframe.

Here the golf

And here the sump saver of golf after 70000 km od daily use (about 45.000 miles)

Lupo is low but not enough as golf.

I also will buy the sump saver for lupo and i think and hope that are useful like on golf

 

 

[mk2]

OMG! 👍🏻😂