Another one? The Journey of Chad.

A lovely day today in the sun, in the garden, perfect weather for get all the bits bolted on. I have decided to order new disc and pads now as the suddenly don’t look as good as they did! It’s now put a away ready to be fitted when the garage is a bit more clear
 

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Currently the garage looks like this…..bits of old car and motorcycle engines strewn about everywhere 😂
 

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some may notice that I did a modification on the brake pipes….the originals were quite corroded, and they are a weird one piece pipe with the flexi part of it, not sure if they are available, and no doubt expensive? I decided to buy 2 extra flexis to keep it simple, and then buy banjo adapters to join the caliper to the flexi. Doing it this way keeps it cheap, simple and a bit more future proof hopefully. The banjo fitting is round and deeper than the original, so I had to file the sides slightly to fit the caliper, and longer banjo bolts are on the way.😀
 
some may notice that I did a modification on the brake pipes….the originals were quite corroded, and they are a weird one piece pipe with the flexi part of it, not sure if they are available, and no doubt expensive? I decided to buy 2 extra flexis to keep it simple, and then buy banjo adapters to join the caliper to the flexi. Doing it this way keeps it cheap, simple and a bit more future proof hopefully. The banjo fitting is round and deeper than the original, so I had to file the sides slightly to fit the caliper, and longer banjo bolts are on the way.😀
Looks a great job restoring it all. I dread to think what it's cost. With the banjo fitting, do you think it's going to be liquid tight at the mating surface?
 
Looks a great job restoring it all. I dread to think what it's cost. With the banjo fitting, do you think it's going to be liquid tight at the mating surface?
😱😱close to 350! However, once done, it’s done, and I shouldn’t have to look at it again for a few years hopefully. It has new shocks and springs last year……the previous owners paid for the new springs to be fitted and the cost at the garage was more than the whole of this rebuild cost. Thats how I justify stuff😂. The banjo sealing area shone fine, I’ve taken a tiny bit off to flatten the sides. On hydraulic machinery these things will run over 3000psi, so fingers crossed 😀
 
😱😱close to 350! However, once done, it’s done, and I shouldn’t have to look at it again for a few years hopefully. It has new shocks and springs last year……the previous owners paid for the new springs to be fitted and the cost at the garage was more than the whole of this rebuild cost. Thats how I justify stuff😂. The banjo sealing area shone fine, I’ve taken a tiny bit off to flatten the sides. On hydraulic machinery these things will run over 3000psi, so fingers crossed 😀
I realised after asking that it was the sides of the fitting that had been squared down rather than the mating face. daft question lol
 
Not got the axle in yet, but it’s ready to go in soon, however, there are other bits that need doing and I’ve realised that this weekend is the last bit of free time I have for the next 6 weeks as I have camping and car shows to attend….. so Chad is in the garage and over the pit, and I have these bits to do…..another clutch ( this time an expensive one) oil chain and cam belt! I’m hoping this will sort the gearbox chatter/ rattle that it has. 2 gearboxes, 2 clutches ( one old and one cheap) and it still does it. We will see!😀
 

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I’m doing a big northern trip in July, Timmus for cruise, then the North East, then up to Scotland fully loaded with the caravan, so I am wanting a stress free trip.
 
So the day was spent in the garage today, and the LUK clutch fitted. I am pleased to say that finally the awful rattle has gone!! It has made a big difference as not only was it awful at idle, but at lower revs when driving it would chatter. That’s now 3 times I’ve had gearboxes out of this car now, so I’m hoping that’s it for a while
 
Another afternoon in the garage today…..I got the axle swapped over at last! By far the worst part of the job was getting the old flexi brake pipes off, horrible!! I didn’t disturb the cast mounts, just removed the long bolts and dropped the beam out. Whilst out I gave the brackets a clean up with a wire brush and a paint. Everything else seemed to go back together ok, and the brakes bled up ok too. I got the wheels back on and decided that was it for the day, I’ll give it a run tomorrow.
 

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Took it out for a good run this evening, everything seems good, the new discs and pads obviously need to bed in as there is a bit more pedal travel, and it feels a bit springy, but improved as I went. The handbrake works well but feels like the cables are made of elastic, however the brakes are without a doubt better than before which I was not expecting?
I was worried the rear end would be higher as it now has the yellow spring seats which were missing before, but it’s looking ok.😀.
 

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Looks good Drew. No more rusty drums to spoil the looks. According to 7Zap the flexi cables are held by clips. I've so far not been able to source these. What state were yours in and are they made of steel and rust?
 
So it was hot today!! The air con does work quite well on Chad, but I’ve noticed if it’s very hot it’s not always as good, also last winter the webasto wouldn’t fire up on its own, it’ll fire up no problem with VCDS channel 22 , and when it was really cold i took the lap top out with me !😂😂
apart from the usual flap motor codes the G263 always comes up. Changing this on our other A2 got the air con working along with the pressure sensor. I’ve had the new one for ages, so decided to get it done.….
When production of the A2 started, the first thing put onto the conveyor belt was the G263 sensor, and then they added bits like the body shell, engine, dash etc until the car was finished. Replacement is said to be a dash out job, and thanks to a lot of information on here, it turns out it’s not. With patience and care it can be done from the driver’s footwell, and removing a few bits. You do need small hands though. 😀 I’ve done 2 now, and it takes around an hour to do. I’m hopimg this will please the God of air con, and possibly the God of webasto next winter ??😂😂
 

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So today I had a session in the garage……the mission was to make an adapter so that Claude the caravan will sit level on Chads tow bar. I made Claude 8 years ago to tow behind my stiletto and the hitch is low.
it took a few attempts to get it level, slightly high as with weight in the car it’ll sit lower…….that’s the plan anyway 😂
we are going on a long road trip later this month.
 

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