Black Ur Project

[Rikki Kitto]

I'm just waiting for my big win so I can drive my tatty old S2 over and leave it with you cost no issue

[Tractor Dave]

I've been pondering for the last few days about whether to swap to servo brakes. Today I decided to keep it oe (for now).
So I cracked on with brakes and thought the master cylinder a good place to start.
It's very mucky. Brake fluid has been leaking down onto to bias valve causing a lot of rust.


So everything came apart quite easily.


And I set about cleaning it up. Replacements are nla.








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[4WDrifter]

Lovely! Just lovely. That’s how to spend a Sunday!

[jbrentd]

Just getting caught up on the last few pages. Great job, as usual!

[Tractor Dave]

Got a good few hours in the garage this morning and I'm making progress.


You can see where the brake booster has been leaking and caused the rust.
I will replace both seals.


This tool makes nice flares.


I'm using brass pipe fittings in the wheel arch and some stainless steel ones I had knocking about at the cylinder. I was surprised to find only mild steel on the car already. They are the original lines and still quite good apart from corrosion around the pipe nuts.


My little Chinese heater outlet is a good place to paint. HeHe.


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[Tractor Dave]

Doing the drivers side pipe was quite difficult as everything was in the way.



But got there in the end.




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[Tractor Dave]

The brake force regulator came out ok.


Putting it all back together.


I had to use a stainless steel washer to space out the pipe nuts where they meet the flexi. My brass pipe nuts are slightly longer than the original and the spring clip wasn't tight.


I ran the pipe to the back of the car before calling it a day. Onto the back pipes over the weekend.


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[Tractor Dave]

Rear brake pipes all finished. I quite enjoy this job when everything is going well. And it went well today. Only forgot the pipe nut before flaring once. Doh.







Then I made a start on the fuel pies. A 6mm long socket is good for tightening up these clips. Just a tap with hammer closes the tabs back in.



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[Nuvo]

Brilliant work as ever. In the past, I've just turned the clamps by hand to get them on or off the thread.

[B5NUT]

Then I made a start on the fuel pies. A 6mm long socket is good for tightening up these clips. Just a tap with hammer closes the tabs back in.



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Always wondered how your work was so good! Now we know, it's Edd China doing the work

[vonbeck]

great work matey

[K Simmonds]

Looks great Dave! Forgetting a fitting when making up new brake pipes is infuriating, it's not that much bother to sort out but I always feel like a right wally when I do it.

I also use a socket to push those clips back on.

[Tractor Dave]

It was a lovely sunny day here in west Wales and a pleasure to be in the garage. I fired up the sand blaster.


Unfortunately, the heat shield was a bit worse than I thought and came out like Swiss cheese.


Now these are available from Tradition but price has gone up to about £40!
I figured it would be easy to make.
I made a template using masking tape.




The little side bracket is good so I can cut it off the original and weld onto my new piece.
Looks like I will need to weld a new bottom onto the radiator cowl as well.
Sad face.



On another note, I found that Heritage VW parts sell good oe spec vac pipe for a reasonable price.


I'm just about ready to start putting the fuel pump, accumulator and filters back on the car.


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[4WDrifter]

It’ll be better than new when you’re finished Dave.

[Tractor Dave]

So when I went to cut the little bracket off the rusty bit, I found it too was quite crusty. So getting a bit more confident making parts I thought I would give it a go. I used the masking tape method again and find this really easy and a reliable way to copy complicated shapes.


The original is spot welded so I drilled some holes to plug weld.
It then got some weld through primer.


And plug welded.


Just needs a clean up then some high temp paint.



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