My silver RS2 Project

[Tractor Dave]

This morning I visited the engineering place to check on progress. My head is almost done.


Then this afternoon the rear subframe went up. This is so much easier with a lift.





Then cut the brake pipe to fit.


And flare.



Torqued up the subframe bolts and diff carrier front bracket.
Parts pile is reducing. Grin


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[K Simmonds]

looking great Dave, as always... I see you've made IMO the best choice regarding replacement bushes, they're so easy to fit and don't seize up nearly as badly as the stock one's which be a PITA come tracking time.

[Ryan80]

3d Printing company from Norway seems to have the rear bumper bracket at reasonable enough money...
https://kustom3dprototyping.com/coll...or-rear-bumper

[The Spanish]

Also the company name is confusing. Is the original part. I bought from them the rubber seals for the coupe door cards. All perfect and they look like new original parts, not 3D printed

[John.]

3d Printing company from Norway seems to have the rear bumper bracket at reasonable enough money...
https://kustom3dprototyping.com/coll...or-rear-bumper

Wow nice find. Mr. Google currency calculator says 17.55gbp, almost makes me wish I needed one !

[Tractor Dave]

Nice but they dont seem to do the other side which i need.

[Tractor Dave]

I was fortunate to get two new handbrake cables with the car.
Fitted them today.





It appears the gearbox seal has been leaking for some time.
The housing is full of sticky crud.


It's contaminated the clutch plate.


I've sent it to CG Motorsport to get a new lining. The pressure plate and dmfw are good.
These little bushes turned up from Koni. You need them for the front inserts.


And I ordered some new oil ready for the gearbox. I've used this on all my projects and is good stuff.


It's the right spec and GL4.


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[GT500]

I hope they sort it for you. Not far from me. Tried them once. Shocking service. Questmead are a top company.

[Tractor Dave]

Thanks Rob. They did a clutch for me once before and it was good. I have seen mixed reviews on different forums. Hope it comes back good. If it's bad i will have to get the Sachs performance set.

[K Simmonds]

I need to put a clutch in my RS2 at some point, I'm pretty sure a mate has a good used one I can buy, I installed it for him from him about a month before he wrote the car off so it's practically new, I wouldn't normally use a second hand clutch.

Anyway, I hope the relining goes well for you, I've been looking into that as a back up option as it's not that expensive and I'm yet to actually get the parts from Charlie.

I reckon there's probably a pressure plate and friction disc for a newer turbo diesel engine that is designed for that much torque and still readily available from LUK/Sachs. However I need an old RS2/ABY S2 clutch to compare to with all the the scrap one's at work to see if I can find one suitable.

Do Sachs still offer their SRE option for a duel mass flywheel? I thought they only sold the one for a single mass set up, though I guess the friction discs may be interchangeable and it's been a long time since I checked what they currently offer, all bloody expensive though. I'd be slightly hesitant about using a second hand pressure plate as that's what normally fails first. Though that friction disc look's virtually new so I guess the clutch hasn't done too much work and it's use that kill's them as opposed to time.

The half a dozen or so I've done on S2's and RS2'S were all pressure plate failures an I'm 90% sure that what's wrong with the one in my car.

[Tractor Dave]

Thanks Kit. I will let you know if I'm stuck.
The Sachs SRE parts seem to be the only new option now. Not sure if they are compatible with OE dmfw? Anyone?
Pressure plate and friction disc are dated 2012 and the cars been off the road for a few years since then so not many miles done at all. Its a black Diamond kit but under the black paint and stickers are Sachs part numbers. Guess they just re lined the oe friction plate with fancy material?
I contacted them and they wanted £200 to re line the plate CG Motorsport want £45 plus vat.

[K Simmonds]

No problem, £45 is a bargain presuming they do a good job, much better than £200!

Black Diamond clutches are pretty well regarded, I have one of their kit's in my G60 Golf and it looked to be good quality, though Jim went for a full blown racing one with a six puck friction disc which is horrid to use, very heavy pedal and not at all smooth moving off. I've always assumed they made everything themselves but as I say I've only handled that one.

If the clutch has done that little work I wouldn't worry about reusing the pressure plate, if they fail they tend to do it around 100K miles, all the one's I've changed have been in that age range though perhaps that's simply coincidence.

[Tractor Dave]

Saturday night TV is rubbish so spent the evening reading through a few old RS2 restoration threads on the forum. Found that RS2 handbrake cables don't take the usual route via the lower wishbones so will need to re fit them. Doh.
Also, any RS2 owner confirm if the right cable should go between the front diff carrier and the chassis or outside? I've tried both ways and neither seems quite natural???




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[Tractor Dave]

Someone asked me how I treat my nuts. Not those!
Anyway, after a really good clean in the wire wheel on the bench grinder they get a very thin coat of rust converter. Then a cold galvanise spray. I found this to be good.

After torquing up, there is inevitably some damage to the paint. So I then touch in with a small brush with some more zinc. When dry it gets a coat of Bilt Hamber clear wax.
It's not as good as the oe new galvanised nuts and bolts but not bad.


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[Tractor Dave]

A kind member of the forum sold me his old pistons. Unfortunately they got damaged in the post. Sad face. So I'm still after a single standard size piston if anyone has one knocking about.

Now I know what it's like to be a bomb disposal guy.


But got there in the end.



My coolant bottle had a strange black sludge in it. It's not oily.

It wouldn't wash out. A soak in bleach sorted it.


Anyone doing this, fit your abs sensors before fitting the rear subframe. Now I've made that job more difficult for myself. Doh.


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