My silver RS2 Project

[Tractor Dave]

Brakes fitted on the other side.





Coming together now.


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[Tractor Dave]

I didn't have any heat shield for the back. They probably rotted out years ago.
Thanks to John in sunny Scotland for sending me a template, I was able to make some out of aluminium sheet.


Cut out with a jigsaw


A little sanding


Far from good but good from far


I will paint them satin black so they don't stick out like sore thumbs.


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[Tractor Dave]

I have bought a couple of different makes of rear shoes and they both are a little thick to fit the adjuster cog. I took a measurement and it's less than 1mm that needs shaving off. So I got shaving.


Perfect


A little vht black to stop it rusting.



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[John.]

Thanks to John in sunny Scotland for sending me a template, I was able to make some out of aluminium sheet.

And thanks to you I have bump-stops

[Tractor Dave]

As soon as the paint was dry I got cracking.


Everything is new. Springs, adjuster, cable lever and back plates. I've used a little ceramic grease on the moving parts.


It was a pain to fit mind. I've always disliked drum brakes. Ever since my Mrs had a Mk2 Astra gte with rear drum brakes. Those nasty little springs are a pain to fit and always get you. I have the scars to prove it!

Anyway. Let's press in the hub.


And test fit the disc


All good so onto the car it goes.




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[Tractor Dave]

A very kind forum member in Germany (Rik) found me a pair of custom made stainless guide tubes. The quality is fantastic.


I think the purpose of these tubes is to keep the cable away from the driveshaft.



I wasted no time in getting them fitted. It's a fiddly job with limited space. I used two screwdrivers to open out the shoes. Plenty of ceramic grease on the little bushes keeps them in place whilst you wiggle the assembly together.





And just as I said before. They always get me!



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[Tractor Dave]

Rear handbrake set up and working nicely.
Front arb fitted.


Can't fit the rear calipers yet as I ordered the wrong pitch bolts. Surprised to find that they are still available from TPS for £4 each. Hopefully will get them tomorrow.


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[Tractor Dave]

So the caliper bolts turned up. That excellent considering I ordered them on Wednesday afternoon and they came from Germany. Well done TPS Swansea.


So
I wasted no time in getting them fitted. Plenty of thread lock and 85nm



And then the brake hoses.



The anti roll bar went on this morning.




Now I can get some brake fluid in her and then work towards an engine start. Nervous grin.


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[Tractor Dave]

So today I set up the pressure bleeder and cracked on.


The brakes all bled easily and there were no leaks.


The clutch was a different matter.
Nothing was coming out at all!


So I disconnected the hard line connection and tried from there. Still nothing.
So I upped the pressure as much as I dared. In the end I went up to 20psi.


Pumped the clutch and slowly a dribble.

Then a big gush as whatever the blockage was flushed out.


After that it was fairly simple to bleed the slave.

Next I put a couple of gallons of super unleaded in the tank.


Disconnected the fuel supply line and placed a bottle over the end.


My plan then was to use the power probe to run the pump and flush the fuel lines with clean petrol.


However, these things often don't go to plan. Just a click from the pump. So I thought maybe the power probe wasn't giving sufficient amps. Tried a hot wire direct to the battery.


Still just a click. The pump appears to be dead. Sad face.
Anyone have a good RS2 pump?


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[John.]

Still just a click. The pump appears to be dead. Sad face.

Try alternating the polarity and it might ease it's way into working ?

[Tractor Dave]

I did try that yesterday quickly. Just a click from the pump each way. Now its been sitting in clean petrol overnight, I will have another go.

[John.]

I did try that yesterday quickly. Just a click from the pump each way. Now its been sitting in clean petrol overnight, I will have another go.

[Tractor Dave]

Out it came.


Bench tested


It's dead.
Dated 94, its the original pump. It's done well.
Now I do have a nice new Bosch pump. Just happened to be knocking about.


But I don't really want to chop up the basket to get it in.
I see Audi Tradition have the original pump for (sit down) 545 Euro.
However, the same Pierburg pump without the Audi part number is still available for about £150.


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[newsh]

Out it came.


Bench tested


It's dead.
Dated 94, its the original pump. It's done well.
Now I do have a nice new Bosch pump. Just happened to be knocking about.


But I don't really want to chop up the basket to get it in.
I see Audi Tradition have the original pump for (sit down) 545 Euro.
However, the same Pierburg pump without the Audi part number is still available for about £150.


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Definitely go for the Pierburg

[Rikki Kitto]

Isn't there a transporter fuel pump basket that fits the Bosch pump or am I imagining things again