Club 80-90 Forums

Also worth mentioning I have 2 slave cylinder pushrods, these are the original and a new replacement. Slightly different lengths, neither allows for full disengagement. The slave master cylinder has been checked, the pushrod and nut allow for a small amount of slack before pushing on the cylinder, I...

Hi All, I have been trying to get my clutch to release on my conversion, ej20 engine, RJES bellhousing and release bearing, VW clutch disc. Initially the problems were from the clutch bracket bending and not allowing the clutch release arm to travel enough, I have checked the arm position on the tee...

Perfect I will blank it off. thanks both for the info.

Hi All,

What have others done with the fuel breather line on their Subaru conversions?
The EJ engine has fuel feed, return and breather connections.

Blank off?
Tee into VW breather setup?
Leave open to atmosphere?

Thanks

I checked the Subaru hose, definitely just a hose with nothing inside, suspect it is part of the servo in that case..
Anyhow I will proceed with the VW valve.

Hi All, Original van engine 1.9dg had a one way valve on the vacuum line at the engine. The Subaru EJ engine removed from donor vehicle did not have a valve, direct to servo from manifold. Do people tend to fit a valve anyway or will it work without, I'm not certain on the operation/protection the v...

Hi All, I'm not convinced I have set my gear linkage up quite correctly after a gearbox rebuild. All gears select fine (including the detent spring for 1st/reverse) but the natural position the gearstick sits in appears to be 4th/5th gate, this is due to the spring pressure on the selector shaft wit...

This is an amazing restoration,fantastically documented. You are doing an amazing job . It’s fantastic to see how bad the van was at the start and how well you have made the repairs. Thank you for taking the time to share all this valuable information. Can I ask what your background is , how did yo...

@Irishkeet -  to remove the underseal, paint and rust was a combination of tools. Underseal (the thick rubbery VW stuff) Propane Blowtorch to heat it up then various scrapers to remove. Old Cavity Wax Same process as underseal Old Paint and rust 13mm electric Belt Sander from screwfix Flapdiscs, 40g...

Almost certainly a hydraulic operated clutch, 
should be a 228mm clutch disc, available as a kit with pressure plate and release bearing for just over £150 at Brickwerks.

VW Clutch Kit - T3 / Most Petrol Engines (brickwerks.co.uk)

 

The chances are the welds were not hot enough and did not penetrate into the trailing arm sufficiently, or the prep was not ideal, lack of shield gas resulting in porosity. In general I have learnt weld the hottest you can, a blow through can be dealt with should it happen. If the perch plate is not...

Or they're dragging a bit, let them cool down then see if they spin easily or still binding. Piston could be stuck in which case a strip down could be in order, easier to replace with a new caliper sometimes. Thanks. That's what I thought too.  What would you recommend I replace to bring the front ...

Current Progress

The van is back on its own wheels with steering all installed, the gearbox rebuild is underway and i am also getting the pieces together for the engine installation. Watch this space.

Brake and Clutch Lines now this was an experience,,, Took a while to even get hold of a decent tool, 2 failed attempts before I got a good one which was up to the task. (1 snapped, 1 produced poor seats) Eventually got it sorted out and ran new Kunifer lines, all the standard 4.75mm (Brake) and 6mm...

Fitting Suspension and Steering Components Did not get too many pictures of this stage, but here is what i have. The rear drums have been converted to disc brakes so larger steel wheels are required to allow clearance. https://i.imgur.com/eE7jTIg.jpeg https://i.imgur.com/3C2kwHx.jpeg https://i.imgu...