Club 80-90 Forums

"Existing halogen headlamp units on vehicles first used on or after 1 April 1986 must not be converted to be used with high intensity discharge (HID) or light emitting diode (LED) bulbs. If such a conversion has been done, you must fail the headlamp for light source and lamp not compatible. Thi...

https://drive.google.com/file/d/1th3CUl ... c4gbW/view

RTFM

R0B wrote: ↑15 May 2026, 18:37 I have a hole in mine almost identical to that. I have just learned to live with it.

Ron Dennis and tiles....

New pads need bedding in, but, what was the state of the old disks like? If they were badly worn, then the pads could only making contact on their inner and outer edges. I'd have a look at the disks first.

The correct way to make them would be to use a deep case hardening steel. Have the threads copper plated to mask them off and prevent them becoming brittle when the heads are hardened. But how much to people want to pay for them? Be interesting to test them on a hardness tester, I know someone who ...

And, then, the idle jet....

I'd slip a thin piece of card or plastic underneath your repair to be safe 
 

Newman Cams?

https://www.newman-cams.com/

 

A dash of lube perhaps?

Also, to quote the sheet metalworker tutor in the first year of my toolmaker's apprenticeship, "one good hit is better than lots of little ones"

Can you get it to fit without the booty thing?

Crap/water in carbs, blocked idle jet(s), air filter, fuel filter........

If the parts were printed in two pieces, it might be worth considering a tenon/dovetail location feature where the parts mate together.

The return spring looks a bit nackered...

What's the state of the flexi hose?

I've had brake hoses act like a one way valve before; you apply the brakes and the fluid can't return to the master cylinder causing the brakes to bind....

VW policy was "don't give them too much power, they will break the drivetrain" so the vans were woefully underpowered to get a long service life. Even though you had to thrash the thing senseless to get anywhere, which somewhat defeated the point. The precursor to the Volkswagen emissions...