Auto to Manual conversion, Porsche cv's, Linkage refurb

[Dueller]

there's a spring inside so will go to full length when free and can bind there because of corrosion beyond the piston normal operating range

Damn thing, refitted and bled the system, easy enough to do just takes longer than doing a car, slave was stuck open again, made me question everything about the adapter/flywheel measurements, not looking forward to taking it all apart again.

Went to Schofields at Glossop yesterday (open on a Saturday!) as only an hour from me and grabbed a new slave cylinder and accelerator cable for a manual van while I was there.

Didn't realise the slave pipe fitting is a different size, tried to take it off nicely but ended up belting a 12mm spline socket onto it, made the pipe up and refitted with mole grips, works fine for an ugly Sunday fix!

So bled it up in 2 minutes as had clamped the hose under the dash and it works, drove the van forward and back today

Still loads to do...

[Robsey]

An ugly fix is better than no fix.

I only live 5 miles from Schofield's. Driven past many times, but never popped in.
I usually buy enough to get free delivery, so no point using up my own diesel.

I really should pop in one day.
I would be like a kid in a toy shop, wanting everything.

[Dueller]

An ugly fix is better than no fix.

I only live 5 miles from Schofield's. Driven past many times, but never popped in.
I usually buy enough to get free delivery, so no point using up my own diesel.

I really should pop in one day.
I would be like a kid in a toy shop, wanting everything.

Yeah its a proper old skool kind of place, stuff everywhere that you can see and drool over

I've always thought the Weekend bodge doesn't get the respect it deserves, an ugly win is still a win

[Dueller]

Thought id pop in some costs here, so far anyways:

Gearbox and driveshafts £200
215 Clutch (ebay bargain) £85
Flywheel for above £45
Clutch slave and accelerator cable £60
Spigot bearing £9
5 speed linkage from H reg DG engine van £110 collected (3hr drive)
Brickwerks refurb parts for linkage £116 (amazing shift now)
Engineering costs to flywheels £200
Tub of CV grease £9

So thats £834

Also from my previous spends i have 4x CV joints, throttle cable and a previously trimmed down flywheel

Not much change out of a grand so not bad, im happy at this as my used autobox (not the Porsche stuff) was £800 so similar costs

The exhaust still needs doing as the next major expense, i have everything in stainless so just need to set it up and have it TIG welded


 

[Dueller]

Forgot my clutch bolts £27

[Dueller]

Amazing how much access you have from above to the clutch slave





Been busy on the linkage, got a new manual accelerator cable and I don't want to chop and add to it so got busy making it work as the factory intended. Also the engine sits higher now so everything needs reworking, usual stuff when modding...

Fitted a bracket in the engine bay so the cable feed is inline with the throttle body mechanism, opposed to coming in from above. Had to add a return spring but that's it.

The cable end fits into the linkage clip, after I drilled it out to 4mm, very pleased with this as very neat.





No pics of it fitted as got carried away adding the MAF and built the air inlet system up with all the engine breathers

[Dueller]

Broke my accelerator pedal the other day, lucky if it's lasted 100 miles after the original broke on me

So I've made a few changes to it with a random hinge I found in my shed, seems good

[R0B]

The accelerator pedals are rubbish. Much better if you use a wood hinge. The strip of plastic that holds the pedal to the plastic hinge is thinner than a thin thing.

[tobydog]

It's thinner than a thin thing by design

AKA a living hinge:


https://en.wikipedia.org/wiki/Living_hinge
 

[R0B]

It's thinner than a thin thing by design

AKA a living hinge:


https://en.wikipedia.org/wiki/Living_hinge
 

The ones I have replaced over the years I would describe as dead hinges.
The one I repaired with a wood hinge has lasted for over five years upto now.

[tobydog]

I'm not going to tempt fate....

[multisi]

The accelerator pedals are rubbish. Much better if you use a wood hinge. The strip of plastic that holds the pedal to the plastic hinge is thinner than a thin thing.

Its the repro ones that are pants, the original ones last a long time, new vw production pedals are available from Brickwerks.
 

[silverbullet]

Almost everything repro is inferior to OEM because punters demand cheap.

[Simon Baxter]

It's actually the other way around, we stopped selling the VW ones as we had a couple split, the aftermarket ones are more durable.
A plastic hinge was never a great idea really.
I've got a bag full of VW ones that I'm reluctant to even put in the clearance section.

[R0B]

I have only ever bought the bought the VW ones. And had three fail on me. Attaching a wood hinge has done the trick.

If anyone is thinking of doing this, I found shaving a bit off the ribs in order to get the hinge to sit flush with the pedal is preferable.