Furious Fastback

[Rhysos]

But it isnt that different to using a pressure bleeder on a tyre. Who knows how wet or dry the air is in there?

You have a valid point there, I didn't really think that one through

I also 2nd peter, use the red rubber grease. Its a great seal preserver.

Ok, so I shall toss the hydraulic assembly paste in favour of red rubber grease. I take it that I can also give the walls of the cylinders a thin coating using the grease as well as applying to the sealing ring? Would this grease also be good on the master cylinders grommets? Thanks as always for the advice and hope you guys are enjoying the weekend

[broady_6]

Id just use it on the seal. The fluid will act as lubricant on the cylinder walls. You can use it on them as well, itll help them slide in a bit easier.

I am, I got the fasty running again yesterday. I havent looked in the gargae this morning to see if there is any oil on the floor yet.

[Rhysos]

Cheers Broady, that'll help me during the rebuild of the callipers. Paint is on and looking sweet. Just letting it cure for 24 hours before giving a top coat of lacquer. Hopefully I can start putting things back together next week as and when I find time.

Good luck with giving your Fasty a run out today! May she loose no more than a thimble of engine oil

[Rhysos]

Well, I must say that I am pleased with how these turned out:

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I applied 6 thin coats of calliper paint and allowed it to harden for a few days. I had a faff trying and failing to find a suitable lacquer to go over the top (conflicting information about compatibility). I decided to get in touch with the paint manufacturer to see what they would recommend. I didn’t hear back for a while, so went ahead and applied 2 coats of their regular clear lacquer. Literally, half an hour after I got the lacquer on, I got a response back saying that the lacquer layer wasn’t needed as the paint is formulated with a resin system that will resist brake fluid and give a good gloss. Sods law! Oh well, it is extra protected from road wear now!

I should get a chunk of time over the weekend to crack on with rebuilding and installing the front callipers. I am reasonably confident that I have now acquired everything that I need in order to get the job done:

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[purplepeter]

Bloody Hell! That tub of red rubber grease will last several lifetimes!
Do you have the Bentley Manual? (for caliper Torque settings?)

[Rhysos]

Bloody Hell! That tub of red rubber grease will last several lifetimes!

Tell me about it It was a quid more than just a tiny tube, so seemed like a savvy move, but there is no way I will ever get through it. Well, you all know who to come to if you ever need your small tins of red rubber grease refilling!

Do you have the Bentley Manual? (for caliper Torque settings?)

I don’t have the Bentley (its on my list), but the Haynes covers it; “tighten [socket head screws] from the centre outwards in sequence to 7 lb (1 mkg) ft and then again in sequence to a final torque of 15 lb ft”.

Earlier this evening I cleaned up the pistons the best I could using some 2000 grit abrasive paper to polish up the walls:

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I fitted up the internal seals (coated in red rubber grease of course) and then inserted the pistons into the housings (probably too much grease smeared on that, but have an abundance of the stuff don’t you know!):

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Got the new rubber boots on and seated everything down into the bores. Wrestled with the clamp rings, but eventually won. I then got the retaining plates on and the new ‘o’ rings in place:

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I just need to clean up the bolts and then I can get the callipers back together. Moving along nicely though!

[Rhysos]

Quick q: I have the car in the garage, jacked up, wheels off and fuel tank out. I’m currently replacing the low pressure fuel hose. The elephant is the room is the master cylinder. It’s all good mechanically and doesn’t leak, but has a lot of surface rust:

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Is it worth the hassle to whip it out, wire brush and repaint or would it not really be worth the effort beyond just smartening it up ….in an area that no one will see?!

[broady_6]

Thats all down to you, its just external surface rust, it has no effect on performance.

[Rhysos]

Cheers Broady, figured that would be the case. If it were a show car or in a visible place then I would take it out and clean it up. However, on this occasion I think I will leave it be; “if it ain’t broke, don’t fix it” comes to mind. It would be just my luck that something gets damages or shears off if I attempted it

I got the blue cotton braided low pressure hose fitted last night and cleaned up the fluid reservoir. All looking smarter:

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Gonna pop out and pick up some new SAE J30 R9 fuel line this afternoon. Good opportunity to replace it whilst the tank is out and access is good.

[broady_6]

Thats looking much smarter! Dead right about the fuel line too!

[Rhysos]

It was a great VW-related weekend. Firstly, I met Peter in a carpark on the outskirts of town to pick up his old brake discs (that sounds like more of clandestine operation than it was). He also gave me the old fuel pump mounting plate that came off a fuel injected model:

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This will be a little project for down the line, but I think with a little modification this could accept my Carter electric fuel pump and will ultimately be a more elegant install. Now, being the generous soul that he is, Peter remembered from ages back that I was missing a venturi screw and dug one out for me:

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Thanks again Peter, it is greatly appreciated! On Saturday, me and the fam went to Bristol Volksfest (sadly, not in the Fasty). Always a great fun local event, with something for everyone. As I was browsing the swap meet, a certain stall drew me in as most items were decidedly Type 3 shaped. Looking up I realised it was Danny’s pitch. We had a good chat and I also had the pleasure of meeting Clare (greenfyregirl here on the forum). After some chin scratching, I ended buying a distributor from Danny:

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It is a 205T model, which according to previous discussions here, would be more appropriate for my 1600 engine. Before I get to that, I first need to finish my brake overhaul. That is an ongoing saga, which has tested my patience, hence why I haven’t posted in a minute. I will start to write it up this week, but it has been one step forward and two steps back. Think I have a way through though, so hoping to get back on the road soon.

[Rhysos]

Had some time today to get the front discs (donated by Peter) reconditioned. Knocked back most of the surface rust with a wire wheel in a drill and then went over with a 60 grit pad in my DA sander:

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Cleaned and degreased with brake cleaner and masked up:

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Hit them with some high temp paint to help protect the centre hub section and generally smarten them up:

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I have now greased bearings and started to mount them to the spindles. In doing so, I realised that my old discs were not correct and were either Beetle or early Type 3 items. That explains why they appeared so thin when I measured them with the digital callipers. It was partly due to wear, but those old discs were thinner from new anyway! Well, no worries now, the reconditioned discs have a respectable 10.5mm of thickness, so should see me well for quite a few miles to come!