My Rally Project

@#!/:*#@ :mad:

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Clutch fork has broken away from its pivot point by the looks of it..... deep joy
 
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Not sure yet, the pivot point looks like a really crap idea, it's just a plastic ball and socket arrangement that as far as I can see just pushes on to the clutch fork!

Not too expensive for a new one apparently, it's just a pain I could do without.
 
That's just it, it WAS all back together :p Well, the gearbox was anyway. Looks like the bush has just weakened and the arm has got knocked off.

All looks very haphazard to me but apparently they are all like this!
 
After a quick consultation with Miles it seems this should do the job

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Now I might be able to use my clutch again :)
 
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That yellowish plastic bush was knackered - the pins holding it to the big metal arm had pulled through so there was nothing holding the arm to the gearbox. Now it has 2 self tapping screws holding it together.
 
Yep, where there are now screws there were 2 plastic pins - they just push in place and then using a soldering iron the ends are melted to stop it falling out. Obviously this isn't very strong and 19 years later they have unsurprisingly given up!
 
Bit more fiddling done over the last few days.

Went to Loughborough to the DHL depot (spit) to collect my replacement clutch cable. For unknown reasons, they have sent me an air filter element for a Vauxhall VX 220 :p New cable will hopefully be here by midweek.

Also bought some replacement tips for my MIG, some brake fluid, and some vacuum hose.

Gearbox has been heaved back into place and bolted up (not a fun job)

The "Brown Multiplug of Doom" responsible for so many starting problems on 205 GTI's has been chopped out and replaced with lengths of new wire:

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Radiator and fan box dropped into place - still need to paint the slam panel but I'll leave that for a bit as I have a few other bits in need of painting that can all be done at once.

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I forgot just how much space gets robbed by that slam panel and rad!

Coming together nicely now :

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I have also welded the bracket in for the hydraulic handbrake and bolted it in position, I've run the fuel lines throught the car - just waiting for some bigger P Clips to arrive this week so I can fix them down.

Still need to :

Plumb in the rear brakes and remove the old brake lines
Remove the old fuel lines
Fit clutch cable
Repair bonnet hinges or fix bonnet down with 4 pins
Bleed brakes
Fit seats and harnesses
Sort out exhaust
Refit windscreen
Fill up with water + check ignition timing
Replace headlamp washer bottle
Refit bumpers + arches
 
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It's done.

No pics as batteries are on charge but the pins are fitted ready. I'll be going with a fibreglass bonnet by the summer anyway so I thought I may as well get them done now.

MOT station will love that I bet :p
 
Is it able to pivot on the rear pins, or can they pivot?

I don't know how much hassle that'd be, but then for all intensive purposes it has hinges and can be opened normally, then you just pop the pins and take the whole bonnet off. :)

And it doesn't upset the MOT testers. :p

InvG
 
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