Hibiscus Red TQS - New Car, New Project, cars been here before though.

midas

Registered User
Well a week of running, can’t say I can see it’s dropped more. Sandip certainly said he noticed a difference when he spotted me around town. I’ll be honest……..I thought the ride might have been a little more supple now I’ve had time to get a good feeling of it. But I can live with it.

My lower door strips arrived today from Latvia. These were the only ones I could lay my hands on since the Genuine ones are now long gone. I did think I had some new plastic clips to hold them on. But having replaced the ones on the passenger door, it seems my clips make the trim sit proud of the door slightly. So I’ll have to try and find the correct ones. I’ve cleaned all the crud off the door also, there is some small patches of corrosion, but nothing I’m really worried about currently. I also had to get the white spirit out and rub this horrible shiny top layer off they came with. Horrendous, I think when the strips were packaged they were still wet, so the nylon bags they were in, stuck to the strips making a right old mess. All looking good now.

I also took apart the shocks, as I’ll look to sell the springs on to those who need them. I now know why the car was higher on one side at the back, an issue highlighted by the previous owner MaverickTDI. Looks like somebody put an aftermarket special spring on, which was nowhere near the sport spec spring.
I think my shocks were shafted too, can’t quite believe the state of them. The top arms when removed, the inner bushes were actually loose in their casings. No wonder the car feels so much more planted at the rear now.

So cars all polished now, for a trip to Oulton Park for the BTCC tomorrow. Not sure if anybody else is going? Had a fair few admirers last year and it was nowhere near the condition it’s in now. If anybody’s there, come say hi!

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midas

Registered User
Managed to get a job done tonight, and thank holy god it’s now done. Was attempting previously to try and get the yoke out of the prop shaft. But along came injury and some other issues. Couldn’t get my press to do it as the arbors wouldn’t stay still. So some brute force and ignorance combined with using the vice as a press, and it’s out. Managed to grind out the stake marks, being careful not to grind too much off. Just need to press the bearing caps in, and then improvise a staking tool to stake the new end caps in place. I stopped going any further as I want to add more grease to the bearing caps, and I don’t have any lithium grease.

I also got my caliper halves back from a friend who has media blasted them. So have sprayed these with 3 coats of colour, and 2 of lacquer. Hoping with these fitted the alignment should be much better. I’m trusting it that much that I’m going to order to better discs, and new pads as well.

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midas

Registered User
Calipers done today, bleed nipples were a bit rubbish, struggled to undo them, even with heat. So took them out, got a wore brush on the thread and reinstalled with a sliver of copper grease. I’ll have to find time in the weeks ahead to reinstall everything.

I also managed to spend time doing the prop shaft today. Was so relieved to get the older UJ out, I was inspired to carry on this evening and get the new one in. Used the vice to close the caps into the prop, filled with all new Lithium grease. Once in, I used a 20p, and closed the caps in to the depth of the 20p. Once everything was installed, I needed to stake them. I’ve tried and tried to get a staking tool, but cannot get one on its own. So I adopted another strategy I’ve seen done, a cold chisel. Managed to use the corner of the chisel, to get the correct result. Once all the stakes done, I sprayed it with under seal as it looked a bit snappy all rusty. I do have a brand new prop bearing to go on also, still deciding if Im going to use the standard bearing carrier, or an aftermarket version. Brand new prop joints at each end as well. Hopefully this will go some ways to address the banging and bearing whirring noise.

Im happy now though, as the prop is ready to go on, as is the exhaust!


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midas

Registered User
Little bit of work at weekend. Managed to get the prop shaft completely rebuilt now, with the dreaded bolt wound back in, and the centre prop bearing pressed into position. I’m not putting the outer CV’s on until it’s being fitted To save any damage.

The new drivers door handle is fitted now also, looks 100% better, and the tension on the handle spring makes door latching a lot better.

Also saw something that’s been winding me up for a while, a replacement cigar lighter assembly. Just need to get that fitted now.
Has anybody ever seen a ‘how to’ on replacing the armrest internal mechanism? To stop it clicking down randomly when you lean on it? I have a spare armrest (in blue) which I’d pull apart to swap parts out with if it was an easy-ish job.

Anyway, hopefully some more parts from AUTODOC tomorrow. Can fit the original calipers then.

Last picture is now Ive just washed it, in some ways I wish the suspension was a bit lower. But then I drive it on the fantastic roads around Bolton and I know any lower would be a mistake.

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midas

Registered User
Managed to get the newly repainted ‘Genuine’ calipers fitted on this Thursday this week. Bled up using a power bleeder, things certainly went back together a lot better with these calipers. Pads slotted straight in, no bending, the pad retainer on the outside slotted straight in, was a breeze. Gave it friday to see if there was any catching, and there wasn’t. So just goes to prove, all the trouble I’ve had with these brakes is thanks to using non-Genuine aftermarket calipers. There’s a moral here somewhere. I did however have quite a long pedal on test drive however, so I’m thinking there is air somewhere in the system.
So today I’ve got up early to fit the new Zimmerman discs, TRW pads and bleed all 4 corners again. All went together really well. And this time round I sprayed the pad retainers in black enamel, with an ‘S’ sticker to finish off. I know some wont like that at all, but I thought it finished it off, and looks in keeping with modern big brakes. This time on test drive there was no long pedal, and the brakes felt great. Should feel better once everything’s bedded in.
I really wanted to get some more jobs done, as I’ve got a new rad fan, as this replacement unit I got from Edinburgh is noisy. Plus I really wanted to get the new cig lighter surround in. But in this weather, I’m not going to do mechanics especially inside a car.

Before:
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After:
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And with the wheel back on:

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midas

Registered User
New parcel arrived today as well. A Mishimoto universal power steering oil cooler. So now I can find some time to fit the intercooler I’ve already got. I really didn’t want the original oil cooler just cable tied on like I’ve seen with some installations. So this should look a hell of a lot tidier. I’ve a funny feeling I’ll be fitting a new P/s pump when I fit this though, as it’s really starting to wine now.

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Gops

Badger 5 Edition
VCDS Map User
Great progress on this mate! I agree with the weather it’s not kind to any work being done at all!

Loving the brakes, really does make it look cleaner i the wheels!


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Gops

Badger 5 Edition
VCDS Map User
Well a week of running, can’t say I can see it’s dropped more. Sandip certainly said he noticed a difference when he spotted me around town. I’ll be honest……..I thought the ride might have been a little more supple now I’ve had time to get a good feeling of it. But I can live with it.

My lower door strips arrived today from Latvia. These were the only ones I could lay my hands on since the Genuine ones are now long gone. I did think I had some new plastic clips to hold them on. But having replaced the ones on the passenger door, it seems my clips make the trim sit proud of the door slightly. So I’ll have to try and find the correct ones. I’ve cleaned all the crud off the door also, there is some small patches of corrosion, but nothing I’m really worried about currently. I also had to get the white spirit out and rub this horrible shiny top layer off they came with. Horrendous, I think when the strips were packaged they were still wet, so the nylon bags they were in, stuck to the strips making a right old mess. All looking good now.

I also took apart the shocks, as I’ll look to sell the springs on to those who need them. I now know why the car was higher on one side at the back, an issue highlighted by the previous owner MaverickTDI. Looks like somebody put an aftermarket special spring on, which was nowhere near the sport spec spring.
I think my shocks were shafted too, can’t quite believe the state of them. The top arms when removed, the inner bushes were actually loose in their casings. No wonder the car feels so much more planted at the rear now.

So cars all polished now, for a trip to Oulton Park for the BTCC tomorrow. Not sure if anybody else is going? Had a fair few admirers last year and it was nowhere near the condition it’s in now. If anybody’s there, come say hi!

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Ahh mate I got the same side trims and the bag they came in made a permanent indent in the things. I'll get some white spirit on them too, it's a horrid shine on them!!
 

midas

Registered User
Yeah there isn’t really a out of choice with these trims anymore. Have to get what you can from the eastern block. The good thing is, with all that horrible shiny stuff off, they actually look ok. Thank god.
 

midas

Registered User
got busy with the lower rear arms this weekend. A friend gave me this Triflow stuff, which I coated the brake hose unions with, and my my they came undone pretty much straight away. So brake pipes off, brake cables off, and then a right old task of removing the old bushes and chiselling out the metal casings. What a nightmare. So I’ll get to these over to my friend this week, he’s told me he’s going to do his best to get the rear uprights, driveshafts, and wishbones done as soon as he can. The it’s a case of building everything back up, make sure I’ve got replacement bolts, and then choose my week to have it off road to change everything. I’ve already got hold of Powerflex bushes for these arms.
I really think I’m going to need new brake cables, removing the remnants of the old cables from my repacement rear arms required them to be broken. So I guess mine will be the same. Finding new cables though is proving difficult.

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definatly needed all the tools on this bench for this job.

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midas

Registered User
Few more jobs this weekend. Sorted out my non working siren. Just a little issue that was annoying me. Already bought a later spec siren which wa also capputt, so this the second time of having everything out. Tested this one before I reassembled everything, and it works, hurrah.
Also swapped out the used fan I got last year, the bearings had gone and the noise it was making was also annoying, so installed a brand new NRF fan. Not an easy job to do, but it’s done now.
Also tried rejigging the TIP, which is a silicone one I bought through ECS Tuning. For some reason when I installed my new headlamps, together with the filter box, it was becoming squashed by the high beam bulb door on the headlamp. I’ve moved the filter firewall up as far as it will go, and also cut down the TIP. But it’s still squashing it. I’m a bit frustrated by this as I know thats interfering with airflow to the turbo. I’ll have to come back to this, and rejig some more at a later point.
My next jobs I really need done is the prop shaft and exhaust system. Hopefully see about doing them in the next couple weeks.

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midas

Registered User
Little bit more work done today. The ratcheting armrest is really feeling my head in. So since I have a spare tatty armrest, thought I’d try and take it apart. Once past the horrible circular clip holding the central axle together, it all came apart. I’ve noted the fingers which are operated by the armrest handle. But the fingers are fine, so I focused on the teeth on the upright. Sure enough these fingers were not great. But thes fingers I think will be in far better condition than the one in my car. So I’ve degreased the teeth, pulled all the debris out of the gaps, and then got a triangular file and filed the teeth a little. This sharpened them up, giving more of a step for the fingers to engage with. So…..this weekend, I’ll pull the whole centre console out, again, and try to install my refurbished upright. I’ll fit my new cig lighter surround as well. Small jobs, little steps.


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midas

Registered User
Well, certainly hot weather this weekend, so glad I installed that new pusher fan so the a/c works as best it can.

Made my mind up I was doing jobs today though, so jobs it was. Took the centre console out (again), and completely disassembled it. Once the armrest itself was in its components form, I chiselled the push fit washers off, took the central axle out, and reinstalled my substitute axle I’ve filed down. Reassembly is really easy, and I bought some more push fit washers off Amazon, so all secured nicely. I also bought some HiFi Speaker cloth, with the intent of templating it, and bonding it to the outside of the armrest shell, which will hopefully stop the god awful squeeking sound the seats make when 2 people are sat up front. Second job was to fit the new cigar lighter assembly I purchased. What I’d didnt know was this assembly is totally different to the normal facelift assembl, looks like it’s missing a piece somehow.
On refitting, the speaker cloth has indeed stopped the Recaro from squeaking. However, the armrest still clicks down. So…..back t the drawing board. I can’t help but feel the locating fingers have lost some springiness and this is making the engagement weak.
Anyway, at 31 degrees, and sweating lile hell, I stopped for the day.

I have got some new wheels though!! I’ll save this illustration for a later date.
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I’ll let this be the only teaser.
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midas

Registered User
Busy week it turned into. With the forthcoming weeks being hectic, and a looming MOT, with an ABS sensor/ ring requiring replacement, my friend who stepped in to help me got busy.
My rear uprights, hubs, lower wishbones and driveshafts have been media blasted, and then coated in etch primer to stop any corrosion. Plan this week is to get them painted in black, clean out all the threads, clean out all the bearing/bush journals, and start getting everything made up. So glad I can see light at the end of the tunnel with regards to renovating the rear suspension. If I still have a drivetrain knock after all this, then looks like I’ll be fitting a new diff.


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midas

Registered User
Busy again this afternoon, and last night. I’m actually painting these with a Simoniz paint called underbody guard. So it’s not stonechip, and it’s not under seal. Drys like a thick Matt paint. Hoping this will be durable on these components. Removed all the masking, so now just need a quick flick round with a flap wheel on the bearing journal, and the hub front faces. Then I can start pressing bushes in, and pressing the bearing in. Oh, and assembling the CV’s on the driveshafts of course. I’ll class this as a productive week. So much better without an injury holding you back.

And this week, I’m off to Somerset. So cars going with me, not sure of anybody lives that way but look out for me. I’m also going to Caffeine & Machine on the way down there, never been, and it’s only a minor detour.

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midas

Registered User
Couple little jobs, since it’s taking me to Somerset on Monday.

The brake pad warning light keeps coming on over bumps, and I already know the wires on the passenger side are shot. Drivers ones not much better. So I bought some plugs with wires already installed. Getting the old wires to tin, so I could solder the new wires on was horrendous, but got it done.

I decide a while ago that if the wires are bad on the temp sensor, then I could be getting bad starting from this wiring when hot. Just like the brake pad warning keeps triggering, the temp sensor could trigger when not needed just because of the wiring. So I’ve fitted the plug today that I bought a while ago. Hot starting so far today has been perfect, but we shall see. I’ve heatshrinked everything, but I need some loom tape and I’ll go over it with that to look a bit tidier.

I also had to renew the temp sender o-ring and plastic clip yesterday. Not sure why but it started weeping. Good timing since it’s doing a lot of miles this week. Did a short journey on Thursday, to find the temp gauge above half way, and then coolant all down the gearbox underneath the temp sender. Awesome. So far the new —ring seems to be holding.

Finally, a wash and a wax ready for tomorrow. Try and get some pics at Caffeine & Machine.


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Gops

Badger 5 Edition
VCDS Map User
Mate the paint job looks wicked. I just painted it in situ until I can actually take the whole rear
Subframe out.

Looking gorgeous though!


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midas

Registered User
Mate the paint job looks wicked. I just painted it in situ until I can actually take the whole rear
Subframe out.

Looking gorgeous though!


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Thank you. Taken a fair amount of preparation to get this far. Hopijg to start rebuilding when I return from holiday. Once it’s all together, should be a weekends work to swap everything over.
I hoping between the driveshaft swap, and the prop shaft swap, the banging from the drivetrain will be eliminated.
 

midas

Registered User
Nice to have a bit of a break down Somerset way. Called at Caffeine & Machine on the way down, couldn’t resist some photos.

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And some more whoring through Cheddar Gorge.

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midas

Registered User
Well, not been my week it would appear. Nice week off in Bristol, unfortunately marred by my crashing the Audi into a concrete pillar in a multi-storey. Long story, don’t ask. My new carbon fibre mirror cover on the drivers side is a mess, brand new glass is scratched, this kind I need an entire new mirror unit. But……the drivers door is now badly dented. Really unimpressed with myself. But….I’m going to try and get it fixed this week.
Took the door trim off this yesterday, and removed all the sticky adhesive with a caramel wheel. The state of play was then clearer to see. I’ll take it to a dent specialist on Saturday. Cross my fingers.

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midas

Registered User
I did get busy with some of my painted rear axle parts though. I’ve got the Powerflex bushes fitted into the arms, plus the brake lines temp installed just to get sizing correct.

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I was looking at getting the correct tools to put my hub carriers together, but, as I work in parts anyway I sent them to a garage who I thought was good enough to do the job for me. Sure enough the hub carriers came back fully built today. And……….well. See below.


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Right now I’m speechless. Subdued. Annoyed. Head in hands.

Let’s hope the dent man can fix my door, and make me feel a little better About this week.
 

midas

Registered User
So the visit to mr Dentman paid off yesterday. Left it with him whilst I was at work, and he worked on it all day in between doing other customers. And……..I’m amazed. These things are never perfect, but wow did he try his damndest to get it right. There were also about 4 minor dents in the front door, which he got out, and about 3 dents in the rear door, including a really nasty one. He got them all out. Really impressed. He said the car was clearly looked after, and so was happy to spend time getting it right. He said I should have left him the bump strip though, and he would have made sure anything visual was behind that. So 70 quid later, and my faux pas has been erased (almost).
So I’ve had my DA polisher out today, and done both doors, to make sure any scratches from removing the bump strip were removed. Looking really like glass now.

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So today, once the polishing was done, and the bump strip back on. I got back to building my driveshafts. Outer joints went straight on. Inners not so much, these require a spring washer, and the one that came with the joint was too big. So I’ve had to find a suitable one at work. The straps that came with the boots as well were horrendous. So again i got some more normal ones from work. 1 shaft done, I’ll build the other one evening this week. Then, it’s just a case of removing my squashed bushes from the uprights again. I e bought some Powerflex ones now to keep it simple on installation.

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I also got my loom tape out, and tidied up the wiring on the temp sender. Sure they’ll be those thinking why did he just leave the wiring like that. So it’s all wrapped up tidy now.
Soldering in a new plug however hasn’t fixed the warm start issue. So…….starting to think it could maybe be the fuel pump? Or maybe even leaking injectors. Unsure. Have to do some more research.

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midas

Registered User
Have you had the compression checked by anychance?

i haven’t had the compression checked no Sandip, it has been something I’ve thought about. Might get my mate to do it in a week or 2.
Thing is, if compression was down, wouldn’t it just struggle to start all the time?
 

Sandip

Registered User
i haven’t had the compression checked no Sandip, it has been something I’ve thought about. Might get my mate to do it in a week or 2.
Thing is, if compression was down, wouldn’t it just struggle to start all the time?
I've seen it on another where the compression dropped when it was hot, might not be that but it's worth a check i guess
 

midas

Registered User
Well, my poly bushes arrived for the lower upright. So I took this evening as the day to remove the incorrectly pressed in bushes. What an absolute pain in the proverbial. Angle grinder, gas torch, brute force and a lump hammer got the brand bushes back out. Nearly had a small fire in the shed, but luckily no incidents. Poly bushes in, and now I’m ready for the complete installation.

So, with any luck, hopefully, in the next couple of weeks I’ll be removing/installing all these components. Plus, fitting the propshaft, plus fitting the full Jetex. Then cross my fingers and hope the knocking from the drive is swapped out also.

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