CRD upgrade

[JoergM]

Yesterday and today I installed the upper control arm flex joints and the upper and lower ball joints. While doing this I remembered why I hat this so much. And the effin press kit always missing a cup for the right job. And so it can that a job which should not take longer than 2 h became a 2 days job since I had to fabricate the missing cup first.
So it pays off that I am a hoarder, since I never throw anything away, esp. metal or wood. In this case I used the cut off from the axle sleeves, as well as a old bushing housing and one of the cups I had 2x and just welded a 6 mm plate on top and grinded it down. Worked like a charm I have to admit.

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[RTB]

This thing is going to be awesome by the time you are done. Looks like you are very well set up.

[JoergM]

I am almost done with the differential setup. Have the pattern and the backlash right just want to get a sense for a particular pinion depth setup but that should not take too long before I can button up everything.

Since I have the new shifter board installed, all my transmission issues seem to be history. At least one thing Incan cross off.

At the moment I am dealing with excessive water in the foot well. After the heavy rain here both of my passger side front and rear are soaking wet and I can hear squishy noises when I push the carpet. I removed the seats and lifted the carpet off and there was literally a pond. I also had a very damp headliner and I was worried that mould will build up. Lucky me, I have very little rust and as well as the sun roof seem to be ok. I tested it again just to make sure that my problem does not come from above.

The issue still is the door and I did another test and sure enough water is leaking above the seal and dripping in. In a normal scenario, this seems not to be worried bit with all the rain it was just too much.

I bought new door panel seals and took the factory ones off and the tar seal where it was leaking just peeled off.

I am in the process in drying everything out before I re-install all the panels and the seat again. Using a small compact heater and let it run for a couple of hours during the day. Works pretty well so far. The front is dried just need to do the rear as well.

On the second picture you can see where the water is dripping over the seal.

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[RTB]

I still find it amazing how much water is getting in. You're misses must be hating this car......

After all the work you have had to do, you are going to be one of the word's leading experts on the WG.

[5oclock]

That foam on the floor is so thick it would never dry if you didnt use the heater. I seem to recall having to pull the rubber seal above my drivers door partly off and bending the metal bit on the body a little to give a bit more pressure to stop wind noise in wild cross winds. I was testing the seal pressure with a strip of paper which was between the door and the seal after I closed the door on it. Maybe worth checking?
The adapters you made for the press kit are worth the effort, next time will be a breeze. Had to make a few for mine also and it was a pain hunting around for the bits to make them, but next time I used the press I was smiling!!
Just remembered, the clips that hold the inside door panel on(but snap when you pull it off) are on ebay. I have got some in the past and they were great either green or yellow, but take ages in the mail.

[bodgie]

I had to do this recently with my insulation in the front footwells. A hair dryer worked the best as you could direct hotter air into the right places more easily.

[JoergM]

The V8 as I had it does not exist anymore. I took allmost everything out, except the airlocker compressor, the front seat as well as the heater core and th A/C evaporator. Somehow sad to see this thing going bit I guess it was beyond repair, or better: I would need to put a lot of effort into the repair if this car. Will do the rest tomorrow and then call the tow truck to pick the shell up.

On the pictures the rear axle is still attached but that has been resolved already.

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