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 ALLY RESTORATION EPESODE 2

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The G
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My Ride(s) : 1983 T25
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Sun Aug 07, 2011 3:43 pm

U did shit loads today but forgot to take some pics.
I Will take some next time i'm out on it.
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The G
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Thu Sep 06, 2012 7:03 pm

Been a wile so here are some more picks of the Ally retro....





















And the kitchen so far....





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The G
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Thu Sep 06, 2012 7:04 pm

Some of the picks may have been duplicated so if you seen em already .... good aint they lol
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The G
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Sat Sep 22, 2012 7:31 pm

ALLLL STOPPPPS.....
Well last weekend we when to visit family in Nailsea Bristol, on the way back we just got past burnham when the engine started making some strange noises. so naturally I accelerated to 65mph noise got louder so dropped down to 50 and crawled to puriton where I stopped to investigate. checked the oil.............. on the min level and the engine was squealing like a bitch so got a friend to get me some oil topped it up by this time the level had come up a bit whilst the engine settled.
squeak stop but the noise was bad engine shaking all over the place, sounded like it was only running on three cylinders.
Another friend stop by to give a hand and confirmed that it sounded like its thrown a piston ring and compression is to low.

SO today I have spent leisurely pulling the engine out and stripping it ready for the new one.

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The G
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Male Number of posts : 613
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My Ride(s) : 1983 T25
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Sat Sep 22, 2012 8:04 pm


Engine ready to be removed.

Engine out.

Left side of engine.

Right side of engine.

Alternator and water pump removed.

Oil filter/cooler removed.

Bits left for new engine.

Sump off bear engine left.

This is what I found in the bottom of the sump, its hard to see but its a bag of all the metal fillings that used to be "what we think" is piston rings however there may also be bits of shell in it as well.
Crying or Very sad
I also have both the manifolds off, the engine mounts, oil pickup and fuel pump locked off redy for removal.
Unfortunaly I have to remove the fuel pump from the new engine and put mine on it so have to make sure both the engines ore set the same so that the timing will match. TIME FOR TIPEX AND LOTS OF IT lol
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dubberatlast
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Sun Sep 23, 2012 11:05 am

You got another engine sorted them mate
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The G
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Sun Sep 23, 2012 11:45 am

yeh just waiting for delivery.
cleaned up the sup today and had to remove and clean the oil pick up gause as it was full of bits of mettal, must have been breaking down for a wile.
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swettyring
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My Ride(s) : t25 holdsworth villa, passat estate 1.8t, mk1 golf gti
Registration date : 2011-09-14

PostSubject: Re: ALLY RESTORATION EPESODE 2   Wed Sep 26, 2012 2:26 am

shame the engine work had to stop the progress on this, keep up the good work, and the pics coming!!
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The G
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Wed Sep 26, 2012 7:31 pm

Turns out the engine has ABL so no good.
Think iv found another but costs a bit more.... hayho
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The G
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Mon Oct 01, 2012 6:49 pm

New engine arrived today bounce

New parts arrived for the conversion.

SUMP GASKET.
INLET GASKET.
EXHAUST MANIFOLD GASKET.
EXHAUST DOWN PIPE GASKET.
SPIGOT BEARING.
FLYWHEEL BOLTS.
OIL COOLER GASKET.
OIL FILTER.
OIL COOLER RING.
SUMP GASKET SEALANT - same as VW use.
Just waiting for oil and cam-belt kit and will have it striped and rebuilt on Saturday and then in on Sunday.
Not going to run it till next weekend as there are a few mods that need to happen.
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The G
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Mon Oct 01, 2012 6:54 pm

The Sump gasket is'nt the one I ordered but is the same as the one I used last time.
However I am in convo with brickwerks to get the one I did order as it had a baffle on it, not sure what different it makes Question only added stability when I but it together.
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The G
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Tue Oct 09, 2012 8:33 pm

Ok here some more picks.

New engine unwrapped, very clean and only 79miles on the clock.

Old engine de-pipped and un-wired

old engine out and on the floor ready for strip down.

Oil filter and cooler assy removed.

Alternator and water pump removed.

Sump and manifolds off, just bear engine left.

These bits will go back on the new engine

New engine came with manifold for the donor golf.

removed

sump removed along with oil pump and pickup

Flywheel clutch and engine mounts fitted

pulleys ,alternator bracket and alternator fitted, I used the original water pump as this sounded better than the one I rem0ved from the old engine.

I re used this cover because I had already modified it to clear pulleys and belts.

Engine now ready to go in. I haven't taken ant picks of this but I had to modify the dipstick tube because I snapt it when trying to remove it, however I successfully removed the one from the old engine, cut it about 15mm from the bottom of where it sits in the hole, bored it out to about 8mm but only 5 mm down and whilst it was hot put the longer dipstick tube in it and smeared the joint with sump sealant.
The idea is when it cools it makes a tight fit and the sealant was there as a secondary seal..... works a bute.
hour's later in the dark with the help of two friends using a trolly jack and scaff pole.... it in and ready to be plumed in.

This is all the unwanted bits left, If any one is interested in any of it let me know?

As the engine came with the same BOSH injector pump as the old one I decided to leave it in and mod it rather that swap it for the one that already modded and have to go through the stress of timing it up.
The mods were removing the immobilisers box with a hammer and chisel to get to the fuel cut off valve.
I have also repositioned the accelerator cable connection and cut off the excess metal with an angle grinder so that it will clear the lid.
I also wired the cold start solenoid with the fuel cut off so that it would reduce the revs over a short time instead of using the cable in the cab, Its just cable tied up so that it all else fails I can but it back to manual cold start.
Oh ass clenching moment when getting it in on Saturday night I could not turn the bottom pulley by hand even if I put all my wait on the ratchet so first thing that entered my head is the new engine is seased.
Left it for the morning with out much sleep worrying about it piped it and wired it, oiled and coolant in span it over with the starter motor and thank fuck it turned affraid

To Be able to prime the pump, get oil pressure and water circulation I flattened the battery with in the first 15 minuets of turning it over.
So charged it for an hour and with the help of the works car and alot of turning over she sprung in to life.
Iv had a problem with cooling but I think it sorted now and the problem was with air in the system, The T3 uses 16 liters of coolant with a 50/50 mix of antifreez oh and I have replaced the 87deg thermostat with a 80 witch worked fine on the old engine.






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The G
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Male Number of posts : 613
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Location : Bridgwater
My Ride(s) : 1983 T25
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Thu Jan 24, 2013 8:09 pm


This is all the bits I cleaned out of the sump and oil pickup. not good haho.

The engine is in just needs plumbing and wiring.
It took three of us in the dark to get it in using only a trolley jack and a scaf pole.
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The G
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Thu Jan 24, 2013 8:29 pm

















Iv taken a few pics of the current problem areas I still have to tackle, unfortunately some areas of rust have reappeared due to only being covered by primer. live and learn.
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The G
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Male Number of posts : 613
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PostSubject: Re: ALLY RESTORATION EPESODE 2   Sun Mar 17, 2013 7:46 pm

Its been a wile since my last thread/progress report so after along wait Ally was delivered to Damian Hartfield at THEBUGNBUSSHOP for it new coat of paint and general tidy up.

In the mean time I am in the process of detailing the wheel hubs and re painting the front grills.

Watch this space Laughing
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