Putting everything back, part II

So after yesterday's disappointment - needed some time to rest and think. It gave a result, went to local autoparts store, bought newer clutch slave cylinder (dirt cheap, hope it will last for a while), put it in the gearbox, bleeded, and SUCCESS! Clutch is working. So started to bolt everything again. Propshaft (not visible in a picture, but believe me - it's bolted already):Bolted driveshafts (took a while , because my measurements were wrong, driveshaft flanges from typ44 are bigger, and I forgot, that I had typ44 flanges on my spare gearbox, which was used as reference - they were given to my friend some years ago). And if you notice, turbocharger went from the floor into engine bay ;)Also wrote more blog entries with past dates. Had no time to do this before, because my schedule for these two weeks was - eat, sleep, work in the garage, or search for the parts. Enjoy...

2008.05.11 Trying to put everything back

First, old clutch was inspected. It had no obvious signs of damage, however it was visible, that it had contact with oil (which is leaking from valve cover gasket), and was burned somehow. There were a lot of copper and feredo debris inside flywheel. Also pressure plate was looking suspicious. Old:New:There's visible difference of leaf spring height. So decided to use all the stuff (release shaft, bearing, etc. from apropriate type).

And the fun started. New gearbox requires different type of clutch slave cylinder. So after few hours of grinding, I came with somewhat which can be called as typ85 type clutch cylinder adapter for newer gearbox. We pulled engine back in, bleeded the clutch. And the result was soft and spongy pedal. Inspection showed, that hydraulic fluid is leaking from gearbox. That was a disaster :(. Pulled slave cylinder - it was too short, and spitted a rod under pressure :(. I hated all world and had no strengths to work further...

2008.05.09 Engine pulled out

After many hours of fighting with oil cooler fittings, cutting some bolts, badly injuring my right hand, and many dirty words - engine was successfully pulled out and gearbox was separated.

2008.05.09 Painting finished, dismantling starts

After hard work, roll cage is finally painted. It looks not bad, not good. Assuming circumstances, I personally think, that result is very good (no time to really work on it, no light, no expierence with two component paint, HVLP spray gun and high performance compressor). From objective judgement side, I can tell that result is about 6 from 10. Some shots of finished result:
Closer look:So now its time to pull engine out (to change gearbox, flywheel, clutch). Like always, I will do it by dropping engine and gearbox to basement. To achieve this - you need to dismount everything, and leave bare engine. So it started like this:And in the evening all the hoses, and fluids were out:

2008.05.08 Spraying black paint in the dark...

As I have mentioned, I was painting in lack of light. This is no go if you want to spray paint anything. Especially roll cage. White primer helped a bit, but not too much. After first paint layer, deeper inspection (without goggles) revealed, that covering was too terrible event for me. So took virutally every light source I had, and put it into the car. Results:It is obvious, that I have sprayed paint somewhere, but not on tubes. Especially in the places where shadows like to be:

2008.05.07 Filler for paint

As weather outside garage went from bad to worse (wind, rain +10), I was forced to work in a closed garage. After doing spray test of black paint on black/dark brown epoxy primer, I saw nothing, so it become obvious, that I need different color to see what I'm spraying. Also filler fills some surface imperfections (which tubes have). However you need to sand it for that. I've been too lazy to do this (this is roll cage, not the bling bling). After some experiments with thickness, thinner and air pressure, it started to go well :). It looked really nice (and matt surface hides all spraying mistakes).

2008.05.04 Painting started

First sprayed the cage with anti-rust epoxy primer. This is not the best choice for thing like roll cage, however it does not require any surface preparation (I had no time and patience to prepare anything). So it ate all the rust, and coated everything. Now nothing will rust there (tested on rusty garage elements ;)). It was just about 1000 times harder to spray that stuff on a tube, than on somewhat flat with no obstructions...