The engine: let the fun begin!

I started to work on some engine components. The I-beam con rod bolts were first in line:

My new toy was very helpful, a jewelers scale with an accuracy of 0,05 grams!

I removed some material on the tip of the heavier ones, now all bolts are exactly 25,50 grams!

Now, on to the I-beam con rod assemblies, The difference from heaviest to lightest was 3,5 grams. After some fine tuning: Here are 4 different pics, but their weight is exactly spot on now!

Rod #1

 Rod #2

Rod #3

Rod #4

Also, I hauled a few more parts from my latest trip to the States:

lightweight piston wrist pins,  ChroMoly cylinder head studs (in M8 and M10), single
hi-rev valve springs, valve spring retainers; oil pressure boost kits, Crankshaft spacer - and the I-beam con rod set - which I marked as fine tuned.

Hau Ruck!

Arbeiten am Feiertag? Nach dem Neujahrskaffee mal eben die Karosserie auf's Chassis gehoben...

Danke an alle Helfer!

Body to pan seal installation

Currently I am attaching the body seal onto the pan. Again, Sikaflex 221 is my best friend.  A bead of Sikaflex around the holes for the screws will help to keep the installation water tight:

The holes for the body screws have been punched out before the seal is positioned onto the pan. Some masking tape will keep it affixed until the Sikaflex has cured. 

 Maybe the body will be fit onto the pan within the next days...

high grade fine threaded bolts...

... is what you need to mount the rear shock absorbers. Luckily I know of a company nearby which provides almost every screw and nut you can think of, so I bought these:

 I use nylock nuts instead of the toothed washers which VW used in the days (all 10.9 hardware in this pic). Unfortunately you do not get everything in cad-plated / zinc finish...

the only thing missing now is 1 more drive shaft, then I can test fit the body!

everything else is finished, I also started to mount the body to pan seal!

Always a pleasure; shiny new bolts!

Thank you, Anneliese!

Today I finished the remaining brake lines. With the professional flanging tool from (Anneliese) Rothenberger it was a matter of minutes!

(Photo found on www.annelieserothenberger.ch)

Well, the tool is actually not from Anneliese Rothenberger, but from company Rohtenberger - and Ralf was so kind to borrow it to me, so I have to say : Thank you, Ralf instead...

... with the right tools everything can be accomplished! 

I also redid the oddly routed brake line in the rear center, as it was too long in the first place:
before - several s-bends all over the place:

and after:

new brake line left rear:

and right rear:

Oh - and I attached one drive shaft in the mean time...

now I have to order a few nuts and bolts to finally mount the rear shocks! Then I can test fit the body!

brake lines in kit form

There are still some brake lines missing, so I ordered a 5 meter piece of non-corrosive (KuNiFer) brake line and a few end fittings. I have access to a professional brake line flanging tool. Next weekend I will try to set up the last bits for the brake system!

I'll keep you posted!

CV joints serviced

During the last weeks my work flow on the Streaker decreased a little, but I was able to dismantle and service the CV joints (at least of 1 axle):
jummy: +40 year old grease:

dismanteled:

after a good cleaning season in the parts washer and a repack:

Now, the same procedure for the axle...

New axle boots will be used as well during the assembly process!