Date Sytem Comments
     
23 October 2004 HP Pump drive degreased, scrubbed rust and clearcoated 2-part pulley for fitting on camshaft extension.  Scrubbed and painted metal parts of HP Pump shaft.  Have to stop work pending arrival of 2-groove water pump pulley.
7 November 2004 HP Pump Drive can now continue installation of HP Pump now that correct water pump has arrived.  Reassemble HP pump shaft with paired drive belts to water pump.  New M6 fasteners & lockwashers.   Reused M7 fasteners on HP Pump mounts because of unusual length and mid-shaft nut design on fastener.
  Water Pump Have to replace water pump with the one sent by Dave Burnham.  Quick job.  renewed gasket sealer a bit, gasket from first installation was in perfect shape.   Used Dremel to abrade off corrosion and sedimentation from thermostat cover. 
1 December 2004 Torque Bar Colossal waste of a day because Citroen made the torque bars wider at some point after car was manufactured, and all my torque bars are too wide.  Overall goal is to fit porkchop mount.
11 December 2004 Left powertrain mount New 10.9 fasteners.  Red locktite, torqued to specs.  Ring nut on shaft to transmission not final-torqued.
12 December 2004 Starter Not super happy that the guy who rebuilt my starter motor did not replace the wire from the solenoid to the motor.  I decide to put some spiral wire sheath around it & hope for the best. 

Used vise and hammer to tap end of cable to 90 degree bend. 

I discovered that the long bolts to anchor the starter will not clear the HP regulator support.  So, regulator support must come out to enable installation of  through bolts.  Rest of installation went smoothly.  Direct-drive starter is very heavy and is a bitch to hold up for a long time while the bolts are getting screwed in. Torqued bolts to specs.
     
     
     
2 January 2005 Hydraulic Clutch Cleaned & sanded the rust off the clutch /  brake pedal assembly.  Repainted with gloss black rustoleum.  Took clutch master cylinder out of lhm bath of past year and installed.  New M6 fasteners.
  Accelerator Pedal linkage While I'm under the dash looking at the just-installed clutch-brake assembly, I notice that the accelerator pedal assembly has some surface corrosion.  Out it came. I disassembled it, scrubbed off the surface corrosion, and put a new coat of high-gloss rust-oleum on it.  Packed pivot point with grease.  New M8 fasteners.
     
     
8-9 January

Searching for a throttle cable replacement

 Went to a bike shop on Queens - Nassau border.  New York Motorcycles in search of a cable that could be fabricated from raw cable and endcaps.  No such luck, they only stock factory-produced items.  Similar story at a Harley Shop I visited Sunday morning.  Cool stickers at the Harley shop. 
  Carburetor Installation Cleaned and polished throttle cable linkage mount.  Clearcoated the raw metal.  Cleaned carb body a bit, not much surface junk since it was rebuilt relatively recently.   Created and installed filter screen to keep jets from clogging.  Installed carburetor, no control cables installed yet. New fasteners on all.
  Left front wheel swivel Cleaned outer half of caliper. Reinstalled caliper & torqued bolts down.  Cleaned and greased handbrake caliper mechanism.   Lots of brake cleaner and a wire brush!! Reinstalled handbrake caliper mechanism.    Connected new handbrake cable.  New fasteners. 
  Right front swivel. Puzzled over design and procedure to install new bearing and hub.  Decided internet research and yahoo group solicitation necessary.  Postponed job.

Cleaned outer brake caliper.  Brake Cleaner is nasty shit. 

5 February HP Supply lines
  1. I realise that the 3,5mm lines I used for the clutch won't work with the clutch system.  The entire clutch supply system uses 4,5mm lines.   I originally used 3,5mm lines on to pre-plumb the clutch, because the system is fed from the front suspension  lines which are 3,5mm.  At first I'm really worried, because I realise that I will need a t-fitting that is 4,5mm on one arm, and 3,5mm on the others.  Oh shit.
  2. New 4,5mm line from left front lateral member up to where I have relocated accumulator #2.
  3. Wrapped new lines with spiral wire wrap.
     
     
12 Feb DIRAVI Splitter Opened up, cleaned, repacked with synthetic grease.  Does not turn as easily in the synthetic grease as in the original packing.  I suspect the synthetic is too heavy.   I realise that both the DIRAVI drive cable and speedo cable should be replaced.   The DIRAVI cable has a bushing on the transmission end that is way too big to fit in the splitter.  The speedo cable, meant to extend out over a longer length, has fittings that fit, but the shorter distance from the differential to the dashboard  would cause a sharper loop in the speedo cable than what makes me comfortable.
  HP Supply lines Over the week, I recall over installing the HP lines a while ago.  The T-fitting worked ok on 2 lines, but was a real motherfucker on the last one, for the clutch. (I was using 3,5mm line at the time.  I think perhaps the T-fitting really is a 3,5-4,5-3,5 fitting.  I dig it out of the car, and sure enough, it is. I use almost all of what I have remaining of 4,5  line to fabricate the HP lines that run from the master cylinder to the slave on the clutch and from the T-fitting to the slave cylinder.
  Electricity sort out the harnesses, isolating circuits, and labelling wires.  The OEM installation is complete shit.
     
19-20 February, and 26-27 February

 

 Goals
  1. Assemble right side halfshaft - midshaft from 5-speed
  2. Starter heat shield
  3. Exhaust gasket and down pipe
  4. Finish connections for high-volume lines
  5. install supply and discharge for clutch
  6. install cooling hoses aft of water pump
  7. repack DIRAVI splitter synthetic grease is too heavy.
  8. Install slave cylinder on clutch
  Halfshafts
  1. cleaned midshaft from 5-speed
  2. moved midshaft bearing and retaining ring from 4-speed shaft to 5-speed shaft
  3. happy to find outer halfshaft is same length on both 4 and 5-speed versions.  only change driven by relocation of differential was in length of midshaft.  4-speed outer halfshaft fits perfectly in 5-speed midshaft
  Hydraulics
  1. installed low-volume leak lines
  2. fabricated new spider
  3. Used Rilsan T-connector to join spider to other leak system, one line back to reservoir.  must contemplate if this is a good idea.
  Fuel
  1. started installation of new fuel lines from pump to filter to carb.
  2. need new filter, heat reflective sleeves for lines.
     
     
     
     
     
     
     
     
5-6 March Goals
  1. Pop Tripod from 5-speed left side halfshaft
  2. Retract boot from 4-speed halfshaft, salvage grease, pop tripod
  3. Install temp sender on coolant
  4. Install heat sleeves on fuel lines
  5. Install bleeders
  6. Put epoxy on throttle sleeve to stop slop in linkage
  7. repack diravi splitter
  8. nylon ties around driveshaft boots
  did
  1. Completed transition from 4-speed driveshafts to 5-speed driveshafts.  Both shafts ready for installation.
  2. Set sender for coolant temperature
  3. Finalised the fuel lines to/from carb, new heat shielding, new soft hoses, new filter.
  4. Started assembly of air intake bits.  The piece I ordered on ebay about a year ago is a better design for crankcase ventilation than the OEM snout.  I needed a 5/8" or 3/4" crankcase ventilation hose.  The auto parts store wanted $30 for 2 feet of 5/8".  muthafuckaplease.   I found the same thing at JCWhitney for $2.99.
  5. All of Sunday was spent replacing the timing belt on the Volvo. 

 
12-13 March Goals
  1. Ignition system goes in this weekend. I've given up waiting for someone to produce a distributor that has centrifugal & vacuum advance.  
  2. Prepare wheel hubs for driveshafts: calibrate handbrakes, install bleeders

 
  Did
  1. DIRAVI splitter - cleaned out the synthetic grease & replaced with gear oil.
  2. Gearbox - Filled with 8w oil.
  3. Cooling system -took the  radiator to a  radiator shop for recore.
  4. Throttle Cable fabricated replacement cable by combining new throttle cable sold for use in VW dune buggy conversions, and bits from cables I found on ebay
  5. Throttle Linkage found HMD material for a shim, to keep throttle linkage shaft from wiggling in bushing.  Used epoxy to anchor the bushing to the bracket.
  6. Electrical - started plans of new installation
  7. None of the goals I set for myself were accomplished.
  8. Spent most of Sunday working on the GTI to get it off the stands, which I need for the 2200 and to change the oil on the Volvo.
  Carryover open items
  1. Starter heat shield uses M5 screws, but my new 25mm ones are too long. Shield is secure, I had several screws from when it was removed. one of the bolt holes is missing the screw.
  2.  
Costs?   Too much is never enough