The Project Pad

I got back over last Sunday for a couple hours. The timing belt is back on, and the crank sensor is set properly now. I Also made the plug that the wiringing harnesses for the MS3X will go thought. It takes the place of the AC lines in the large boot coming out of the firewall.

And with George's encouragement, I made my own version of the "tuna can" cam sensor. I first milled off the rotor attachment point above the window wheel. Not quite as easy as it sounds.


I then made up an aluminum cap that uses the dizzy cap clips to hold it on. Came out pretty well I think. Should look nicer than an empty dizzy cap in the bay.


Hoping to get over this weekend to work on the suspension portion of this year's work.

That looks awesome. Maybe you could make me one some day? Money to burn here!

88a5tq wrote:That looks awesome. Maybe you could make me one some day? Money to burn here!

Sure, just need to find another MC2 dizzy.

But of course they're all different

88a5tq wrote:But of course they're all different

I'm pretty sure the cap I made will fit all 5 cylinder distributors. The catch is that you need to modify the shaft of the distributor to work. That's the only reason I said about finding another MC2 dizzy.

You should probably just find another 3B dizzy while your at it. When you go to individual coils(and you will), you'll need it for that too

DE80q wrote:The catch is that you need to modify the shaft of the distributor to work.

(cough)Whiz wheel...(cough)

For sure. That was exactly what I did with the 200 going to vems

I don't REALLY need a nice cover as much as I need leak free AN fittings lol

elaw wrote:

DE80q wrote:The catch is that you need to modify the shaft of the distributor to work.

(cough)Whiz wheel...(cough)

That works too a point, but if you want it lower that the trigger wheel, you almost have to use a mill.

Spent part of the day yesterday working on the bandit. Right now the whole car is about 21" off the ground on jack stands. Pretty much right after I got the wheels off, I got a call asking me to go pick my dad up from the air port, because my mom's A4's battery was dead... Go figure.

Anyways, after I got back from doing that, was able to drop the front subframe and replace the bushings! These are in much better shape than the 25 year old OEM ones we took out. Haveing the bushing press make removal fairly easy.


Before we put the subframe back in, and had better access to it, we decided it was a good time to replace the poly insert for the PS motor mount. Here is how it looked...


As you can see in this pic, I managed to melt it enough of collapse it. We had to pry the top washer off of it


Hopefully next weekend I'll be able to get the rear SF done. We have every nut and bolt soaking in PB blaster. The rear has never been off of the car before, so keep your fingers crossed everything comes apart OK.

Don't impact the bolts on the SF fyi. Also, best find a penetration fluid made by Kimball Midwest. Smells like cotton candy and works miracles.

Also, make a heat shield!!!!

Heat shield made, hopefully it's enough.

Regarding the penetrant oil... I re/build refineries for a living, and the two best solutions I've come across are AeroKroil and 50:50 acetone:ATF.

The benefit of the ATF mix is it has a higher surface tension, so it stays in place on vertical/overhead applications better... plus, it's cheaper.

I do love the Kroil, tho... smells awesome, and works like magic.

PRY4SNO wrote:Regarding the penetrant oil... I re/build refineries for a living, and the two best solutions I've come across are AeroKroil and 50:50 acetone:ATF.

The benefit of the ATF mix is it has a higher surface tension, so it stays in place on vertical/overhead applications better... plus, it's cheaper.

I do love the Kroil, tho... smells awesome, and works like magic.

LISTEN TO THIS MAN. AeroKroil is what I meant to say

I use aerokroil regularly at work. I actually used it when I first tore the car down years ago. I didn't have any there when I was working this weekend. I'm not sure where you got it smells like cotton candy though, always thought it smelled like pinesol.

Good to see the progress ramping up on this car. We want more shots of the ex manifold as it nears completion tho!

88a5tq wrote:Good to see the progress ramping up on this car. We want more shots of the ex manifold as it nears completion tho!

You and me both

Yesterday was a good day. My MS is back, and bigger than ever!



It will be awesome to get this wired up and running, but first I need to finish the suspension and get it back on the ground. To help with that, Tim sent me a spare rear diff mount so I don't have to burn out the old one at George's place. This one is ready for the HPR inserts.


I also have the new injector o-rings and the fitting for the intake on the 044. Should be an interesting day...

Another day spent working on the Bandit. Made some progress, and am almost read to put it back on its wheels.

Had to fight pretty hard to drop the rear subframe and diff. I believe this was the first time it was ever out.

Here it is in it's 1991 crusty goodness!


New VS old rear diff mounts.


Then all back together with all HPR bushings and mounts. NO MORE FLOPPY DIFF!


I then decided to install the 044 pump. Things were going well until all 3 of the rubber isolators that the pump/filter mount on decided they don't like being whole anymore. Either way, here it is.


I now need to find some suitable replacements for them. Anyone have any ideas? I may also make up a new line from the pump to the filter. The old accumulator is looking pretty crusty.

DE80q wrote: Things were going well until all 3 of the rubber isolators that the pump/filter mount on decided they don't like being whole anymore.

I now need to find some suitable replacements for them. Anyone have any ideas? I may also make up a new line from the pump to the filter. The old accumulator is looking pretty crusty.

Why not OEM? I think p/n 810906219a is the right thing? They're about 14 bucks each but they'll probably last 10x as long as a Chinese knockoff.

Also if you can find a way to plumb the system without the accumulator you'll be better off. The engine may run slightly better as the fuel system can react to manifold pressure changes faster, and it's one less thing that can fail.

Thanks Eric, I'll have to look into them. I know there are actually 2 different isolators being used. The 2 on the right of the pic are about 15mm tall where as the on on the left is about 20mm tall.. I didn't actually measure them, so I could be off on the heights as I was quite tired at that point.

I'm already looking into the banjo to AN adaptors. The hose length will be very short between the pump and filter though.

You're right! I just looked in ETKA and didn't notice there's another one, seems its p/n is 431616769. I've got a box of various ones of those so when I need them I just dig around until I find something that looks about right. With the term "about right" interpreted very liberally.

Of course finding the correct new parts is often trivial compared to the suckitude of getting the old ones out!

elaw wrote:You're right! I just looked in ETKA and didn't notice there's another one, seems its p/n is 431616769. I've got a box of various ones of those so when I need them I just dig around until I find something that looks about right. With the term "about right" interpreted very liberally.

Of course finding the correct new parts is often trivial compared to the suckitude of getting the old ones out!

Grinders do wonders on the old nuts. most of the time I just grind them off and pop the little Cal off. Thanks again for the Part#, I'll have to look them up.

Coming right along!

It's getting there. This weekend it should be back on the ground, and be all about wiring. You know, the fun stuff...

On a totally different note, picked up some random toys this weekend. This will probably be the closest I will ever be to either an R8 or R18...

Got this pic from George last night.


That should simplify the fuel system nicely. Now I just need the mounts to get here so it can be installed.