Been making more stuff to save me from buying more stuff, plus making stuff is really fun.
Front anti roll bar clamps.. My arb used to break these for a pass time, they would tear the metal and I'd have one half of the bar floating above the wishbone, can't work out why it did this before. Even did it with new OEM clamps. If I'm going to break clamps I want to be able to replace them with ease, so after some mucking about I made a jig and came up with these from 3mm mild steel. The bolts are removable which should make fitting them easier, and it makes the bolts replaceable. Took a few goes to get the measurements right.
![Image](https://i.imgur.com/UotTWlt.jpg)
![Image](https://i.imgur.com/8KVHrQl.jpg)
Then remade the clamps from 3mm 304 stainless steel. Was so hard to roll the loop I had to get the oxy torch out and red-hot 'em.
![Image](https://i.imgur.com/aRbJVbM.jpg)
![Image](https://i.imgur.com/dbgPiwX.jpg)
Had to shape the bolt heads slightly, as it's tight in there. Happy with the finished version though, strong and it wont rust.
![Image](https://i.imgur.com/a8ndVbL.jpg)
Next.. been experimenting with new top mount designs, more on that later. Proper springs up front though.. 400lb
![Image](https://i.imgur.com/Ff8DxeP.jpg)
Next up.. G60 big brake trial test fit for BBS RA's! The big question.. will they fit under the 15" wheels? Can I keep these wheels for this car at least for a short while? They're growing on me a bit and I'd quite like to. Plus they are really light.. compared to banded G60 steels anyway!
To start I removed the 239mm front disc from the car and put up against a 280mm G60 disc for size comparison! Nice improvement over stock brakes. Will need good stoppage too.
![Image](https://i.imgur.com/90x0wkm.jpg)
Trial fitted the caliper spacer bracket. Had to grind out a bolt on the wheel bearing housing (for a dust shield or something). It's not very flat on the mounting face, loads of rust and the bracket doesn't sit flush. I'll need to hit with a wire wheel and see if I can improve things.
![Image](https://i.imgur.com/STvGMJm.jpg)
I boltied on the MK3 GTI brakes and fitted a BBS RA. And.. our survey says.. wheel - potatey - no - rotatey. The caliper carrier fouls the wheel. It's too big right on the corners.
![Image](https://i.imgur.com/uyxMett.jpg)
Hmm I thought. Time for some material removal then. I marked the fouling location through the wheel spokes and marked again with an 'x' here..
![Image](https://i.imgur.com/08ZS4bD.jpg)
Then removed some material with a grinder..
![Image](https://i.imgur.com/SSnwJQL.jpg)
Took a few goes but eventually got just enough off so that the wheel turns now. That's important apparently. And I don't think it makes any difference to the carrier strength-wise. See through the spokes..
![Image](https://i.imgur.com/TJ4AgAD.jpg)
![Image](https://i.imgur.com/Gax7E1I.jpg)
I'm very happy to know that these will fit when it comes to it. So if you want big brakes for cheap under BBS RA's, use the following setup:
MK3 golf 8v calipers and carriers for a 280mm disc. Use from a pre 1996 car as they changed design to 288mm later. These are the same as G60 calipers at a fraction of the cost.
280mm G60 vented discs (a febi pair cost £45)
Adapter brackets from ebay or the like. (£30ish)
A grinder!
![Image](https://i.imgur.com/6BFNZWw.jpg)
![Image](https://i.imgur.com/KjGhk8i.jpg)