it's a Swissmade Gressel, one of the tool companies here in Switzerland and well-known allover Europe. There is no better one if you need a vice, especially those for the work bench but also machine vices. Very expensive but last longer than your life.

Roland,
I’ve been looking for a quality benchtop bender like this for a while now. All I have previously found are the Asian universal benders but they don’t appear very well made. Looking at Gressel’s line of HB benders it appears yours is a HB10 ? Is this correct?

Thanks !

Yes, it's a HB10. I worked also with HB14and HB20. The 20 is what I would buy but the price...

Today I was able to proceed with the fan. I could borrow the tool to set the rivets. After a few Test rivets I set the "real ones". To have a good solid fixation to hit the rivets, I made an massive aluminum counter part as seat for the hub.

http://forums.pelicanparts.com/uploa...1693937352.JPG

http://forums.pelicanparts.com/uploa...1693937352.JPG


It went easier than I expected. Looks quite nice. Only 3-4 hits with the tool and done

http://forums.pelicanparts.com/uploa...1693938080.JPG

And of course test fit to check how it looks, I like it.

http://forums.pelicanparts.com/uploa...1693938365.JPG

The hub is an aluminum replacement. Nice made BUT the rivets needed are not 72° as stock but 90°. No issue so far, but I expect if someone sells replacement which need different hardware, he should inform. For this reason I have now a lot of both versions ;)

When I want to check the amount of shims needed I fitted a new belt. Bought according parts catalogue 710mm but it's way to long. Checked the old one: 700mm?? How this can be? Checked other suppliers like PP, FVD, all the same. 710mm. The only thing left is the Smartracing pulley on the crankshaft, I thought it's the same diameter than stock, but have no stock one to measure... However it is like it is, have to buy a 700mm.

Not sure this will help but, I just went through a similar issue with my belt not fitting after installing a different fan.
It turned out that the fan wasn’t sliding all the way onto the alternator shaft. I re-installed my original fan and everything worked fine.
Your parts are looking amazing as usual. Must be nice to be so close to the finish line.

Thanks for input. But I had the shorter belt with the stock fan hub as well. so issue is not caused by the custom part. I also checked the alignement (housing pushed forward to transmission side). Fan is also all the way onto shaft (can see through the holes it's touching the big shim behind the woodruff key). so left only to check the diameter of crank pulley.

... Thanks, but close to finish? Not at all (unfortunately or not :D) Thousand of things still in my mind. You'll seeSmileWavy

It's been a while since last post... However, after I had to glue most of the cork insulation once again as they fell off after a while (dammit self-adhesive quality) it had no motivation there for a while. Now I started to fit the aluminum coated tissue. Unfortunately the one I had 20 years ago was not available anymore, thick and solid but very good to drape. All samples I received where stiff almost like cardboard, impossible to glue in there without wrinkles. At the end I bought the least bad. To have at the beginning a little feeling of success, I started at the top. Went out not bad. Still have to cover the edges, but this I will do as last.

http://forums.pelicanparts.com/uploa...1724696729.JPG

http://forums.pelicanparts.com/uploa...1724696729.JPG

I like that

Great to see you back here again Roland - and - that you're still havin at it! Lookin good... keep on pluggin away,,,

Step by step
 

Such a time consuming thing, so only little (but at least some) progress

http://forums.pelicanparts.com/uploa...1725448342.JPG

http://forums.pelicanparts.com/uploa...1725448342.JPG

last update before vacation

http://forums.pelicanparts.com/uploa...1725566532.JPG

The tissue us less flexible and drapable as desired. Therefore I had to make smaller pieces. Left over area in the middle will probably not possible in one piece, at least two I guess. But first I am off for two weeks :-)

step by step
 

While I regularly continue, I don't do regarding posting... However here a little teaser about wiring harness (I made all new). Pictures are a bit older, more current will follow soon

http://forums.pelicanparts.com/uploa...1749564636.JPG
http://forums.pelicanparts.com/uploa...1749564636.JPG
http://forums.pelicanparts.com/uploa...1749564636.JPG

Long time ago (check my thread "another EFI conversion") I mounted a BMC airbox and made air tubing from Filter to turbo out of PE-HD tubes. No issues since, but When remounted the box, I noticed the inlet diameter of box seems smaller than stock. So I measured and found about 80mm against almost 100mm of stock airbox... Furhter I disassembled the BMC CDA box to check the surface size of the cone shaped filter. it's not easy to check surface due the wave shape of filter material l left this out and just looked at surface as it would be flat. So BMC Box seems a little smaller than stock...:(

So easy decision: A bigger box has to be fitted. I bought the same CDA Box but bigger version. In- and outlet 100mm. I did not measured surface yet, but quit bigger than stock for sure.

So beside the box, I have to make the whole tubing new. before it was also 90mm reduced to 75mm after 90degrees elbow before BOV connection (and the bottleneck of less than 80mm at box in and out). Now it will start 110mm at box with little 3D-printed adapter (red), reduced to 90mm until after the BOV. Also I made an additional clamp (nothing like on the market) out of SS to take off some weight from the box. Progress so far:

http://forums.pelicanparts.com/uploa...1749567002.JPG
http://forums.pelicanparts.com/uploa...1749567002.JPG
http://forums.pelicanparts.com/uploa...1749567002.JPG

Because of the bigger measurements of the new air box I needed to replace the Filter bracket (still the K-Jetronic piece) with a new. Made it out of hight strength aluminum, anodized in black. So a little weight saving too:D

http://forums.pelicanparts.com/uploa...1749567158.JPG
http://forums.pelicanparts.com/uploa...1749567158.JPG
http://forums.pelicanparts.com/uploa...1749567158.JPG
http://forums.pelicanparts.com/uploa...1749567158.JPG
http://forums.pelicanparts.com/uploa...1749567158.JPG
http://forums.pelicanparts.com/uploa...1749567158.JPG

BTW: the stock bracket was drilled already (you know me, don't you :-) )

Great work as always!

I like the bigger airbox.

Glad to see you back posting.

John

Thank you!

Me too likes box :D

Today I finished the whole inlet tubing from air box to turbo. First I shorten the silicone reduction hose. Easy to do with sharp cutter on the lathe.

http://forums.pelicanparts.com/uploa...1750450054.JPG

http://forums.pelicanparts.com/uploa...1750450054.JPG

http://forums.pelicanparts.com/uploa...1750450054.JPG

PE-HD tubes "welded" using frying pan


http://forums.pelicanparts.com/uploa...1750450187.JPG

Test fit before final cut's to adjust space between the two pieces where reduction hose will be

final version fits like wanted


http://forums.pelicanparts.com/uploa...1750450318.JPG

http://forums.pelicanparts.com/uploa...1750450318.JPG

http://forums.pelicanparts.com/uploa...1750450318.JPG

http://forums.pelicanparts.com/uploa...1750450318.JPG

hmm test fit picture lost... so here it is:

http://forums.pelicanparts.com/uploa...1750450510.JPG

Today I startd with making engine wire harness. To get the right lengths of the cable I made kind of Connector bracket to get the correct position of them similar to engine is car. So it's easier to route the cables and test-fit before mounting pins.

http://forums.pelicanparts.com/uploa...1750883678.JPG

http://forums.pelicanparts.com/uploa...1750883678.JPG

Note: As you can see here, I still will use the spacer to lower the engine. Made this to get the B6 intercooler under the wing. The 965 intercooler is not that thick, so no issue for it. Regardless I like the idea of the lower engine (lower center of gravitiy)

I just saw that I never posted pics of the finished engine bay heat and noise isolation, so here they are

http://forums.pelicanparts.com/uploa...1750884182.JPG

http://forums.pelicanparts.com/uploa...1750884182.JPG

http://forums.pelicanparts.com/uploa...1750884182.JPG

one more

http://forums.pelicanparts.com/uploa...1750884609.JPG

hmm. For some reason 5MB does not work.. So a bit smaller now

http://forums.pelicanparts.com/uploa...1750884750.JPG

Engine wiring almost finished. this time I decided not to pack every wire into one protection hose I made a couple of them, each function/area has it's one hose. This way it's much easier to have access when needed. I also go without rubber grommet at the connectors. Each wire has a silicon seal in the connector, that's enough. I prefer this, as it avoids water inclusion, same as the protection hose. Wires are FLYY, which ist modern standard (finer strands and pvc covering) ecxept the SDS injecton sensor and injector wires, those are high quality as well and supplied with SDS injection.

http://forums.pelicanparts.com/uploa...1755030140.JPG

http://forums.pelicanparts.com/uploa...1755030140.JPG

Some more pics

http://forums.pelicanparts.com/uploa...1755031038.JPG

http://forums.pelicanparts.com/uploa...1755031038.JPG

On most pics there are still a lot of cable ties, which I only used to route the wiring and get an idea of the final position. After I fitted only two (bigger ones) in this area
http://forums.pelicanparts.com/uploa...1755031038.JPG

http://forums.pelicanparts.com/uploa...1755031038.JPG

http://forums.pelicanparts.com/uploa...1755031038.JPG

http://forums.pelicanparts.com/uploa...1755031038.JPG

http://forums.pelicanparts.com/uploa...1755031038.JPG

Because my LH Fiberglass Fan Block-off is quite old and brittle and the RH is still steel I ordered some Sheridans from PP. On the first view, they look quite ok, but when started to fit, they turned out as terrible...

RH needed lot of trimming, but that would be ok, even if I think (as the OEM part fit's really nice and is easy to copy) it could be better from beginning. There are no marks where the mounting holes should be. Also the measurements differ from OEM part, what I cannot understand, no variation needed there. All in all, it's ok, but far away from nice. The biggest issue is that there is way too much epoxy (or polyester) in the inner corners, especially at the lower mounting latch and the inner side of the top bar so you can't get close enough to the engine shroud. about 5mm away. When you tighten the bolts on top, you deform the bar (presses down), so there is alway tension on it (or you leave it loose...)

Will post pics, when both are fitted.

LH has same issues but more than that,the are several angle errors (guess they took out to early out of mold and it warped while harden. Also radius to fan housing is bad and the inner lower area to fan bas has a huge gap. Too much trimming here. Also the area for the bolt to fan housing at the side is to short, not possible to make a hole but only a slot.

Angle issue:

http://forums.pelicanparts.com/uploa...1756815694.JPG

http://forums.pelicanparts.com/uploa...1756815694.JPG


Comparison to old FG piece (which fit's 99%):

http://forums.pelicanparts.com/uploa...1756815763.JPG

http://forums.pelicanparts.com/uploa...1756815763.JPG

For now, I leave them but will make my own copies with FG myself. As it's quite a bit of effort to make good molds, I'll postpone that...

Here now some pics installed of LH

http://forums.pelicanparts.com/uploa...1756841840.jpg
http://forums.pelicanparts.com/uploa...1756841840.jpg
http://forums.pelicanparts.com/uploa...1756841840.jpg
http://forums.pelicanparts.com/uploa...1756841840.jpg