So update time, and things are moving again (apart from the buggy under its own steam anyway) - so three things have happened since last time, I've re-plumbed all the brakes and this time done away with all hard lines and gone with braided PTFE lines with compression fittings, same stuff I used for all the flexi's to the hubs last time, here's a few pics
found Torques on ebay had the correct adaptor to convert my master cylinders over to use AN fittings - image shows the adaptor in the output ports
New lines in and the fluid supply in too!!
all sorted, including the brake pressure switch and you can also see the full length lines going to the back for rear brakes and clutch
Next thing was sort the Fuel tank / filler and the wiring to the pump:
pump, filter and feed and return hoses fitted to tank and the filler neck re-connected
the last bit and by far the most painful was building the replacement loom - the original intention was to modify the existing lighting loom I built to work with the Suzuki switch gear and column, however on closer inspection, I decided it would be quicker to start again with a clean loom built from scratch - there were so many changes it just wasnt worth the effort to pull the old one apart. main reason being the suzuki switchgear was designed to switch earths for everything including headlights which was a pain in the arse last time around - now with the vw light switch / column stalk and column everything went back to normal with switched positive side (like everyone else) - anyway after much frustration and scribbling of wiring diagrams I finished the loom that controls everything APART from the engine (thats still stock) and it works like a charm:
Sidelights with Dip on
main beam with optional roof spots on
Side and dip on with Indicators flashing - might not of caught these at full intensity they are really bright yellow!
So all the lighting front and rear is working now, as is power to the intercom for the helmets / rear camera etc - I can now drop the engine loom into place (im not changing that its already sorted) - then finish the engine and gearbox service and drop that back in, plan is to drop the engine in whilst its still on the buggy lift, plumb it and fire it up before putting the rest of the suspension back on (As when the suspension goes back on there is no space in garage to work around the buggy), so when I'm happy the engine is right I can button it all up and last job is putting the suspension back on and aligning it!!