Clutch cable pulled through bulk head!

Suspension; Gearbox, Clutch and Driveshafts; Brakes; Steering; Throttle and clutch cable issues

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RoccoYaz
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Re: Clutch cable pulled through bulk head!

Post by RoccoYaz » Tue Jan 25, 2011 4:12 pm

Old Mac Rocco wrote:Many thanks.
you might have to make slight alterations with a hammer for a perfect fit.
That's the bit I like. :hugegrin:
I love a challenge. :focus:
Keep me posted mate if ya don't mind and i'll do the same if I do mine before you do yours!


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james butler
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Re: Clutch cable pulled through bulk head!

Post by james butler » Tue Jan 25, 2011 8:00 pm

i manged to make my own by cutting out the old metal thats no good and making a plate that bolted in. ile see if i can find the pics


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james butler
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Re: Clutch cable pulled through bulk head!

Post by james butler » Tue Jan 25, 2011 8:07 pm

i bet your baulkhead looked like this. mine did this 2 years ago. i made these plates and havent had a problem since
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james butler
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Re: Clutch cable pulled through bulk head!

Post by james butler » Tue Jan 25, 2011 8:11 pm

first i cut out all the scrap left in there because the metal was so bad, the white paint either side marked out the position of the holes
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james butler
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Re: Clutch cable pulled through bulk head!

Post by james butler » Tue Jan 25, 2011 8:17 pm

next i made two plates, one on the outside in the engine bay and one inside that secured it to the baulkhead. i will at somepoint write down the dimensions so other people can copy it if they wish.
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james butler
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Re: Clutch cable pulled through bulk head!

Post by james butler » Tue Jan 25, 2011 8:22 pm

as some of you may have noticed i have moved the position of the speedo cable and the choke cable. this really did make the world of difference to the operation of both cables :vcool: it bolted up nice after some jigging and poking. worked well in the end tho.
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james butler
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Re: Clutch cable pulled through bulk head!

Post by james butler » Tue Jan 25, 2011 8:24 pm

heres the finnished article painted up. :vcool:
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RoccoYaz
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Re: Clutch cable pulled through bulk head!

Post by RoccoYaz » Wed Jan 26, 2011 8:45 am

That's really good James! Wish I had the skill to do this... for me though, I will just buy the repair kit from GSF and hopefully make an attempt at fitting that and like Jim91 said earlier, worst case scenario it ends up going to a garage anyway...

James, it would probably be useful for other members on here to have the dimensions as you mentioned so peeps with skills can have a go themselves. Thanks again matey! :yup:


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scirsteve
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Re: Clutch cable pulled through bulk head!

Post by scirsteve » Sun Jan 30, 2011 12:35 am

Had the same prob. (Had it happen on a B1 Passat also)
I disconnected the cable at the pedal end, bent the sharp metal over.
Then got a piece of dexion (one with the wider section to it)
I managed to cut a 4" piece of dexion so one of the long slots was open at one end then slide
the clutch grommet washer section into the long slot.
(You had to floor the clutch pedal to change gear but it worked.)
I never fixed it in position, it has lasted years until my recently done
proper job, fabbed a 2mm thick metal plate bit like james's job.
I went to look at the GSF one but thought its not big enough for a bulkhead
that looks like its been shagged by an elephant!
:hugegrin:

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scirsteve
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Re: Clutch cable pulled through bulk head!

Post by scirsteve » Mon Jan 31, 2011 1:17 am

Found me trusty piece of dexion.

The ultimate bodge it job!

Image

I was very surprised it last more than a few weeks let alone years.


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T0M
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Re: Clutch cable pulled through bulk head!

Post by T0M » Mon Feb 07, 2011 1:13 pm

Same thing happened to me about 8 months ago. GSF claimed they don't do a repair
Panel anymore, nor VW. I just had a local welder put a nice thick plate in there then drilled some holes. Cost a grand total of 20 quid.
Last edited by T0M on Mon Feb 07, 2011 6:27 pm, edited 1 time in total.


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PeteGLi
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Re: Clutch cable pulled through bulk head!

Post by PeteGLi » Mon Feb 07, 2011 1:28 pm

T0M wrote:.........GSF claimed they don't do a repair Panel anymore, .........................
They may not do for a Scirocco - in any event the Scirocco one was far too small to do the job properly, if at all.

They do, however, still list the Golf repair plate

715VG0420 REPAIR PLATE - LARGE G1 >12/83 £9.50



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ash-lough
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Re: Clutch cable pulled through bulk head!

Post by ash-lough » Thu Feb 24, 2011 12:05 pm

How much changing needs to be done to the mk1 golf repair kit to get it to fit? Does it need drilling?


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james butler
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Re: Clutch cable pulled through bulk head!

Post by james butler » Tue Jan 17, 2012 9:50 pm

apologies it was a long time since i followed this post as to be honest i completely forgot about it.
here`s some drawings for the plates i made to repair the bulkhead hole.
one thing i haven't mentioned on the drawing is you will need some m8 bolts with some inch wide washes front and back to help spread the load and clamp it properly
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wasted
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Re: Clutch cable pulled through bulk head!

Post by wasted » Fri Jan 20, 2012 2:21 pm

That's more or less what I made up for my car - drilled two holes through the rain gutter and mounted it from there after bending the top of the plate over 90 degrees though, with a hefty dollop of glue between the plate and the bulkhead. Still working two years later, but I will be welding it in place at some point (probably when dropping the engine to replace the clutch, since it'll make it more accessible).

NB: The measurements above should go into the FAQ for sure.


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