Sunday, January 6, 2019

Back to the Jetta, I decided to test fit the Girling 60 front brakes.

They aren't as visible through the wheels as I hoped, but that's OK.


Since these brakes weren't designed to fit this car, I had to modify the rotor a little bit.  Most people fitting these brakes grind the inside of the caliper for clearance, but I decided to modify the rotor instead.


Mounted up in the lathe.  I bolted to the face of an old hub so I could indicate it concentric to the spindle rather than simply gripping in the 3-jaw chuck.


My lathe only goes down to 60 RPM.  At an 11" diameter, this works out to roughly double the recommended cutting speed (SFM) for high speed steel turning tools in cast iron.  I had to re-sharpen a few times, but it worked out alright!


Perfect gap!


Organization!

For the past few years, my shop space has been a mess.  Before I started grad school, back in 2015, I was thrashing to complete as many Jetta-related projects as possible at the expense of organization.  Over the past 3 years, any free time went directly to working on stuff rather than organizing or cleaning.  Now that I have a little more time, I focused some effort on cleaning and organizing my space!

Starting with some drawer organization, I whipped up this tray for my puller drawer.  I don't use this stuff very often, so I made this tray so I can stack things in one drawer instead of taking up two.




I also added some Schaller bins to the drawer where I store bolts and fixtures.

My measurement and layout drawer has been a mess, so I cleaned it up with even more Schaller bins.  Now everything has a place and can't move around too much.  By the way, the empty bin was for a metric feeler gauge set which is now filled.


I reorganized one of my punch drawers, this drawer is primarily Facom in molded trays.

I whipped up this shitty wooden material rack. It isn't my proudest work, but it's on casters for easy mobility and holds everything I want!  Also shown in the background are some dollies I made for storing wheels.  These are made from the $10 Harbor Freight moving dollies with some scrap pieces of wood added.


I made this box from plywood scraps, Harbor Freight casters, and an old VW box.  I filled it with carpet and seat parts, and it fits perfectly under the bench.


Some Akro Mils plastic bins for even more organization:

The bins under my lathe hold small round scraps of various materials.

These bins hold used hardware.  It's really handy to have a variety of old bolts around, and now I can keep them organized.

I also rearranged and cleaned up my "finished parts" rack, and consolidated some of my spare parts to the bottom shelf for ballast.

Whipped up a box for spare axles from plywood scraps

And of course, some new tools!  Snap-on purchases:

PB Swiss Black Friday:

Some 3/8' drive impact deals from Cripe Distributing on eBay:

After cleaning everything up, I moved the Jetta out of the way to sweep and mop.  Now I'm ready to get back to work!