Gear box with axels cleaning

Looking at what is required to take apart the gearbox and thefact that it was working fine before I took it out of the car, I decided to only clean it up, remove the rust and paint it.Almost there. Had some bags on the axels as they tend to leak oil when tilted down.

I will replace the 2 cv boot joints (seen here) and the hub seals.

Tinware painting

Got some heat resistant paint today.

And more wire brushes!
These have got arbours that screw together got the brush to fit in the drill. I have now 7 of these kits. I still have the body of the car to do, so I am sure they will be used.
The tinware all painted with two coats. I think there will be enough for 3. I won't bother with the exhaust as I'm not sure if its ok or not. I haven't started it in over 2 years!A close up of the fan. Looking a lot better now.

Fuel tank

After some thought, I've decided to keep the fuel tank. A new one would be simpler but it is possible to refurbish the tank with kits that completely renew the inner wall after removing any unwanted deposits. It goes against my nature to get a new one, even though the cost is only about £20-30 different from a new tank, I'll refurbish. After all, if I wanted something new I wouldn't be driving a VW!The outside was straight forward. Just need to get that fuel tank kit.

Fan shroud

The fan shroud is quite rusty on its inaccessible insides. These wire brushes that fit my drill are whats left of the process so far.

The result is quite good. I'm never really going to be able to reach the inside though. So I thought I'd try a rust bath. One ordinary pallet becomes...
A bath frame?
Seems to be the right size and didn't take to long to make. Perhaps there's a few too many holes at the moment.
Just need to find some plastic sheeting and everything will be ready.

Oil cooler

Needed to clean up the oil cooler. Wasn't going to be able to reach all the rust of course.It started to look good.

But then disaster as I went through some of the metal.
As you can see the hole is clearly visible. With possibly more holes to be uncovered, I'm not sure its worth the time and effort to repair this. At around £65 these aren't cheap.

Charging the battery

Got the original battery that came with the car. Not sure if it will hold much of a charge anymore.
Only one way to find out.
Got an old charger and hooked it up. Will probably need a new battery but its worth a try.

Kurust

So this is what I'm using on the tinware to stop the spread of rust.

No matter how much you try you can never remove all the rust. Unless that is, you want to start cutting bits out and welding in new bits.
A close-up of the finished surface after kurust.