Assembling

Beam got new mount bushes (4pcs), genuine pug items. I also bought set of offcentre spacers for the torsion bars. Assembly of the bars was straightforward. I set the dummy shock to 297mm.

Time to press some greese to the bearings

Greese comes out nicely through the outer bearing which has no seal in either side. One has to be very careful pressing greese to the system when antirollbar endplates are installed, too much pressure is guaranteed to pop out the trailing arm outer seal. Anyway, it would be good practice to remove the endplates when adding greese, the color of the outcoming greese will show if there is rust in the bearing space...

A thicker ARB 24mm, from a S2Rallye/GTI was acquired from a scrap yard (via a fellow pug enthuasist) and for some reason both endplates were removed from it. The threads in the ends of the bar needed to be tapped (M8) clear in order to screw the plates to the splines.

Supports for the brake hoses were screwed in. One cleaned and painted support piece is missing, I thought I may not find it so took a rusty one from the parts bin and put it to electrolysis bath... Hoses must be bought too. After these small things it's time to install the axle to the car.

New brakes

Here are pics of new brake shoes and brake cylinder:

The brake cylinder has build-in pressure limiter (so the brakes are not load-sensitive).

Must say that its a joy to assemble parts when they are clean, compare with this one :)

New bearings and seals

Preparing for the grease nipple. Nipple is M6 thread

Best is to drill about 28mm from the end, here the hole is a few millimeters less. Just enough clearance to bearing. One should be careful where to drill (especially if bearing are in place), there is not that much space to play with.
This pic shows the location of the outer bearing

The outer bearing is the smaller one without internal seal. New bearing in place

Inner bearing has an internal seal and is flush fit

Inner and outer seals

Parts porn

Pics...

Antiroll bars are from 1.4XSI and 1.6 Rallye. Both rallyes will get nice shiny valve cam covers. I'm going to have the S1 rallye steels also cowder coated at some point, to white color of course.

Parts are back!

It took ages, but the parts are finally back. Sandblasted and powder painted. They look fantastic, will be a joy to reassemble. Pics will follow...

Some random pics of disassembling the brakes:

 Close up of the wheel bearing seals:

Stuff ready for sandblasting:

As can be seen, not all these parts are from 106:

These spring pans are from spare xsi:

Parts delivered to sandblasher last monday and will be powder coated.

S2 update

S2 was weighted in Kehakatsastus:

324 + 292 + 165 + 156 = 937  (+- 10)  kg. Minus driver weighting (appr 80kg) --> 857kg. Thats with all the seats etc in place.