Unexpexcted issue when changing shell

[ArthurH 7]

For various reasons, we are re-shelling our 1.6GTI race car.  Rather than 'waste' a genuine GTI shell, we are using a very sound '94 1.8 NA Diesel (Inca) shell.

 

We have put quite a bit of effort into enlarging the rear wheel wells and raised the rear arch line.  We have also reengineered the rubber mounts above the engine subframe to allow for the brackets on the chassis rails being 19mm higher.

 

The project is finally nearing its end, but after fitting the GTI rear beam, I found some interference with the chassis rails that I hadn't expected.  The solution may be as simple as removing some of the horizontal lip from the rails (it is identical on both sides).  But I wondered if anyone had seen it before?  if so, it never seems to get mentioned.

 

The pictures are in full droop, so it only gets worse as the arms rotate.  Does this lug on the casting serve any purpose?

 

 

[welshpug 1,668]

That beam needs adressing, the seal isnt even touching the arm!

 

That lug is there on most arms, never had it cause any issues, i can check later today how close it sits but the trailing arm not being fitted properly rings alarm bells with the condition of the beam and it's mountings.

[Tom Fenton 1,551]

The only time I can recall an issue with that lug is with a 309 (wider) beam onto a 205. I cut it off, its not used.

Like Welshpug says, the beam looks like it needs an adjustment at the very least.

[ArthurH 7]

Thanks guys.  I have to put my hand up to this one.  It was me who last assembled the beam in 2020.  I hadn't realised the gaps (it's the same both sides) were wrong.  It hasn't given us any issues over the last 4 seasons, but obviously I will have a look asap.  Another difference between the base and GTI shells is the four holes that the forward studs of the rear beam bolt through.  They are significantly larger on the GTI.  What this means to me, is that there is no play between the studs and the cage feet, so removing and refitting the beam is a much trickier job than it had been.