Restoration/upgrades of FFR3490, MK2 built in 2002.

[johnnybgoode]

New video posted. Relocation of the battery to the trunk pretty much done and I found that the thermostat housing is still leaking. Next up will be pulling that back apart.

You could use a coarser grade of sandpaper to help cut the aluminum faster. I use 320 on a flat wood sanding block. I wouldn't polish the surface either. There are two O-rings on those water necks, make sure you replace them both. The flange O-ring can get compressed and lose its seal. Replacing usually does the trick. You should not need to use any sealant with those necks, I've had very good luck with them installed dry.

You can also use a cooling system pressure tester to pressurize the system to 16lb. and see if it holds and/or spot any leaks.

Good Luck. Scott