Bognor Lean-to Project

[Mazza]

Well today was all about watching other people working on Zeds

A day out in Basingstoke to collect some parts and get other bits stripped, after an early morning Breakfast meeting.
it was onto Zedshed HQ, to sort this lot out...

I had a list of things that I needed to get done.....and other than being allowed to use the bug nugga gun on the front hub nuts....but for the majority I just watched as Lee and Gaz whizzed through all the work........
First the two bushes were installed in the newly powder coated rear beam....
Then the bush was installed in the diff housing.

Another quick job.....which would have taken me ages if I had done this at home .....like the picture
Lee did actually have a hand in it

Then moved over to the spring compressor and dismantled the front shocks. Springs and plates are being shot blast and powder coated next week, along with the front ARB, ARB clamps, and front hubs. Which had to be disassembled first.

Bearing removed, and what was left of the back plate was binned. The other one also had to have the sensor drilled out as it was stuck in......but all sorted ready to go for treatment next week.

I did pick up lots of powder coated parts, and they look pristine.....going to be so nice to reassemble them all when the time comes.

This is the passenger side arm , that Lee supplied. Just a shame he didn't have the drivers side one
But Gaz and Lee stripped the bearings out of the one I got from the USA, as that will be going off for powder coating next week so they all match.

Meanwhile...As Lee and Gaz were sorting my stuff out , outside there was a major dismantling going on on Dino’s Z3.

Dino, Trev and Paul removed the whole interior......and in time the whole car will be dismantled, and the shell scrapped.
( it was nice to meet @Dino D and put a face to a forum name)

I did get to help on the Z3M.......but I was slowing Lee and Gaz down when they gave me a simple task of removing four nuts off the exhaust flange at the front end.......What a pain.......wont be buying an ‘M’ if everything is a difficult as that!!!!
In my defence ......and after struggling for quite a while, Gaz removed the underpan and the cross beam.... to give me more access..... but I could not shift the fourth nut and also one of the bolts was rusted in and wouldn’t move....so after admitting defeat....Lee sorted it out .....but he did use a heat gun
( obviously gave me that job to make me look stupid and useless..............and it worked .....)

Once the exhaust had been separated, in no time the rear end assembly was on the deck.....and separated into four parts

One arm off already and removing the other.....

At this point I had to go as I was calling in on Andy ( Spurs) on the way home to collect another load of bits.

Oh, and Dino ....look what I’ve got.................... and honestly its not the one I was looking at on your car....I got it from Andy

Thanks to Lee and Gaz for all the help today in getting all these parts sorted out, and Andy for sorting out the spares for me.

A good day out , and the best bit is .........it will happen again next week when I’m having both trailing arms rebuilt, so I will only have to bring them home and bolt them on to the beam and diff......

 

[t-tony]

Told you it would be a great day out Malc.

Tony.

 

[Mazza]

Another 5 hours in the Lean-to......with some good stuff , and some not so good..........

Removed the front bumper, as I wanted to check a few things......and I am fairly sure that the car has had a front impact at some time.
The power steering cooling loop has the bottom bracket bent and the rubber mountings damaged.
The O/S light unit is damaged,

as is the plastic trim that goes below it.

Also the plastic housing that the light unit sits in is missing...
( this is the N/S one)

But no structural damage, so just need to replace the damaged parts.
That explains why there was no O/S wheel arch liner, other than the bottom piece, which acted as a collector for crap to build up.

The other problem of the wheel arch liner missing was that I found rust problems......more welding to do !!!!!

Doesn’t look too good but it is repairable.....

On the good side...I managed to remove the two 22mm nuts holding the wishbone to the trailing arm. Not the easiest of tasks but had been given some good advice yesterday at ZSHQ as to how to remove them.
Also removed the track rod ends at the same time. Luckily the Cooling fan spanner is the right size and simple to undo.

I had to persuade them to separate from the front beam.....

The brackets holding the horns are badly rusted, so I will have to make some new ones. I will also cut the off the nuts rather than trying to undo them as I have a feeling the stud will break off.

When Lee stripped down the trailing arm yesterday, part of one of the bearings was stuck on the hub, so I will need to cut it off or somehow remove it......but Realised today that the other two I had are the same!!!!. That could be a long job !!!!

But I did have a visitor today. New forum member Nick (@Nickskip ) came round for a chat and to show me his new acquisition. Needs some TLC, and the drivers seat needs to be looked at to get it moving back and forth, but not bad for the money paid.

Number plate won’t be staying on it though!!!
Always nice to meet new forum members.

Then finished of today just tidying up, ready for the next onslaught!!!!

Oh no.......these bits fit up the other end.....



Lots to do before next Saturdays trip up to ZSHQ.....so will be busy this week.

 

[Dino D]

I always though this thread was about an actual shed build - some sort of ‘not so grand designs’ project so never clicked on it!

now I get it - not quite a Zedshed but a mini version hence ‘lean to’


You certainly been busy and sorting us all out tank straps - brilliant effort @Mazza

 

[t-tony]

An easy way to remove those inner races is to just grind them with an angle grinder, once you get them thin enough they will split and then push off.

Tony.

 

[Mazza]

An easy way to remove those inner races is to just grind them with an angle grinder, once you get them thin enough they will split and then push off.

Tony.
[/QUOTE]


I’ll order two new ones when I cut them in half with the angle grinder

 

[t-tony]

They come as part of the new bearing mate.

Tony.

 

[Mazza]

I meant the actual hubs

 

[Mazza]

Bit busy with other things today, but managed to get a bit of work done. Organised my welder to drop in next week to sort out a couple of things.
Cleaned all the handbrake parts

Removed the bearing shells from the rear hubs. Using my bench grinder.....

I won’t show the first one that I practiced on

Now that the new bush has been fitted, assembled the diff ...

Thats a few bags emptied, and looks so much better being cleaned and with the new parts.

I put together a set of tank straps in readiness

and while I was at it, I had a strap modified this morning locally to add the two countersunk holes and made up the last set of the Z3M straps

That was about it for today, other than a bit of tidying up.... ready for more cleaning tomorrow.....

 

[Althulas]

And hopefully the last of rust holes Malc

 

[Synclare]

.

 

[Mazza]

Have no idea Adrian......but I know one thing it wont be coming out again


I have a choice today of what to do......cleaning and painting ......or under the car with grinders, dremel, chisels hammers..etc to remove the last bit of exhaust pipe from the flange........

So cleaning it was.....
I picked up loads of spares from @Anthony Brashill in Brighton about a month or so ago, which included a set of discs which hadn’t done a lot of miles but just need a bit of tlc.....so that was todays task.
An angle grinder with a with a wire brush and an electric drill with a little pointy wire brush....

Rears....one done to show comparison...

Fronts

A couple of coats of red oxide and I will mask and spray them with a grey stone chip later.

If Carlsberg did brake disc renovations.........the bloke doing them would end up p*****

These are certainly better than the ones I took off. Mine had scores on the faces and wouldn’t have been worth trying to clean up.


I removed the broken aerial, but had to move the roof motor out of the way first

Treated the other bracket and will refit tomorow.

Can anyone tell me what this is....

In the back of my mind I think I have read that you can remove it, but its not a part used on the 1.9 M44 so not sure.
Be grateful for any info on what it is and what it does......

 

[Eddie Zedder]

That's the secondary air pump Malc. Used in the USA for emission control at start up. No use whatsoever in the UK. It can be removed with no issues, just need to blank off the small vacuum hose and the port on the exhaust manifold. @t-tony sells the blanking plate.

 

[Mazza]

Not a great deal of progress today, as I have decided to bin the project and take up knitting....


I did put together 10 sets of tank straps....as I will be sending some up to Zedshed ( Midlands) in the near future for those that would like them fitted......15minute job on Tony’s new car lift....... but dont worry @t-tony will receive full training
( yeah, like I can teach any of these guys anything )

I did venture out i to the garage at one point and found that what I thought was rusty metal on the bonnet turned out to be sealant coming away......
So a quick clean off and rust treatment may have saved the bonnet....I can always add a sealant bead to match later

Just picked it off with my finernail...

This bead runs all round the edge of the bonnet so if I can find out the correct sealant wont be too difficult to replace.

The only other thing that I did .....and I didn’t realise till I went out to the garage was to create a ZEDBED........

Daffodils dying off and strawberries coming through ...

 

[t-tony]

Don’t eat those yellow strawberries though, what ever you do.

Tony.

 

[Mazza]

Sum total of todays effort.......masked and sprayed the discs.
Took off all the masking and left them in the kitchen all day to dry. Too cold out in the garage.

 

[t-tony]

Sum total of todays effort.......masked and sprayed the discs.
Took off all the masking and left them in the kitchen all day to dry. Too cold out in the garage.
View attachment 183321

You're not kidding mate, the heating is back on tonight. Like bloody winter outside.

Tony.

 

[ViperKen]

Sum total of todays effort.......masked and sprayed the discs.
Took off all the masking and left them in the kitchen all day to dry. Too cold out in the garage.
View attachment 183321

Not so cold here, but persisting down all day and tomorrow doesn't look much better !! might still get out for a sneaky drive though

 

[Mazza]

Not a lot done on my project today, other than I snapped the rusty horn brackets off to bin both horns.....( Andy.....more bits for the list )
The whole plug connector snapped off!!!!!

Then had a visit from New member Nick ( @Nickskip ) with a view to sorting out a stuck drivers seat......
Two and half hours it took to finally get the seat out of the car......rear bolts just visible......and the front nuts visible doing a head stand in the drivers footwell
I ended up grinding down an old imperial spanner to get access to the 13mm nuts and could move them a fraction at a time then turn the spanner round.....but, eventually the seat was out ......

Using my 2.8 battery I could move the seat on one side to get access to the T45 screw, took it out and pulled the rod out. Needs a clean but ok to reuse......the other side , could not move it and only access to the T45 was through the rear bolt hole. .....but the head of the torx bolt is too big........so only thing to do was file it out just enough to allow the bolt through it. Only about 1mm so wont affect the fixing bolt.

Then with my usual engineering skill, I finally removed the shaft, with a bloody great hammer ( not really Nick)

The cause of everything is the block has seized to the shaft.......

Will try and free it off but may be better to replace....have to wait and see on that.....

But ......having no drivers seat means the car cant be driven........so I have two silver 1.9’s outside the house
Mmmmm.......wonder if I need any spares ?


At least putting it back in wont be as long........

 

[ViperKen]

Not a lot done on my project today, other than I snapped the rusty horn brackets off to bin both horns.....( Andy.....more bits for the list )
The whole plug connector snapped off!!!!!
View attachment 183581

Then had a visit from New member Nick ( @Nickskip ) with a view to sorting out a stuck drivers seat......
Two and half hours it took to finally get the seat out of the car......rear bolts just visible......and the front nuts visible doing a head stand in the drivers footwell
I ended up grinding down an old imperial spanner to get access to the 13mm nuts and could move them a fraction at a time then turn the spanner round.....but, eventually the seat was out ......

Using my 2.8 battery I could move the seat on one side to get access to the T45 screw, took it out and pulled the rod out. Needs a clean but ok to reuse......the other side , could not move it and only access to the T45 was through the rear bolt hole. .....but the head of the torx bolt is too big........so only thing to do was file it out just enough to allow the bolt through it. Only about 1mm so wont affect the fixing bolt.
View attachment 183593
View attachment 183591

Then with my usual engineering skill, I finally removed the shaft, with a bloody great hammer ( not really Nick)
View attachment 183595

The cause of everything is the block has seized to the shaft.......

Will try and free it off but may be better to replace....have to wait and see on that.....

But ......having no drivers seat means the car cant be driven........so I have two silver 1.9’s outside the house
Mmmmm.......wonder if I need any spares ?


At least putting it back in wont be as long........

Forever the optimist !!