Bognor Lean-to Project

[Lee]

I’ve changed your name in my phone to Mr Strap and your picture is Ron Jeremy now.

 

[BillH]

It must be like looking in the mirror good meeting you guys And thanks for demonstrating your sticky tyres @Lee

 

[t-tony]

Today was one of those days that just make you smile ...... what a fun day......

And a bit of a thread cross over, where I go from ‘Lean to Supremo’ to Zedshed HQ minion.....

The day started with an easy run to the Basingstoke Breakfast Bar....(for my usual Bagette with everything in it .)
...and met up with all going to the Shed. Nice to meet a new face @BillH

Once at the ZSHQ, I was first on the list , to build up the trailing arms.
First job was for Lee and Gaz to clean the inside face as it had been powder coated ( not normally done ) but didn't take long to sort out.
View attachment 184937

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I would have helped but dont like to slow them down , and I had to record the moment !!!!!

Once cleaned ....and with a few big boy tools .....Bearing was installed.
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This is THE tool......
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The Nugga Nugga gun.......not for use by old people and it loosen your fillings.........

Then inserted the arm Bushes......and they made me do that..( but under supervision) ....no respect for age in the shed.......
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Then the back plate, and Luckily Gaz found 4 little bolts in their stock of fixings, as the new ones I had bought were wrong and did not fit. ( sort that out with the Dealer on tuesday !!!)
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Followed by the hub, the brake cable and shoes
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Then after checking and cleaning the spines of the drive shaft, that was installed, as was the rear disc so the hand brake shoes could be set up .......and then the whole lot was repeated for the other side.......

Amazing to see how quickly this assembly went together...and with all the newly powder coated parts....they just look brand new.
Forgot to take pictures of the last bits but took this one when I put them in the garage at home
View attachment 184951
So one very happy bunny

I also picked up various other bits that had been powder coated as well, front springs , hubs, ARB, spring plates etc...
All look brilliant.

So then attention turned to Bill’s ///M and refitting the rear end ......of which my only input was to hand them nuts and bolts and man the trolley jack at the final lift......cant be trusted to do much more

I had to go then, as I needed to do a slight detour to call in on Andy (@spurs fan in a coupe ) to collect some parts which he had sorted out fo me. Again really lucky as he could supply everything that I had listed to him earlier in the week.
a ONE STOP SHOP for Z3 parts

oh, and Paul ( @pgunter ) , I picked up a couple of relays for you to try....I’ll bring them up to ZSHQ in a couple of weeks when the front shocks have arrived and I need to get the springs installed. ( and bring more doughnuts )

Then a drive back home.....to find a package on the mat.....
The smog filter repair plate c/w bolts from Tony (@t-tony )
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This blanks off the hole after the smog filter removed. So much better than if I had tried to make one.
Thanks Tony .

So that was the day...all very positive and great fun
..........even if Lee thought I looked like 70’s Porn Star Ron Jeremy......and No I’m not changing my forum name to Mr Strap!!!!!!!

Must be something going around Malc, I too have grown a top lip beer filter and strangely 2 of Shirl's mates have quoted "I see he's got a 70's porn star 'Tache". Hmmmm.

Tony.

 

[GazHyde]

"I see he's got a 70's porn star 'Tache".

I’ll help you out with the correct term…

 

[t-tony]

I thought that was what you found under your big brother’s bed. . . . . . .

Tony.

 

[gookah]

I thought that was what you found under your big brother’s bed. . . . . . .

Tony.

That's what your little brother said

 

[Mazza]

Just as well I didn’t mention yesterday that it was much easier when Gaz lubricated the holes with his finger.....if made it much easier to push them in....

Oooops ! Forgot about Siri dictation

 

[t-tony]

That's what your little brother said

I was going to say Dad’s bed, but then I thought that might rattle David’s cage

Tony.

 

[t-tony]

Anyway, my gorgeous Granddaughter told me today that she doesn't like Grandads "beard" so it's gone now and I'm back into the 2,020s.

Tony.

 

[Mazza]

........painting......

First coat.......oh crap..... got to do it all again!!!

Still..........no chance of it collapsing under the weight ... ( @Oldguysrule )

( that will cost me at the breakfast bar next time I’m up)

Another little job....
Replacing the stud where I had some welding done.....

stuck on some masking tape in the area

installed the bracket on the other two studs, and marked where the stud should go

Pilot hole, then a 6mm hole
And new bolt with a square nut which sits in the recess of the bracket but still allows adjustment.

and just checked with bracket in place

dismantled it to red oxide the hole and also need a square hole just above it.
( this is the other side)

but need the wheel arch liner installed to show the position........
And where is it.......at the bottom of this lot...

So it can wait .....

Got to put a starter motor in a granddaughters’ fiesta....once it arrives......I’m sure that will be fun
At this point I have no idea even where it’s located on the car..... some where at the front end I suppose

 

[Mazza]

Not a lot being done......
But had a jiffy bag from Sopers arrive this morning with lots of little bits in.....so now just waiting for the box of stuff from Autodoc. oh yes, and also a box of various size rivnuts. Need to sort out various fixings where welded studs have not survived, so will use rivnuts instead......more on that later.......

Callipers painted and ready for assembly....( when the autodoc box arrives )

New ( or replacement horns ) from Andy. In their new livery
He said they worked but I did try them with the battery.... seem to be a lot louder than those on my 1.9

Worse part about today........I didn't go to ZSHQ today and so didn’t get my breakfast bagette....

I wonder if they managed without me

 

[t-tony]

Those Rivnuts are a great thing. There are some great ways of fitting them on YouTube too.

Tony.

 

[Mazza]

Those Rivnuts are a great thing. There are some great ways of fitting them on YouTube too.

Tony.

Yes much easier to insert and will work just as well. ( just use a bolt instead of a nut )
Plus , The rivstuds need an expensive special tool to install them.

 

[Mazza]

Just 5 hours of mind numbimg boring stuff .......

Set up the front offside wheel arch cover to mark the missing square body nut hole.
Masked up the area, used the cover as a template , then pilot hole and drilled a 6.5mm hole , the filed it out to 7mm square

The nylon insert fits ok and will just need a tap to push it home. But removed it to paint some redoxide and later it will be all undersealed and painted blue

Next was the broken bolt on the cross beam ( one of the bolts that hold the cross brace)

So centre drilled ....drilled through it in stages using bigger and bigger drill bits, then tried the extractor........wouldn’t budge......and I didn’t want to snap the extractor .....so went for Plan B.....drilled it all out using a 7.5, then 8 mm drill bit.
Now just have to fit a helicoil.....

Not the best outcome but it could have been worse......

Then the dreaded exhaust.....

After lots of dremeling...hitting and swearing at it, got the front one separated...

Then lots more of the same......in equal measures....

Then just cut the studs down.....will remove those another day.....

And these broken studs will be drilled out and replaced by the rivnuts when they arrive

Glad that bits over.......

 

[Mazza]

As I had some parcels arrive today, I was able to get on with a couple of things.

A box of rivnuts and the M8 helicoil set.

First job was inserting the helicoil, not a lot to say really , just followed the instructions and the new bolt fitted

So onward to the broken studs at the back of the O/S wheel arch.

Cleaned the remnants of the studs off with a file, then centre popped the stud, and pilot hole and then. 6.5mm drill to give the rivnut a tight fit. ( had to gently tap it in )

Then using just a hex drive screw, a penny washer and a nut, tightened into the hole.

painted round the hole with red oxide before fixing it in……. This is when I got concerned as I could see daylight through the hole ???
It turns out that the other side of the panel is the footwell. And loads of wiring !!!!
Fortunately I didn’t hit anything but was close and may have only missed the loom as it’s been moved a bit when the carpet came out.
I pulled the loom away and drilled the hole for the second one and it went ok.

This is where they come through in the footwell, I had to clean away some of the insulation and painted them as well. When it’s dry I will make sure it’s well sealed before the carpet goes back.

The left hand one is close to the main thick positive cable and the right hand one is sitting in front of the main loom. ( which in the photo is the big one being held up in the air )
So worth remembering that there are cables there should anyone try this in the future!

Now they are done I can finish cleaning and painting the front wheel arches

 

[Mazza]

Just more bloody cleaning, treating , etc etc..
But also sorted out the cooling loop now I have the fixings

made sure it fitted properly… needed to straighten the lower bracket

then the old wire brush and rust treatment…will red oxide and repaint black later

But did go out in the other one for a bit
and a bit of care and attention under the bonnet.

It’s Looks like a shed……only without the skill and knowledge ….
still, Not bad for a Lean-to

also…..Had an email to say my Autodoc parcel is now in the U.K., cleared customs and should be with me by Friday.,..

Could it be a Basingstoke Breakfast on Saturday I hope so !!!!!
And I could get the front shocks assembled while I’m there

 

[IainP]

Not sure if the exhaust studs are the same as the 1.9, I was quoted an astronomical price by BMW. Bought stainless coach bolts from screw fix, cut to length, filed the holes to squares and mig’d in place with stainless wire.

 

[t-tony]

Why bother, nuts and bolts work just as well.

Tony.

 

[Mazza]

I still have to get the old ones out yet….but I will use bolts…. Just need to see how long they have to be.
Already got the proper copper nuts. ( from Sopers)

 

[t-tony]

Was going to say Malc, you need to be careful mate, while you're working in the shed some buggers having bits off the silver one on the drive

Tony.