Yes Malc.
Bognor Lean-to Project
- Thread starter Mazza
- Start date
Some success today but 3 minor setbacks........
Started by getting the beam free....trailing arm nuts and bolts were fairly easy to undo, and the 4 diff ones were a doddle
Anti roll bar bracket bolts were crap...but again no match for the ‘supersockets’
The only other issue was the exhaust hanger bracket, totally shot and the nut was rounded.....so out came the grip sockets again
Result...malc 1 - 0 Beam
Next undid the 6 Torx bolts and either side of the diff.....no problem this time..I remembered to crack them loose when it was on the car and before I undid the handbrake
So on to each of the trailing arms......then things didn’t go acording to plan
Had to cut off most of the brackets and brake lines due to rust and worn parts.....not too worried other than I clipped the trailjng arm with the angle grinder......(still a bit of weld will sort that
But one bolt sheared on the hub....
And the sensor broke off....had to use a socket to remove the screw....
But the sensor broke when I was trying to wiggle it
Just hope it can be drilled out ....?
And the last thing to defeat me was one of the hand brake cable would not push out from the trailing arm, and not being able to hit it square on, decided to leave it until the hub is removed.
But the next stage is to get this lot shot blasted and powder coated, new bearings, new back plates, new bushes all round
Then I will need to get all the new brackets, clips, sensors, cables, nuts, bolts etc etc and on and on
Started by getting the beam free....trailing arm nuts and bolts were fairly easy to undo, and the 4 diff ones were a doddle
Anti roll bar bracket bolts were crap...but again no match for the ‘supersockets’
The only other issue was the exhaust hanger bracket, totally shot and the nut was rounded.....so out came the grip sockets again
Result...malc 1 - 0 Beam
Next undid the 6 Torx bolts and either side of the diff.....no problem this time..I remembered to crack them loose when it was on the car and before I undid the handbrake
So on to each of the trailing arms......then things didn’t go acording to plan
Had to cut off most of the brackets and brake lines due to rust and worn parts.....not too worried other than I clipped the trailjng arm with the angle grinder......(still a bit of weld will sort that
But one bolt sheared on the hub....
And the sensor broke off....had to use a socket to remove the screw....
But the sensor broke when I was trying to wiggle it
Just hope it can be drilled out ....?
And the last thing to defeat me was one of the hand brake cable would not push out from the trailing arm, and not being able to hit it square on, decided to leave it until the hub is removed.
But the next stage is to get this lot shot blasted and powder coated, new bearings, new back plates, new bushes all round
Then I will need to get all the new brackets, clips, sensors, cables, nuts, bolts etc etc and on and on
ABS sensor screw is easy once the shaft is out of the hub as you can drill straight through and tap out the hole. The sensor itself is easy to remove by drilling the centre out and chipping the rest out it's just plastic and copper wire.
Tony.
Tony.
I’m sure Lee will find the information useful....
.
Last edited:
Catch plate?..you mean the plates held by the screws of doom ??? If so, I found a similar shape of bolt M8 x 25 with std hex flange head ( none of that recessed crap !!! ). I cant remember who’s make but I will have to get 20, ......ViperKen wants 4, so you can have 8. That will leave me with four for when I do the next one
edit..... I found a picture on my phone of the comparison
edit..... I found a picture on my phone of the comparison
Last edited:
Unfortunately those household tasks got in the way of much progress today...ie grass cutting , beer drinking...
But I did get everything together ready to make a delivery to ZSHQ.......
One thing I needed to do was to remove the cover from the diff so a new bush can be installed..
The main bolts looked a bit crap but infact were fine and can be reused with just a bit of clean and just dip the heads in some rust treatment.
The sensor itself is ok...might replace the o ring, but one of the nuts needed a helping hand by ‘super-socket’ ( love those extractors) and the plate was in a bad way so another one to go on the list.....
Meanwhile With the cover off, I got a view of Narnia.....have no idea what goes on in there but it all looks jolly interesting...
The only thing I know is that you don't want metal swarf......and there isn’t any.....
so thats the limit of my knowledge.
Last time I had a bush fitted in the diff, it was done at ZSHQ and Lee was really careful in cutting through the steel band in order to remove it without damaging the casting.......( and yes ....I just stood there and watched !!!!!), so this time I thought I would do it....
I did cut out all the rubber .....but it to be honest I dont think it would have taken much effort to actually push all the rubber out as most of it had separated from the steel band.
Then very carefully cut across the steel ring..at the thicker part of the casting ( I remembered!!!) , then after getting nearly through, moved further round the ring and used a round file this time.....just before breaking through the steel gave it a whack ( not too hard) with a hammer and chisel which luckily broke it through, then twisted it a couple of times with some pliers and it broke on the saw cut......the rest of the ring then just pushed out
And no damage to the casting, which had a dunk in the parts cleaner to take off the worst of the dirt.
Next job I suppose will be to clean , treat and paint all the rear end.......only because I dont want to have to sort the two exhaust flanges yet..cant believe I’d rather do cleaning...
But I did get everything together ready to make a delivery to ZSHQ.......
One thing I needed to do was to remove the cover from the diff so a new bush can be installed..
The main bolts looked a bit crap but infact were fine and can be reused with just a bit of clean and just dip the heads in some rust treatment.
The sensor itself is ok...might replace the o ring, but one of the nuts needed a helping hand by ‘super-socket’ ( love those extractors
) and the plate was in a bad way so another one to go on the list.....Meanwhile With the cover off, I got a view of Narnia.....have no idea what goes on in there but it all looks jolly interesting...
The only thing I know is that you don't want metal swarf......and there isn’t any.....
so thats the limit of my knowledge.
Last time I had a bush fitted in the diff, it was done at ZSHQ and Lee was really careful in cutting through the steel band in order to remove it without damaging the casting.......( and yes ....I just stood there and watched !!!!!), so this time I thought I would do it....
I did cut out all the rubber .....but it to be honest I dont think it would have taken much effort to actually push all the rubber out as most of it had separated from the steel band.
Then very carefully cut across the steel ring..at the thicker part of the casting ( I remembered!!!) , then after getting nearly through, moved further round the ring and used a round file this time.....just before breaking through the steel gave it a whack ( not too hard) with a hammer and chisel which luckily broke it through, then twisted it a couple of times with some pliers and it broke on the saw cut......the rest of the ring then just pushed out
And no damage to the casting
, which had a dunk in the parts cleaner to take off the worst of the dirt.Next job I suppose will be to clean , treat and paint all the rear end.......only because I dont want to have to sort the two exhaust flanges yet..cant believe I’d rather do cleaning...
Today was a trip to ZSHQ....meeting at the Breakfast stop ......One Huge Breakfast Baguette later drove to HQ......
Shed extension in place, Trev reversed his Z3 in to do some work swapping over a clock with Paul....so the centre console had to be removed ...so left them to get on with it.......
First thing for me to do was get the beam out of the back of my car and so the bushes could be removed.....unfortunately ......thats as far as it got ......Condemned......Due to too much surface corrosion around the diff housing area...so scrapped
I carried it out and laid it to rest on Lees’ scrap pile
meanwhile, Lee and Gaz started to strip down the Near Side trailing arm In readiness for shot blasting and powder coating.
Lots of big extractors and clever bits of kit....and about 20 minutes later, it was all apart.....I even got to play
That was the good bit......then I pointed out there was a small rust hole in the dome where the spring would sit....
With that, Gaz ( or Iron Man as I like to call him ) , managed to turn a small hole into a massive slot with just his thumb....
So on further inspection.... .....Scrapped, But then Lee produced a Powder Coated pristine one .....so saved..
But another walk of shame to the scrap pile
By this time I dreaded to give them the other one.....but it was duly stripped down ( even removing the old handbrake cable and ABS sensor that were both stuck and I couldn’t shift.)....Annoyingly, Gaz and Lee had then out in seconds
BUT........Lee found the arm was thin in various areas and was not sure how it would stand up to shot blasting......
So an executive decision was made.......and after a quick call to Andy (SFIAC) .........SCRAPPED
This is going well !!!!!!!!
........but there are positives....I wont be putting a load a dodgy components into the car, and I learned how to strip them down
Meanwhile..outside......How’s it going Paul?
Not having anything else of mine they could bin, Lee and Gaz stripped down a drive shaft from the \\\M that is currently being worked on. New rubber boots, end caps, cleaned and repacked with grease.....
I cant say what was being said at this point......far too rude
First one done......just one more to do.....but later on, as I wanted to see some already powder coated parts , especially the spare wheel cage as I had binned mine.......and I now have a new cage....
By the way...........All ok Paul????
Does that mean just one wire to do?..
Still, despite the setbacks on the parts, .....it was great fun, I learned loads, including a demo on making brake lines, which I will have to do on mine. Had loads of questions answered, which gives me the confidence to keep going with the build, Got some great tips from Trev and Paul on relocating switches on the centre console ( which I will blatantly be copying)
Thanks to Lee, Gaz, Trev and Paul
Looking forward to my next visit........
Shed extension in place, Trev reversed his Z3 in to do some work swapping over a clock with Paul....so the centre console had to be removed ...so left them to get on with it
.......First thing for me to do was get the beam out of the back of my car and so the bushes could be removed.....unfortunately ......thats as far as it got ......Condemned......Due to too much surface corrosion around the diff housing area...so scrapped
I carried it out and laid it to rest on Lees’ scrap pile
meanwhile, Lee and Gaz started to strip down the Near Side trailing arm In readiness for shot blasting and powder coating.
Lots of big extractors and clever bits of kit....and about 20 minutes later, it was all apart.....I even got to play
That was the good bit......then I pointed out there was a small rust hole in the dome where the spring would sit....
With that, Gaz ( or Iron Man as I like to call him ) , managed to turn a small hole into a massive slot with just his thumb....
So on further inspection.... .....Scrapped
, But then Lee produced a Powder Coated pristine one .....so saved..But another walk of shame to the scrap pile
By this time I dreaded to give them the other one.....but it was duly stripped down ( even removing the old handbrake cable and ABS sensor that were both stuck and I couldn’t shift.)....Annoyingly, Gaz and Lee had then out in seconds
BUT........Lee found the arm was thin in various areas and was not sure how it would stand up to shot blasting......
So an executive decision was made.......and after a quick call to Andy (SFIAC) .........SCRAPPED
This is going well !!!!!!!!
........but there are positives....I wont be putting a load a dodgy components into the car, and I learned how to strip them down
Meanwhile..outside......How’s it going Paul?
Not having anything else of mine they could bin, Lee and Gaz stripped down a drive shaft from the \\\M that is currently being worked on. New rubber boots, end caps, cleaned and repacked with grease.....
I cant say what was being said at this point......far too rude
First one done......just one more to do.....but later on, as I wanted to see some already powder coated parts , especially the spare wheel cage as I had binned mine.......and I now have a new cage....
By the way...........All ok Paul????
Does that mean just one wire to do?..
Still, despite the setbacks on the parts, .....it was great fun, I learned loads, including a demo on making brake lines, which I will have to do on mine. Had loads of questions answered, which gives me the confidence to keep going with the build, Got some great tips from Trev and Paul on relocating switches on the centre console ( which I will blatantly be copying
)Thanks to Lee, Gaz, Trev and Paul
Looking forward to my next visit........
Last edited:
Shame about the rear beam Malc but there’s some on eBay. You can get the repair panels for the trailing arms perch but a sound arm better though.
They were all on the limit....and I already had my own concerns about if they would be ok, and Lee and Gaz just confirmed it and pointed out other areas that would also be an issue on them.
So not worth the risk to use them. Hopefully sourced replacements already.
Last edited:
And they say you can't teach an old dog new tricks Malc. Load of cobblers I'm still learning .....................Today was a trip to ZSHQ....meeting at the Breakfast stop ......One Huge Breakfast Baguette later drove to HQ......
View attachment 178073
Shed extension in place, Trev reversed his Z3 in to do some work swapping over a clock with Paul....so the centre console had to be removed ...so left them to get on with it
View attachment 178093
First thing for me to do was get the beam out of the back of my car and so the bushes could be removed.....unfortunately ......thats as far as it got ......Condemned......Due to too much surface corrosion around the diff housing area...so scrapped
I carried it out and laid it to rest on Lees’ scrap pile
meanwhile, Lee and Gaz started to strip down the Near Side trailing arm In readiness for shot blasting and powder coating.
Lots of big extractors and clever bits of kit....and about 20 minutes later, it was all apart.....I even got to play
That was the good bit......then I pointed out there was a small rust hole in the dome where the spring would sit....
With that, Gaz ( or Iron Man as I like to call him ) , managed to turn a small hole into a massive slot with just his thumb....
So on further inspection.... .....Scrapped
But another walk of shame to the scrap pile
View attachment 178095
By this time I dreaded give them the other one.....but it was duly stripped down ( even removing the old handbrake cable and ABS sensor that were both stuck and I couldn’t shift.)....Annoyingly, Gaz and Lee had then out in seconds
BUT........Lee found the arm was thin in various areas and was not sure how it would stand up to shot blasting......
View attachment 178097
So an executive decision was made.......and after a quick call to Andy (SFIAC) .........SCRAPPED
This is going well !!!!!!!!
........but there are positives....I wont be putting a load a dodgy components into the car, and I learned how to strip them down
Meanwhile..outside......How’s it going Paul? View attachment 178105
Not having anything else of mine they could bin, Lee and Gaz stripped down a drive shaft from the \\\M that is currently being worked on. New rubber boots, end caps, cleaned and repacked with grease.....
View attachment 178101
View attachment 178099
I cant say what was being said at this point......far too rude
View attachment 178103
First one done......just one more to do.....but later on, as I wanted to see some already powder coated parts , especially the spare wheel cage as I had binned mine.......and I now have a new cage....
By the way...........All ok Paul????
View attachment 178107
Does that mean just one wire to do?..
Still, despite the setbacks on the parts, .....it was great fun, I learned loads, including a demo on making brake lines, which I will have to do on mine. Had loads of questions answered, which gives me the confidence to keep going with the build, Got some great tips from Trev and Paul on relocating switches on the centre console ( which I will blatantly be copying
Thanks to Lee, Gaz, Trev and Paul
Looking forward to my next visit........
Tony.
Part of the Mary Rose anchor?
The entrance to the storage of the zedshed HQ. Be hobbits in that there space.
.
Last edited:
Not been doing much...since the beam and trailings arms were condemned, but nearly back on track now, as just the O/S trailing arm to get now.. a couple of possibilities located just waiting for pictures to check out condition before deciding on which to get.
Just a gentle reintroduction today.....turned the key on the roof pump, and manually raised the roof, to get to the top of the shocks....
Fairly tidy will need a wipe over....
Dont think these are much use
and then did some cleaning
Not too bad this side ....just a bit of surface rust to treat
But not so good on other side.....
I dont think that hole should be there
Fortunately the spring plate below is solid,
And dont think there should be sunlight shining through from the boot!!!!!
From inside the boot you can see the little hole
a little bit of MIG welding called for........( search ....mobile welders in west sussex !!!)
Onwards and upwards !!!!
Just a gentle reintroduction today.....turned the key on the roof pump, and manually raised the roof, to get to the top of the shocks....
Fairly tidy will need a wipe over....
Dont think these are much use
and then did some cleaning
Not too bad this side ....just a bit of surface rust to treat
But not so good on other side.....
I dont think that hole should be there
Fortunately the spring plate below is solid,
And dont think there should be sunlight shining through from the boot!!!!!
From inside the boot you can see the little hole
a little bit of MIG welding called for........( search ....mobile welders in west sussex !!!)
Onwards and upwards !!!!
Another day......
First thing I spot is the shock....overnight its expanded....great, ......might be able to reuse that one
Might as well remove the tank straps, as they aren’t really supporting anything....
Now.....they are two parts that I do know how to fix
After having a general look see underneath......I don't know what came over me........I thought to myself.....that would be a good idea....and unfortunately there was no one around to say ‘ you dopey sod, don't take anything else off ‘ .........so if you ever get to this stage and you are as dopey as me............here is a ‘how to’.....as in remove the fuel tank........
Firstly.....
Inside the car, undo the four screws that hold the panel and disconnect the plug. The outer part of the plug slides back which then allows the plug to be pulled off
Then remove the rubber gaiter from the neck of the tank....
Then underneath........
Red arrow......disconnect the wiring
Black arrow disconnect the line from the filter ....pulls off but bloody difficult ( there are two o rings that may need replacing)
Blue arrow. Take the cover off to allow the pipes to be dropped down. It gives more room to disconnect from tank lines
Yellow arrow, disconnect two jubilee clips, and pull the joints apart. There is a bit of fuel loss but nothing much.
In hindsight, at this stage I should have undone the two bolts that hold the filter ( green arrow) and gone underneath and unbolted the centre support on the propshaft. ( white arrow)......its easier if they are out of the way.....( I moved them after realising The tank was stuck
Then the main bolt.....
Then it falls on you.......
Now there is lots of access to get in to clean and treat all the difficult bits
The tank does look pretty shabby........but what have I got in my shed....
Its the one I bought when developing the tank straps......so may as well use it
And I have a pile of bits that @Lee might just find outside his front door in the next day or so
And many thanks to Mark ( @Althulas ) for finding me a local mobile welder on FB, who I called today to see about the welding repair.
Now I have cleany cleany, painty painty, stuff to do................but probably not till saturday....
First thing I spot is the shock....overnight its expanded....great, ......might be able to reuse that one
Might as well remove the tank straps, as they aren’t really supporting anything....
Now.....they are two parts that I do know how to fix
After having a general look see underneath......I don't know what came over me........I thought to myself.....that would be a good idea....and unfortunately there was no one around to say ‘ you dopey sod, don't take anything else off ‘ .........so if you ever get to this stage and you are as dopey as me............here is a ‘how to’.....as in remove the fuel tank........
Firstly.....
Inside the car, undo the four screws that hold the panel and disconnect the plug. The outer part of the plug slides back which then allows the plug to be pulled off
Then remove the rubber gaiter from the neck of the tank....
Then underneath........
Red arrow......disconnect the wiring
Black arrow disconnect the line from the filter ....pulls off but bloody difficult ( there are two o rings that may need replacing)
Blue arrow. Take the cover off to allow the pipes to be dropped down. It gives more room to disconnect from tank lines
Yellow arrow, disconnect two jubilee clips, and pull the joints apart. There is a bit of fuel loss but nothing much.
In hindsight, at this stage I should have undone the two bolts that hold the filter ( green arrow) and gone underneath and unbolted the centre support on the propshaft. ( white arrow)......its easier if they are out of the way.....( I moved them after realising The tank was stuck
Then the main bolt.....
Then it falls on you.......
Now there is lots of access to get in to clean and treat all the difficult bits
The tank does look pretty shabby........but what have I got in my shed....
Its the one I bought when developing the tank straps......so may as well use it
And I have a pile of bits that @Lee might just find outside his front door in the next day or so
And many thanks to Mark ( @Althulas ) for finding me a local mobile welder on FB, who I called today to see about the welding repair.
Now I have cleany cleany, painty painty, stuff to do........
........but probably not till saturday....
Grand job Malc, don’t forget to make sure the drain on the filler neck gaiter is clear while it’s off.
Tony.
Tony.