For the Love of my Zed! Novice vs Car

[buze]

@ZedHead, your welding doesn't look /too/ bad really,there are quite a few of these spot weld so its unlikely to fall immediately -mine was worse, and I drove it for a few months- you could definitely drive the car (just don't drive like crazy) to a garage.

I had mine done last year at my independant (he's in Langley), they drilled the existing spot welds, drilled some move, then actually made a double 'lip' of weld to cover all of the holes in the boot and underside.

 

[ZedHead]

So, today the welder guy came quoted and welded my car. £165 later and I think i would have enjoyed doing it myself given that it was hard to explain what i wanted and that a non gas mig welder costs around £150. Anyway I’m hoping the following is satisfactory to take additional stresses from stiffer poly diff bushes . . .

 

[ZedHead]

 

[buze]

Did they drill out before welding?

here's a pic of what mine looks like; I didn't take a pic underneath tho...

 

[ZedHead]

I also acquired a couple replacement bolts and washers for the diff and properly drained the diff oil . . .before i had just poured it out the side holes. Tip: make sure you buy washers before (don’t bother with bolts as mine came out fine, replaced them only cause i had them) and also ensure you can undo both top and bottom as you’ll have to replace the oil from the top one. Oil cost me around £120 from BMW but “its the same as they use in the M3 and it stops the wine”. The bolts are also bigger than comes with the Halfords 200 piece set (14mm) so had to order ratchet head separately. They were pretty stuck and as the diff was free, and I couldn’t with me sitting on it, i used a rubber hammer on the ratchet to crack the bolts.

 

[ZedHead]

Did they drill out before welding?

here's a pic of what mine looks like; I didn't take a pic underneath tho...

I have no idea, i was at work and used a few pics i got off the internet to describe what i wanted and why. I don’t think he had done this as he was ademate it was overkill, Bal bla and I’m assuming they weren’t drilled prior. As i said, I’m sure i could have given it a caring, meticulous go had i attempted it and would have enjoyed the process. No crying over spilt milk eh.

 

[ZedHead]

Here are the pics i used to describe the issue to the welder and other half . . .

 

[ZedHead]

 

[ZedHead]

When attempting to fit my poly bush to the diff I found that the bush was too thick by about the same thickness as the inner metal ring within the hole . . .i may have not taken the whole thing out as i assumed to was part of the diff, no wonder the rubber was so stubbornly stuck and required electrical wire brushing! I’m have to do a little digging and take some pics to show you what i mean . . .

 

[ZedHead]

 

[ZedHead]

That ring is just too conveniently the same size as the bush . . .shall i whack it?

 

[ZedHead]

Anyone got a pic of a clean bore of a diff bush hole . . .ha

 

[Mazza]

120.00 for oil !! I was moaning at paying £ 55.93 from Opie Oils for Fuchs Gearbox and Diff oils. ( two litres of each) Mind you, as mine it the 1.9, I could have probably used Tesco Vegetable Oil

 

[ZedHead]

So i need to get an action plan together before i loose momentum, plan to fail, fail to plan and all that. Ive isolated a few bolts and hangers which require some tlc and the next step is getting rust dirty and going below the car for some rust falling in the face extra fun!. I tried the brake hose tool and I’m surprised at how easy it was . . .just don’t forget to put a screw thingy on first. I know I’m going to forget one. Ive also got to remove wheel arch plastic and check sills for rust, clean out debris which gets stuck up all in there.

PS. 5 days later and I’ve still got a body covered in POR15 black splashes and touches so I’m sure this stuff will stick to metal!

 

[Jack Ratt]

That ring is just too conveniently the same size as the bush . . .shall i whack it?

Looks like you've left the ring in the casting from the old bush. You will need to remove that ring and your bush will slide in. Just cut through with a hacksaw and prise it out.

 

[ZedHead]

120.00 for oil !! I was moaning at paying £ 55.93 from Opie Oils for Fuchs Gearbox and Diff oils. ( two litres of each) Mind you, as mine it the 1.9, I could have probably used Tesco Vegetable Oil

I know, i was like, chuck me in a bit of oil . . .HOW MUCH, gulp, this might be the rest of its lifetime oil

 

[ZedHead]

So, as my coolant dripped out onto the floor and I’ve mow decided once the rear is done to move onto the from coolant system, and while I’m there do a manifold upgrade . . .and that I’ve got an issue with the exhaust manifold and a rusty exhaust (phew £££) . . .check this video out . . .

View: https://youtu.be/VH2N44N0WGs

 

[Mazza]

That ring is just too conveniently the same size as the bush . . .shall i whack it?

Whacking stuff is never a good option. If it needs pressure to push it in then two bits of wood and a G clamp would be a better idea.

BUT
Can you freeze the polybush to shrink it.???
And...are they supposed to be greased up all over???

I’m sure someone will enlighten us !

 

[ZedHead]

Box of bits for a little wire brush tlc and prop shift while Imetak doing it and have left over paint

 

[ZedHead]