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Repair of the ground off baffle rivet. I drilled through the stump with a 4mm bit and then popped a thread in there with a 5mm tap. You can see where the screw comes out the side of the sump. I guess it is better to have it go all the way through, seal it with some RTV but be able to inspect it to see if it is working loose rather than do a shallow tap and find out it has worked loose when if punches a hole in the engine
Operated by: Kinetic Melbourne
Built in: 02-2009
Manufacturer: Designline
Model: ?
(Chassis): MAN 16.240
Notes: ex-TransDev
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642 seen on Sunbury Line rail replacement shuttle at Sunshine Station.
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First of 15 polished up rocker cover fasteners and washers next to an unfinished one. They look better in the flesh as the flash shows up all the scratching around the hex part pretty badly
All cleaned up. the white residue is where I soaked it in washing powder to help break the oil down. it will get a good rinse out before it goes back on the engine
Rocker cover after a few coats of VHT satin black. It's not perfect but much better than it was. I've already managed to chip a little bit as it's not had the full heat curing yet which is a bit annoying
This is how I think the hand brake shoes, springs and original parts will fit together. I suspect the retaining springs should go the other way round to prevent the adjuster fouling, but then the lengths plus photos suggest this is correct.
Just need to sort out the cable now
Operated by: SkyBus Melbourne - powered by Kinetic
Built in: 02-2019
Manufacturer: Volgren
Model: Optimus
(Chassis): MAN 19.320
Notes:
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218 on the value carpark shuttle
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getting some of the rear loom out was a bit of a pig as was removing the rear seat back. I pulled the door card off as I've never been able to open the back door due to the central locking. this didn't help as I still couldn't get at the lock
N/S of block painted up.
Next thing to do is get the sump off and cleaned up then the engine should essentially be ready to drop in the car.
At the same time as getting my wheels done I got them to dip my rocker cover to remove the paint.
I had hoped to have bare metal but the primer coat has remained. All the scum you can still see it easy to pull/scrape off
Final push on the donor car today. Cut out some pesky pieces of carpet and removed the heater to allow the O/S bits of loom out (hence coolant on the floor)
I'm still not convinced I should have wasted time on this but it could help as a reference when I'm struggling to figure out how to get tthe sportster wired up again.
It'll just bee thrown in a large box and filed away until I need it
VANOS solenoid cleaned, polished and re-installed. I didn't bother with a new O-Ring as they cost about £10 each which is a tad steep and there was no evidence of a leak anyway.
I've also cleaned up the cam position sensor and reinstalled (black thing behind) and wirebrushed the engine lifting bracket and re-installed
Popped the sump off today for its cleanup
The engine bottom has a bit more baked on oily stuff than I'd expected. I may take off the oil pump pick up and then that baffle plate to clean up and carefully wipe the scum off the pump.
As that's about all I can do for the moment I may just use a flushing oil once I've run it again for the first time even though every one says not to on old engines
Rocker cover seals positioned on top of the engine - outer seal and the pair for the spark plug holes.
IVA test day is tomorrow. I've hired a trailer from a different place to when I took the car for its mini MOT and this one is a much more sensible size. Still 3 foot longer than it needs to be though.
Despite thinking I had nothing left to do, when I went to turn the car around in the road it took a 7 point turn due to the steering rack limiters I installed. In my view this made the car unsafe for the road as you'd struggle to turn through tight bends or make it round a mini roundabout in one move. I figured the examiner would take the same view so set to work modifying them. I was able to chop them down to just 2cm before any issue with fouling of the wheels so I can only assume that my suspension setup modifications have had an impact on clearance. It felt much better when I took it back out to place on the trailer. It was a good job I took two days off to cover any unexpected last minute work.
The battery is on charge over night, the tank is full of fuel and the tow car is jammed full of tools, spares, documentation and can of spare fuel. All I need to do now is wake up on time (5am) and not forget my sandwiches!
baffle refitted with the new screw. this will all come out again as a I still need to spend tomorrow evening sanding and polishing the outside before washing again and then reinstalling back on the engine
inside of the sump. Again, as this is where the oil sits I'd not expected to find any caked on stuff
Kitchen. The food was buffet, a satisfying selection and it's all inclusive (inc. all tips and alch. beverages too!)
IVA test day is tomorrow. I've hired a trailer from a different place to when I took the car for its mini MOT and this one is a much more sensible size. Still 3 foot longer than it needs to be though.
Despite thinking I had nothing left to do, when I went to turn the car around in the road it took a 7 point turn due to the steering rack limiters I installed. In my view this made the car unsafe for the road as you'd struggle to turn through tight bends or make it round a mini roundabout in one move. I figured the examiner would take the same view so set to work modifying them. I was able to chop them down to just 2cm before any issue with fouling of the wheels so I can only assume that my suspension setup modifications have had an impact on clearance. It felt much better when I took it back out to place on the trailer. It was a good job I took two days off to cover any unexpected last minute work.
The battery is on charge over night, the tank is full of fuel and the tow car is jammed full of tools, spares, documentation and can of spare fuel. All I need to do now is wake up on time (5am) and not forget my sandwiches!
Managed to borrow a super size 300ftlb torque wrench from a mate in work tonight so got the front hub nuts tightened and staked down. Still need to buy some dust caps to go over the top but that can wait for the moment.
215ftlb turned out to be only a little more than the 150 I put in already so in future I'll just go for that approach.
out with the 3-legged pullers again. popped a couple of coins over the bush to give a point to press against. You can see that it is pushing just the rubber bit out when I actually need it all to come out
Post de-rusting and a wirebrush drilling
it doesn't look like they were properly installed as that ali/some other metal flange should be tight against the arm
Spend this evening finishing my wire brush butchering of the outside of the sump to remove as much oxide as possible. I then moved on to grinding off the rivet holding the baffle plate in place inside the sump
the case for the bush was made of some very soft metal, not sure what but it was bending rather than moving so I popped my hacksaw through the hole and cut two groves allowing me to tap this strip out. once the tension was gone the rest came out easy
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