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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Sep 05, 2017 9:39 pm 
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Put a SOC in it!
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Location: Fliptop Towers, North Yorks...the flat bit.
Car Model: One or two...
This one...it's been going so long and so sporadically that it pre-dates the projects section...

https://www.uksaabs.co.uk/UKS/viewtopic ... &start=160

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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Sep 07, 2017 7:29 pm 
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Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Thanks for digging that out Al. I think performance mods need to wait until the original planned jobs have all been done, but it's great to know the info is there
Over the last couple of days I've managed to strip most of the front driver's side suspension. Now have a problem getting the lower wishbone brackets off. The two inboard (closest to the centre-line of the car) nuts come off easy enough, but the two outboard nuts are so close to the inner wing I can't get a socket on. Any suggestions gratefully accepted - PLEASE

Drive shaft and hub removed. Freezer bag over the joint to prevent grease getting everywhere (and grit from getting in). CV joint gaitor looks like it wouldn't need much persuasion to split
Attachment:
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Upper wishbone cleaned up and given two coats of smooth hammerite
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Then brake caliper split, cleaned up and the frame parts given two coats of brake caliper paint
Attachment:
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Haven't painted the cylinder yet as I forgot to force the piston out before disconnecting the hydraulics, and don't want to scratch the paint while doing that. Will I be able to get that out with the air line? Again any suggestions gratefully accepted


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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Sep 07, 2017 7:48 pm 
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Joined: Sun Jul 29, 2007 9:32 pm
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Location: Bath/ Dublin
Car Model: 8V-V4
greg124 wrote:
I think performance mods need to wait until the original planned jobs have all been done
If only more people had that approach we certainly would see less projects getting abandoned.

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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 13, 2017 7:16 pm 
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Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
I think some people just get overwhelmed by the magnitude of the task, melle.

Since last week I've been mainly stripping more underseal, and dressing some of the old welding repairs with the angle grinder
Fancied a quieter task today though, as my ears were ringing for ages after 2 1/2 hours with the grinder yesterday - give the neighbours a rest too
Splashed the 'metal ready' about under some of the NSF inner wing, then applied tetrosyl seam sealer with a brush. I haven't used braushable before, but on a previous project the stuff in a gun kept blocking the nozzle if left for a couple of weeks.
Attachment:
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Then borrowed BIRDIEMANGO's recipe for Y9 yellow hammerite from his V3 project - thanks Jules. First attempt was still a bit orange, so adding a bit more white resulted in this
Attachment:
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As it's going under the wings (followed by a load of schutz) and on the floor (mostly hidden by carpets), I'm happy this is a close enough match
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This is just the first coat. Thought I'd do a fairly small area to start with, just in case there are any adverse chemical reactions between the different products


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 13, 2017 7:53 pm 
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Location: Bath/ Dublin
Car Model: 8V-V4
The yellow looks good a good match!

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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Sep 14, 2017 7:26 am 
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Location: Dunfermline
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Yeah looking good...

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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Sep 19, 2017 8:00 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
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Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Cheers guys
I'm pleased with the home blend yellow and now applied some under the other front wheelarch. Need to make up another batch to do the floor inside
Got the lower wishbone off now - without having to remove the brake master cylinder. Had a bit of a wrestle to get the brackets past the exhaust, as it is quite close to the bodywork. Removed the brackets, cleaned up the wishbone and applied etch
Then forced the caliper piston out with the air line. Good job too as one of the seals was in a pretty poor state

Edit ...and bought some sheet steel today. I can feel a bit of fabrication coming on


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Sep 26, 2017 7:13 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 252
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Dug the mig welder out yesterday, and the regulator which allows me to use a pub-size bottle of CO2, instead of one of those ridiculously small hobby ones that lasts about 20 minutes
...and this afternoon started cutting out rust
Attachment:
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Initially just cut out this slot, but on poking around with a screwdriver it soon became apparent that the whole of that bottom edge needed to come out. It was a nasty rust sandwich
Then came to start welding, and the welder wouldn't work, so had to have that apart
Attachment:
SDC13115.jpg
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Welder hadn't been used since I finished the Alvis bodywork 7 or 8 years ago, so the wire had started to rust. Trip to town to pick up a fresh role of wire and some tips wasted another hour
Finally got it all up together and welded the first repair section in
Attachment:
SDC13116.jpg
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Wasn't sure of the correct profile for the lower edge, as both sides have been repaired in the past. The part of the valance which comes down the other side of this repair, I've trimmed back so that it stops just as it goes vertical in an attempt to minimise a future rust trap


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Oct 04, 2017 9:58 am 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 252
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
A bit more cutting out grot and welding in new metal over the last week
Attachment:
SDC13119.jpg
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I thought this was a towing eye, but having read a thread on another forum, apparently they were tie-down points for when cars were being exported. More likely to be used to tie down on a transporter these days
Attachment:
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We weren't exactly in Flintstone territory here, and I really should have taken a 'before' photo before welding up the hole in the floor
Attachment:
SDC13121.jpg
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First attempts at drilling a couple of the stress relieving holes in the corners were met with little resistance. As this is so close to the spring top mount we need to be back to full thickness steel


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Oct 04, 2017 10:09 am 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 252
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Attachment:
SDC13122.jpg
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Attachment:
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This was quite a tricky little patch to shape, due to having curves close to the edges. And due to the position I couldn't get any clamps into place. Had to resort to a couple of magnets to hold it on place and then tack weld, and used feeler gauges to get the gap round the edge fairly even
Attachment:
SDC13124.jpg
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As this is close to the spring top mount I welded from both sides to ensure good penetration.


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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Oct 05, 2017 6:37 pm 
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Posts: 252
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
I'm very fortunate that there is someone in the village who will let me use some of his more specialist equipment. So pressing these wishbone bushes out was a doddle
Attachment:
SDC13125.jpg
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The new bushes have been in the freezer overnight so they contract slightly, and after a cleanup the wishbone brackets went in the oven on a low heat for half an hour to expand a little, before a quick squirt of wd40 then press in using an improvised (cobbled together) insertion tool
Attachment:
SDC13127.jpg
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Had to add an extra spacer (oversize bolt) to get them all the way home
Attachment:
SDC13126 (1).jpg
SDC13126 (1).jpg [ 278.88 KiB | Viewed 431 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Fri Oct 06, 2017 1:39 pm 
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Put a SOC in it!
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Joined: Mon Feb 07, 2005 4:48 pm
Posts: 21095
Location: Fliptop Towers, North Yorks...the flat bit.
Car Model: One or two...
Good work and excellent bodgery :haynes: :mrgreen:

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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Oct 10, 2017 7:05 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 252
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Cheers Al

Well a little more progress. This corner is now all welded up, etched, seam sealer-ed and two coats of home-blend hammerite

Attachment:
SDC13129.jpg
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Don't know what had gone on with those two areas near the front edge (done by/for a previous owner). A lot of pigeon-poo welding, yet the other side of the panel looks fine. Ground the worst of it off but it still looks a bit gash. Anyhow it's solid
Now I have to decide whether to go for a wax-based under body treatment or stonechip :?


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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Oct 14, 2017 5:47 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 252
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Decided on stonechip, and applied a couple of coats earlier in the week
The upper wishbone bushes I pressed in last work were plain sailing. No such luck with the larger lower wishbone bushes. One side would enter first and the other side get all chubby. No point trying to proceed after that point as it would only damage the bush
Figured that as I was winding the nut on it was applying more pressure to one side, so had a trip to Dave's to see if it was any easier in his press. No. Tried several times with same result :wall: :cen:
Had to send out for another bag of expletives. Ever had jobs you wish you'd never started...

Started thinking about some sort of tool to ensure that the bush was always kept in line, then stopped for a mug of tea
During which I thought about using a jubilee clip in much the same way as a piston ring compressor. Compress one end of the bush. Plenty of lube. Back in the press. Can push the bush about half way in before the jubilee clip fouls the press. Unscrew and extract the jubilee clip. Press the bush fully home. Bingo :D
Repeat for the other side. Return expletives to stores
Didn't think to take the camera with me, so sorry no pics of this bodging

The refurb'd wishbones and new bump stop went (back) on the car today

Attachment:
SDC13133.jpg
SDC13133.jpg [ 160.13 KiB | Viewed 318 times ]


Got to start looking for suitable spring compressors, as don't fancy using the same ones I took the springs out with. Very awkward and I wasn't confident they were safe


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 Post subject: Re: V4 Custardwagon
PostPosted: Sun Oct 15, 2017 8:05 pm 
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Put a SOC in it!
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Joined: Mon Feb 07, 2005 4:48 pm
Posts: 21095
Location: Fliptop Towers, North Yorks...the flat bit.
Car Model: One or two...
They're really not easy without the proper spring compressor, not least because of the "bend" that the springs get when pre-loaded on the car - that's why on the 99 & C900 the lower spring mount is on a swivel.

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 Post subject: Re: V4 Custardwagon
PostPosted: Mon Oct 16, 2017 11:32 am 
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Joined: Sun Jan 15, 2012 4:24 pm
Posts: 2607
Location: Dunfermline
Car Model: 10 cars
You got the proper spring compressor Al..? I'll borrow it 1 day :wink:

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 Post subject: Re: V4 Custardwagon
PostPosted: Mon Oct 16, 2017 1:33 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 252
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Just spent £80-odd on a set of Sykes Pickavant spring compressors, which were the only ones I could find long enough, and the hooks seat on the spring nicely, which gives me confidence. Money spent on good quality tools is never wasted
When taking the springs off the car I used a third (shorter) compressor to combat the 'bend'. I could do that again, but I've been thinking of using a piece of thick wall tube metal of the appropriate diameter, but in half, and attached to the compressors such that it can slide to the required position

Also, Steve at Malbrad gave me a tip for putting the springs back in - remove the lower bump stops to make a little more room


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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Oct 21, 2017 4:14 pm 
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Joined: Fri Oct 14, 2005 9:03 am
Posts: 10
Location: mid Wales
Car Model: 1972 96V4
looking good
Keep up the good work!


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 Post subject: Re: V4 Custardwagon
PostPosted: Sun Oct 22, 2017 11:47 am 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 252
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Cheers restoman

Spring is back in! I can recommend the Sykes Pickavant spring compressor part no. 08380000. It gave me confidence that I wasn't going to lose any body parts (either mine or the cars) and I didn't experience the usual bending problem, these are road springs, not competition springs though. However, when the spring is back on the car, even with the suspension left dangling the spring is under some compression, so it's a bit of a fiddle to get the compressors off. I was expecting for some of the hammerite to be scratched off by the compressors, which OK as it's easy to touch up. Unfortunately I took a small patch of stone chip off as well... :cen:

Having removed the lower bump stops to make a little more space, to get them back in I used the old windscreen rubber insertion trick - Wrapped a piece of string around the 'waist', popped both ends of the string through the hole in their mounting bracket, apply WD40, lowered the wishbone a little to apply some pressure - but not too much, then gently pull the string. Went back in a treat

Just got to swap the track rod end and rebuild the caliper and that's this side done. Having learned a few tricks and techniques on side one, side two SHOULD go a bit more smoothly. Think I'll then take a small break from the Custardwagon and give the rest of the fleet a little attention - one needs a service, one is nearly due it's MOT and the other needs the advisories attending to, so the spanners won't be idle


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Nov 08, 2017 8:05 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 252
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Everything went back together a couple of weeks ago
Attachment:
SDC13139.jpg
SDC13139.jpg [ 186.78 KiB | Viewed 65 times ]

New wishbone bushes, ball joints, track rod end, polybushes for the ARB (they seem to be the only type available), Monroe shocker with new bushes (I wasn't happy with the paint on this so it had a couple of extra coats of satin black), stainless spacers and locking tabs and new nylock nuts all round
Unfortunately you can't see the refurbished caliper with stainless piston and john-saab seals
I can now move the car around the yard, but won't be taking it on the road until the other side is done, as the handling would probably be rather 'interesting'

Have now serviced the E30, the Alvis passed its MOT yesterday and finished fixing the advisories on the 900 this afternoon, so the way is now clear for some more Custard-action


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