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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Nov 08, 2017 8:11 pm 
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Location: Bath/ Dublin
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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Nov 16, 2017 4:37 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 495
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Cheers Melle.
Had a couple of days scraping off the last of the underseal from under the passenger side front wing, welded up a couple of small holes, etch and applied seam sealer. Then I couldn't ignore this anymore:
Attachment:
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Attachment:
SDC13160.jpg
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Someone has crudely added another 'bracket' underneath at some stage, while not addressing the rust in the original. It'll all have to come out
Attachment:
SDC13161.jpg
SDC13161.jpg [ 205.94 KiB | Viewed 1565 times ]

It only took an old screwdriver and fine adjusting tool No.2 to peel off the original bracket, but a bit of scraping and poking uncovered more rust :cen:


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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Nov 16, 2017 4:52 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 495
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Used a cutting disc to cut vertically through the welds in the remaining bracket, and it didn't take much persuading to remove. Then decided the best approach with the rest of the rust was to cut a slot, grind off the remaining outer panel at the bottom, then let in a repair panel
Attachment:
SDC13163.jpg
SDC13163.jpg [ 217.99 KiB | Viewed 1564 times ]

Had to let a couple of small pieces into the inner panel first
Attachment:
SDC13164.jpg
SDC13164.jpg [ 217.13 KiB | Viewed 1564 times ]

Before welding in the main repair panel, and dressing
Attachment:
SDC13165.jpg
SDC13165.jpg [ 197.87 KiB | Viewed 1564 times ]

Quite a fruitful hour's bodging, but when the sun went down behind my neighbours' roof it suddenly got rather cold. Still got to weld the lower seam, fabricate the bracket (the original job!) and get some protection on. Oh well, more tomorrow with any luck


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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Nov 16, 2017 4:52 pm 
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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 495
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Used a cutting disc to cut vertically through the welds in the remaining bracket, and it didn't take much persuading to remove. Then decided the best approach with the rest of the rust was to cut a slot, grind off the remaining outer panel at the bottom, then let in a repair panel
Attachment:
SDC13163.jpg

Had to let a couple of small pieces into the inner panel first
Attachment:
SDC13164.jpg

Before welding in the main repair panel, and dressing
Attachment:
SDC13165.jpg

Quite a fruitful hour's bodging, but when the sun went down behind my neighbours' roof it suddenly got rather cold. Still got to weld the lower seam, fabricate the bracket (the original job!) and get some protection on. Oh well, more tomorrow with any luck


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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Nov 23, 2017 8:06 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 495
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Have just spent a crazy sum of money on a rear axle complete with trailing arms and brakes. Won an online auction and had to part with a whopping 99p

The downside - had to make a 120+ miles round trip to pick it up

However the vendor is a super guy, who has a fantastic V4 (I'm not going to tell you about it. It's his business if he wants to go public). He was having a bit if a clear out so I picked up a few other useful parts while I was there. Many Thanks Mark, if you read this


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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Nov 23, 2017 11:26 pm 
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Location: Wigan, Lancashire
Car Model: 9000 Anni, 9-5s by the score
greg124 wrote:
Have just spent a crazy sum of money on a rear axle complete with trailing arms and brakes. Won an online auction and had to part with a whopping 99p

The downside - had to make a 120+ miles round trip to pick it up

However the vendor is a super guy, who has a fantastic V4 (I'm not going to tell you about it. It's his business if he wants to go public). He was having a bit if a clear out so I picked up a few other useful parts while I was there. Many Thanks Mark, if you read this

Man Maths means fuel is free. :)

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 Post subject: Re: V4 Custardwagon
PostPosted: Fri Nov 24, 2017 8:27 am 
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Joined: Wed Dec 14, 2016 9:09 am
Posts: 12
Car Model: 95 v4
greg124 wrote:
Have just spent a crazy sum of money on a rear axle complete with trailing arms and brakes. Won an online auction and had to part with a whopping 99p

The downside - had to make a 120+ miles round trip to pick it up

However the vendor is a super guy, who has a fantastic V4 (I'm not going to tell you about it. It's his business if he wants to go public). He was having a bit if a clear out so I picked up a few other useful parts while I was there. Many Thanks Mark, if you read this




I'm very happy to help in a good cause, I shall follow the project with interest....


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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Nov 25, 2017 3:16 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 495
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
When I bought the car, the rear bumper was held on one side with a cable tie
Attachment:
SDC13170.jpg
SDC13170.jpg [ 154.26 KiB | Viewed 1445 times ]

I hadn't bothered to investigate, but as I knew either the bumper or bracket needed replacing, I picked this up when collecting the rear axle from Mark
Attachment:
SDC13171.jpg
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So on Friday decided to investigate, and cut the cable tie off
Attachment:
SDC13174.jpg
SDC13174.jpg [ 212.89 KiB | Viewed 1445 times ]

The fillet welded to the inside of the bumper, which attaches to the bracket, has completely disintegrated


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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Nov 25, 2017 3:27 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 495
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
...as has the one on the end
Attachment:
SDC13175.jpg
SDC13175.jpg [ 237.55 KiB | Viewed 1443 times ]

Luckily, these bumper end sections are not handed, so regardless of which side it originally came from, the replacement section will fit

As Friday afternoon was lovely and warm, I was keen to get a second coat of hammerite on the inner wing to protect it during the coming winter
Attachment:
SDC13173.jpg
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and on the 'bracket' that I was repairing last week
Attachment:
SDC13172.jpg
SDC13172.jpg [ 214.31 KiB | Viewed 1443 times ]

Unfortunately I hadn't taken the road spring out first :wall: so the bump stop turret will have to wait.
I really want to get the suspension on this corner dismantled before the weather gets too bad, so that the parts can be refurbished indoors. There was a bitter wind this morning, and snow on the tops just over the border in Wales, so the 'outdoor workshop' will soon be having a seasonal shutdown


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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Dec 09, 2017 7:29 pm 
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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 495
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Managed to get all of the NS suspension off the car before the temperature dropped. Currently in the process of cleaning and repainting, but pretty much the same as the other side, so I haven't bothered with photos.
I've also been doing another inside job. The aluminium brackets that retain the front indicator/side light assembly are badly corroded (I understand they are usually steel and suffer the same fate). So I'm re-purposing the lid off an old deep fat fryer, which is stainless steel
Attachment:
SDC13178.jpg
SDC13178.jpg [ 171.66 KiB | Viewed 1348 times ]

Visited a mate in the village who's a hot-rodder and geared up for machining stainless, to drill the hole. Then cut to size with a cutting disc in the angle grinder, and dress with a file
Attachment:
SDC13181.jpg
SDC13181.jpg [ 219.94 KiB | Viewed 1348 times ]

Keeping the returns on each end of the bracket, so there is a smoother, less sharp, contact with the inner wing, which should be less likely to cut through the underseal. This does however mean that the bracket will be longer than the original, and contact the inner wing in a different place. This necessitates the bends in the bracket being at non-right-angles, which took a bit of experimentation
Attachment:
SDC13182.jpg
SDC13182.jpg [ 216.08 KiB | Viewed 1348 times ]

I'm thinking of using these plastic number plate screws, which were left over when I replaced the plates on the 900; they will need trimming to a suitable length. Again, just trying to minimize future corrosion problems.
Just got to make another one now. They will be 'handed' as the angle of the bends is different at each end


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 Post subject: Re: V4 Custardwagon
PostPosted: Fri Mar 09, 2018 1:55 pm 
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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 495
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
It's been a while since I last posted, but work on the front suspension and brakes is almost complete. Bought some "Professional Parts Sweden" discs off t'internet for a very reasonable price. Just got to clean off the protective coating and fit the new pads.
Attachment:
SDC13209.jpg
SDC13209.jpg [ 257.32 KiB | Viewed 965 times ]


So work on stripping down the rear suspension and brakes began this morning
Attachment:
SDC13210.jpg
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Attachment:
SDC13211.jpg
SDC13211.jpg [ 343.42 KiB | Viewed 965 times ]


The drums came off easily once I remembered to release the handbrake :loco: They're obviously home to spiders, but plenty of meat on the shoes, and the springs look fairly new. Letting the duck oil soak in before attempting to undo any nuts


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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Mar 10, 2018 7:43 am 
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Joined: Sun Jan 15, 2012 4:24 pm
Posts: 2743
Location: Dunfermline
Car Model: 11 cars
Looking good there Greg...
Doing a great job, how did you get your yellow hammerite paint to turn black on the inner wings :lol:

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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Mar 10, 2018 10:13 am 
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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 495
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
About one and a half tins of this...
Attachment:
SDC13212.jpg
SDC13212.jpg [ 197.66 KiB | Viewed 942 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Mar 13, 2018 5:47 pm 
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Saab Nut
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Joined: Sun Jul 29, 2007 9:32 pm
Posts: 1071
Location: Bath/ Dublin
Car Model: 8V-V4
greg124 wrote:
Bought some "Professional Parts Sweden" discs off t'internet for a very reasonable price.
Most PPS (formerly known as Scantech) parts are reasonably priced for a reason... I have not tried those brake discs but generally their stuff is utter rubbish.

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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Mar 13, 2018 8:07 pm 
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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 495
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
melle wrote:
greg124 wrote:
Bought some "Professional Parts Sweden" discs off t'internet for a very reasonable price.
Most PPS (formerly known as Scantech) parts are reasonably priced for a reason... I have not tried those brake discs but generally their stuff is utter rubbish.

Oh dear! They look quite well machined, so I guess it will be down to the quality of the steel that has been used. These were quite a lot cheaper than I've seen at 'list' price. so I'll just hope for the best


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 Post subject: Re: V4 Custardwagon
PostPosted: Sun Mar 25, 2018 7:29 pm 
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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 495
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Spent rather longer than I had planned removing the driver's side rear wing. Two of the captive nuts down the front edge became de-captivated as soon as I put a spanner of the bolts, so had to remove the interior trim panel.
Then most of Friday was taken up with removing underseal
Attachment:
SDC13220.jpg
SDC13220.jpg [ 235.49 KiB | Viewed 705 times ]

When I took the trim panel out it revealed this mess.
Attachment:
SDC13221.jpg
SDC13221.jpg [ 261.59 KiB | Viewed 705 times ]

Someone has welded a patch in without cutting out the rust. Just patch it up to get it through one more MOT kinda thing. You could argue that if it had never been patched the car would at some point failed an MOT big style and ended up being scrapped.
There is only one cure for this. Nurse, pass the cutting disc please
Attachment:
SDC13228.jpg
SDC13228.jpg [ 200.06 KiB | Viewed 705 times ]


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Mar 27, 2018 7:40 pm 
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Light Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 495
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
Removed the remaining patch piece at the top as I din't like the shape, then decided that making the repair sections was a 'two pint problem' to paraphrase Sherlock Holmes. After a couple of pints I decided to make the flat part from one piece, and the curved section from a further two.
Flat section clamped in and ready to weld
Attachment:
SDC13230.jpg
SDC13230.jpg [ 172.79 KiB | Viewed 660 times ]

Some metal bashing and welding later
Attachment:
SDC13231.jpg
SDC13231.jpg [ 208.2 KiB | Viewed 660 times ]

A bit of tidying up and we have a reasonable approximation of the original shape
Attachment:
SDC13232.jpg
SDC13232.jpg [ 226.16 KiB | Viewed 660 times ]

Still got to plug weld the flange to the outer panel, then start to tackle the carnage in the boot


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Mar 28, 2018 7:44 pm 
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Joined: Sun Jul 29, 2007 9:32 pm
Posts: 1071
Location: Bath/ Dublin
Car Model: 8V-V4
Looking good again!

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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Apr 14, 2018 8:02 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 495
Location: Herefordshire
Car Model: 900i '87 96V4 '72 E30 Alvis
The rear lower spring seats are both past their best, with very thin weak metal round the edge. Harvested a good RH side one from the spare axle picked up from Lumpey back in November, but I have a small selection of LH side ones which all have rust holes. Here are a couple
Attachment:
SDC13233.jpg
SDC13233.jpg [ 132.92 KiB | Viewed 438 times ]

Didn't particularly fancy spending £75 on a new one, so it was out with the grinder and MiG welder, and selected the least worst one, which had a thin area on top - sorted
Attachment:
SDC13237.jpg
SDC13237.jpg [ 379.03 KiB | Viewed 438 times ]

and a couple of holes in the side - that should do the job
Attachment:
SDC13240.jpg
SDC13240.jpg [ 133.61 KiB | Viewed 438 times ]

The rear axle is now completely stripped with the exception of one handbrake cable. It's had a soak in a mixture of Acetone and ATF for a week, a few gentle taps with a hammer, and attempts to rotate with the mole grips, but it doesn't want to move. I don't want to use heat as it would risk melting the outer sleeve on a perfectly serviceable cable...


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 Post subject: Re: V4 Custardwagon
PostPosted: Sun Apr 15, 2018 3:41 pm 
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Posts: 37908
Location: NETTLEHAM, LINCOLNSHIRE
Car Model: 99GL, Fiat 500 & Volvo V70
Nice work so far 8)

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