Bognor Lean-to Project

[Mazza]

I am.......’cos I just got the thing unseized and apart

Rusty bits of metal. 0 - 1 Bognor Lean-to ...........

 

[Nickskip]

Not a lot done on my project today, other than I snapped the rusty horn brackets off to bin both horns.....( Andy.....more bits for the list )
The whole plug connector snapped off!!!!!
View attachment 183581

Then had a visit from New member Nick ( @Nickskip ) with a view to sorting out a stuck drivers seat......
Two and half hours it took to finally get the seat out of the car......rear bolts just visible......and the front nuts visible doing a head stand in the drivers footwell
I ended up grinding down an old imperial spanner to get access to the 13mm nuts and could move them a fraction at a time then turn the spanner round.....but, eventually the seat was out ......

Using my 2.8 battery I could move the seat on one side to get access to the T45 screw, took it out and pulled the rod out. Needs a clean but ok to reuse......the other side , could not move it and only access to the T45 was through the rear bolt hole. .....but the head of the torx bolt is too big........so only thing to do was file it out just enough to allow the bolt through it. Only about 1mm so wont affect the fixing bolt.
View attachment 183593
View attachment 183591

Then with my usual engineering skill, I finally removed the shaft, with a bloody great hammer ( not really Nick)
View attachment 183595

The cause of everything is the block has seized to the shaft.......

Will try and free it off but may be better to replace....have to wait and see on that.....

But ......having no drivers seat means the car cant be driven........so I have two silver 1.9’s outside the house
Mmmmm.......wonder if I need any spares ?


At least putting it back in wont be as long........

Malc, I can’t thank you enough you went above and beyond. Your patience, skill and knowledge was epic! I am greatly in your debt. Thanks again and all the best Nick

 

[Mazza]

Woke up at 5.30 this morning ......all excited as its breakfast in Basingstoke day

So went out in the garage for a bit ....

Cleaned all the bits of the seat runners....remembering to keep them separated and which one goes on which side....
One has RH thread, the other has LH thread

Also painted them with a rust converter....and while it was out, cleaned and derusted the underside of the seat.

Leave that lot to dry .........now its tea and a wee and a drive up to get a breakfast roll.......yummy!!!

 

[Nickskip]

Wow!

 

[Mazza]

Finished off the seat repairs this morning.
The little gearing unit on the front end had snapped off so fitted a replacement ( I think Nick got it from Spurs)

The little piece was all that was left of the old one that was connected to the seat

Chipped off the araldite where someone had tried to glue it back, then set up the drive rails so they were equal lengths and refitted everything,
Bench tested it first and it moved ,
Then straight back in the car in about 5 mins.... bit quicker than getting it out.

Nick collected it and I got on with some cleaning and derusting.

Callipers in better condition than I thought they would be.

and after full instruction yesterday by Trev ( @Oldguysrule) and Paul (@pgunter) on the ‘hang ‘em high’ method........I painted two washers......didn’t want to overdo the weight though..........

That’s it for now.....don’t want to overdo things

 

[Nickskip]

Malc, I can’t thank you enough. The car is a pleasure to drive now I can get comfortable. Can't wait to pick up my new Mora one tomorrow, just been and bought the train ticket! Thanks again, all the best Nick

 

[Mazza]

Run in to the same problem as i saw as ZSHQ on saturday.....
Callipers off the car but need to have the pistons removed.....on saturday , reconnected to the car and used the brake pedal to push them out........


But today at the ‘Lean-to’ I have the ‘ MazzaMoova’.........and it even works

And they are NOT available from a store near you

View: https://youtu.be/jOks0__swlo

 

[t-tony]

I use compressed air Malc, didn't know if you have a compressor or not.

Tony.

 

[Mazza]

Nothing as exotic....just a footpump.
But managed to connect an old brake hose to a schrader valve and it works ok.

 

[t-tony]

Necessity is the mother of invention so they say mate and it is very true. I like finding ways around problems.

Tony

 

[Lee]

I used to use the compressor to expel our brake pistons till one was a little stuck, when it did eventually go it launched 10 foot and left a sizable dent in the wall. We take it a bit easier now

 

[t-tony]

You just need to use lower pressure or, put something across the calliper to stop it shooting out.

Tony.

 

[Eddie Zedder]

Tie wrap a condom around it, stops 98.9% getting through

 

[BillH]

Hi Mazza, just been catching up on the site and found your thread - a good read and just want to thank you for struggling with the exhaust on my M at the Zedshed on the 15th. Will try and pay a visit this weekend just to check out a Saturday at the Shed, see how the rebuilds progressing - and get sustenance for the guys devoting their time to fettle! Maybe see you there?
Cheers
Bill

 

[Mazza]

Waiting for the post office to open to send a parcel off to Ireland...( no prizes for guessing whats in it)......

So a quick 10 minutes in the garage to finish off stripping down the callipers

This lot has to be cleaned and inspected now and see which bits need replacing....
Where’s Trev and Paul when you need them......Oh yes.........probably off on a coffee run

I suppose I will have to do it myself....

 

[mrscalex]

I use compressed air Malc, didn't know if you have a compressor or not.

Tony.

I find the compressed air hit and miss. Usually okay for rears. More problems with front. Never know how to get best air seal. Biggest problem is I usually end up with brake fluid exploding in my face which is clearly a stupid thing.

 

[Mazza]

3 hours of removing rusty broken bolts and nuts....

Didn't really get very far either.....

But first remove the bumper brackets......if I hit my knee or head on them once more!!

The eagle eyed ....spot anything missing from this photo......

Managed to remove the rusty nuts that hold the two horns on.....Dremel time !!!!!

The other side more or less the same....but took ages...

Then removed all the broken fixings from the power steering loop....and straightened the bracket....
.near enough for now

And removed the smog filter.....
Still need to cap off the hole and block the vacuum line....

But did remember to put a bit of tissue in the hole to stop any crap getting into the engine.

Still the sheared bolt to remove from the main crossmember, and get the last bits of the exhaust off the manifold downpipe but thats for another day now.....

The sun is shining and theres another Zed outside that needs a run....

 

[Mazza]

Thought I would make an early start today as I had Martin the Welder coming to sort out a couple of rusty bits under the front wheel arch.......
So I was in the garage at 9am to sort out all the callipers and see what parts I need to order........

One bit at a time....no rush.......and there wasn’t as Martin didn't arrive till 3pm ........6 hours of mind numbing cleaning

These are the usable parts.....

These are parts I need...

So not too bad, and I even found 4 new bleed valves in my box of spares

Then at 3pm Martin arrived and got straight on with sorting it all out

Halfway through putting in a panel in the wheel arch....


This was cut out , To ensure no rust left on the panel

Once this bit was done , moved on to the front end of the drivers side sill, and again cut out a lot more than I thought, and made up a new end panel.
Eventually all sorted , and I will leave it for a couple of days then prime and paint it ( the seam sealant needs to dry out)

You can see a stud in the piece above, and in the middle of the rusted hole should be the location for a nylon body nut.
So I will have to use the bumper bracket as a template (located on the other two studs ) and drill a hole to suit and use a nut and bolt. Fortunately access ok to do this.
And also assemble the arch liner to mark where the body nut goes.....then just a case of drilling a square hole...

Lee let me know that the rest of the powder coating is back, so tomorrow is Breakfast in Basingstoke
and a full rebuild of both trailing arms......as I watch !!!!!!

Put all the bits that I need to take in the car already, as it will be an early start.
Just hope I haven't forgotten anything......

 

[Althulas]

Square hole easy Malc just drill hole to near size and either needle file it to size or use a square punch. A piece of reamer bar ground down is good for this or end of an old file tang, it’s what I did and worked a treat.

 

[Mazza]

Today was one of those days that just make you smile ...... what a fun day......

And a bit of a thread cross over, where I go from ‘Lean to Supremo’ to Zedshed HQ minion.....

The day started with an easy run to the Basingstoke Breakfast Bar....(for my usual Bagette with everything in it .)
...and met up with all going to the Shed. Nice to meet a new face @BillH

Once at the ZSHQ, I was first on the list , to build up the trailing arms.
First job was for Lee and Gaz to clean the inside face as it had been powder coated ( not normally done ) but didn't take long to sort out.

I would have helped but dont like to slow them down , and I had to record the moment !!!!!

Once cleaned ....and with a few big boy tools .....Bearing was installed.

This is THE tool......

The Nugga Nugga gun.......not for use by old people and it loosens your fillings.........

Then inserted the arm Bushes......and they made me do that..( but under supervision) ....no respect for age in the shed.......

Then the back plate, and Luckily Gaz found 4 little bolts in their stock of fixings, as the new ones I had bought were wrong and did not fit. ( sort that out with the Dealer on tuesday !!!)

Followed by the hub, the brake cable and shoes

Then after checking and cleaning the spines of the drive shaft, that was installed, as was the rear disc so the hand brake shoes could be set up .......and then the whole lot was repeated for the other side.......

Amazing to see how quickly this assembly went together...and with all the newly powder coated parts....they just look brand new.
Forgot to take pictures of the last bits but took this one when I put them in the garage at home

So one very happy bunny

I also picked up various other bits that had been powder coated as well, front springs , hubs, ARB, spring plates etc...
All look brilliant.

So then attention turned to Bill’s ///M and refitting the rear end ......of which my only input was to hand them nuts and bolts and man the trolley jack at the final lift......cant be trusted to do much more

I had to go then, as I needed to do a slight detour to call in on Andy (@spurs fan in a coupe ) to collect some parts which he had sorted out fo me. Again really lucky as he could supply everything that I had listed to him earlier in the week.
a ONE STOP SHOP for Z3 parts

oh, and Paul ( @pgunter ) , I picked up a couple of relays for you to try....I’ll bring them up to ZSHQ in a couple of weeks when the front shocks have arrived and I need to get the springs installed. ( and bring more doughnuts )

Then a drive back home.....to find a package on the mat.....
The smog filter repair plate c/w bolts from Tony (@t-tony )

This blanks off the hole after the smog filter removed. So much better than if I had tried to make one.
Thanks Tony .

So that was the day...all very positive and great fun
..........even if Lee thought I looked like 70’s Porn Star Ron Jeremy......and No I’m not changing my forum name to Mr Strap!!!!!!!