Bognor Lean-to Project

[IainP]

Why bother, nuts and bolts work just as well.

Tony.

They do, until the time you have to do something in the dead of night, on your own, always in the pouring rain and find your arm isn’t quite long enough/ not enough space/ manifold is stinking hot, then stainless studs are wonderful things.
Oh yeah, been there, done that!

 

[t-tony]

I’ve been there, done that all my working life Iain and I would disagree.

Tony

 

[Mazza]

A big box from Autodoc arrived this morning and I was lucky to get it.....never heard the doorbell, ( making to much noise.....erm....having a practice session...... ) luckily the driver brought it round to the back of the house.......

He asked if we did requests......I said yeah,, so he said....turn it down !!!!!!! @pgunter may be getting a call to do a sound check at the request of the neighbours


Anyway lots of bits.....

Got all the parts now to assemble the front struts.....


And got all the parts to assemble the callipers, now the seal kits have arrived...

I need to have a tidy up as well......parts stacking up in the conservatory....

A bit more rust treating and red oxiding this afternoon. ....and probably will be cleaning and painting for another few days yet......it will be nice to get to the point when its just assembly and have all the running gear put back on the car....as pretty much every part has either been reconditioned or its new, so should go together relatively easily.


...I forgot about the 6 exhaust studs to remove, and brake lines to make.........
perhaps it will take longer than I thought

 

[PHILIP BAXTER]

Great job @Mazza, I'm loving your work.

 

[Mazza]

The other day I sent a text to Lee with a question regarding the cleaning of the front bearings. Just as well as I may have done something stupid........ .....but I got useful info regarding new ones if I wanted to go that route.......

Today I thought I would clean up the originals as the bearings seemed ok.......
Then looking at them, I had my mind made up.....

Completely different hubs........

More new parts to order......I have to keep my credit card in the fridge.....its gets red hot with all the use its getting

When people say can you see the light at the end of the tunnel.........No........I’m still digging the bloody tunnel


Oh, and thanks to the thread on Diff bush orientation, that I read yesterday.....I now know I’ve got it in the diff cover upside down..............oh well backwards and downwards.....

 

[Mazza]

Well if this morning was not too good.....this afternoon was a disaster.....

Thought I would try to remove just one of the studs to see how long it would take.......that was my first mistake!!!!!

Ground the remains of the stud close to the exhaust flange and centre punched and centre drilled it to get a start.
Then stating with a 3mm drill commenced drilling it out....Definitely need sharp drills , and I might have to get a sharpening jig to save buying lots of new drills. The studs are rock hard.....
But, bit by bit, I started to get through it gradually deepening and widening the hole getting closer to the diamter of the stud hole in the flange....one more drill should do it.........BUT NOT IF IT BREAKS IN THE HOLE........the recoil on the drill when it caught nearly broke my wrist................ I did try whacking the stud with a drift to see if it would release, but no.

Absolutely no way to remove it......So plan B was devised.......
Take the manifolds off.......So read Bentleys......and I still cant fathom out why is says removed the washer bottle, which is on the other side of the car, up near the windscreen......Past caring by this point so out it came.....
Then it says ‘undo the manifold nuts’ ...two hours later , covered in crap, arms bleeding, I finally had the front 8 undone.

6 of The studs came out so I will get the other two out and replace them all, plus the gaskets.

So the front manifold was now loose....but can’t take it out as it still has a sensor screwed into it. The lead I assume unplugs some where....but at that point my LED light went off and needed to be recharged.

Can anyone tell me where the sensor wire unplugs from???
Once I can get it unplugged and out of the way I can then do the same again for the rear manifold.

Then I can work on them on the bench, which should be a lot easier than scurrying about underneath.

So for now.....Beers , get something to eat, and watch the first game of the Euros ...

and worry about all this tomorrow!!!!!

 

[t-tony]

If you're going to the trouble of taking the manifolds off Malc, take them somewhere to get them heated red hot and drift the studs out of the holes. At least that bit is easy on the bench.

Tony.

 

[Mazza]

Tony, Tony, Tony.........do you know what!!!!! Thats exactly what I will do....... when I get the sensor disconnected

Good idea !!!

 

[t-tony]

I'll have a look at my engine after tea and see if I can see where the cable is routed mate. Got to be similar I would've thought.

Tony.

 

[Synclare]

.

 

[gookah]

hope you find the plug or its engine out next at this rate.......

 

[Mazza]

Hi Adrian, these are the two sensors that screw in, one in each manifold header, before the flanges.

I can’t see where the cables go and where they plug into the main loom.

 

[gookah]

Mazza, the plugs live under the inlet manifold cover and go around the back of the engine to them

You dont need to take the rocker cover off,
mine was off to change the gasket

 

[Mazza]

Found them where you said!!

I will label them before disconnecting....but the day ends on a happy note .....Thank you

Hopefully not too many clips to undo.......

 

[Mazza]

Marked up which was which. And it turns out the front one goes to the rear manifold and the rear one goes to the front

Then……
With a wiggle wiggle here , and a wiggle wiggle there,
Here a scrape, there a cut , every stud got sworn at……

But ……they’re off
Now let someone else get the studs out

That’s it for today…..3 games of footy on the tele….. and beers in the fridge

 

[t-tony]

There must be some logic in those wiring connections somewhere Malc. Glad you got them off anyway mate. Enjoy the footy and beer.

Tony.

 

[Mazza]

What broken studs????

Just need 6 new
Stainless Steel bolts now….


Plus 16 studs, 16 nuts and 2 gaskets!!!!!!

just to get back to where I started

 

[Althulas]

At least it will all be done properly Malc and get rid of any future headaches.

 

[Mazza]

Bloody hot down here on the coast, but I thought I better do something today.

So 4 manifold studs to remove......

Went with the two nuts method, and just prayed that none of the studs would snap

Luckily all came out but took ages to do....


P

Gave it a bit of a clean, but laying underneath getting showered in crap not a lot of fun.....so gave it up to find something else to do....

Could build the callipers.......Nah !!

So went with sorting out the problem on the drivers seat......UP and Down has a housing come loose and jammed.

Ended up stripping the whole seat base down. It was the only way to get enough play to screw the housing back on to the thread. The two washers nut and pivot pin were under the seat when I removed it from the car , so just put them back and built it up as far as the motors, then tested it using the battery and a flying lead.

Success , all working , back and forward and up and down.

While its all dismantled I also treated the rust spots.
Wont bother to reassemble the seat as I have to install new seat belt guides at some point, and I want to fit heat pads too.

postman turned up with a parcel for me.......
New Front bearings

Now something else I need to get ......a socket ........I think its 45mm but I will take one of the nuts with me when I get it.

I ordered the new manifold studs and nuts, and the two gaskets last night but they will be about a week.

 

[colb]

Re heated seat pads just fitted after market pads to the Z4, ebay cica £16 a set all pre wired with switches. Stock up on hog rings and hog pliers or use cable ties to put the covers back on