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Chat Area => General Car Chat => Topic started by: Nick W on 10 September 2016, 19:42:03

Title: This Week in Wheeler's Workshop
Post by: Nick W on 10 September 2016, 19:42:03
For the first time in ages, I've managed to get up and do something every day this week. Hopefully it will be good practice for when I get around to finding some full time employment.


Monday, I made these:


(https://www.dropbox.com/s/f77wz67gzd143g8/JackAdapters.jpg?dl=1)


They're adapters for jacking the tail of a small aircraft, and apparently they're normally a lot more expensive than the £25 I charged ???


Tuesday I collected a friend's Grand Vitara, fitted new shocks and wipers and put it in for an MOT.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 10 September 2016, 19:56:11
Wednesday's job was to make this look better:


(https://www.dropbox.com/s/mthlhoteu805hlh/TiredMGFSteeringWheel.jpg?dl=1)


That's off an MGF, and the 'aluminium' trim had worn through. Think Irmscher wheels for an Omega.


A couple of minutes with some scotchbrite had it ready to mask:


(https://www.dropbox.com/s/8flof70l1h9pum6/ScotchbritedMGFSteeringWheel.jpg?dl=1)


Then I designed and fabricated a high-tech Custom Clamping Fixture**:


(https://www.dropbox.com/s/nxexnytj5306mi5/MGFSteeringWheelCustomClampingFixture.jpg?dl=1)


Yes, I know I'm not very good at masking!


(https://www.dropbox.com/s/b5hxagg95u7e8b1/MGFSteeringWheelBasecoat%20-%20Copy.jpg?dl=1)


A couple of coats of Z147 Star Silver, and some 2-pack clear:


(https://www.dropbox.com/s/5dqtayiveiuz7kh/CompletedMGFSteeringWheel%20-%20Copy.jpg?dl=1)


It wouldn't match a piece of trim that it touches, but it is bloody close! Plus, it's going to be much more hard wearing. And I already had the paint. One of those it ought to work jobs.


** The CCF only looks like a scrap bit of 2x2 softwood, with a 14mm hole drilled through and then cut in half to clamp a 15mm rod in my bike workstand.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 10 September 2016, 20:02:06
Thursday's job was to find out why the resin adjusters in Andrews headlamps weren't working.


So, I stuck them in the oven, and replaced the adjusters with some scrounged aluminium ones which we know work.


The resin ones showed a couple of problems:


The inserted pin and ball can be pushed out if you wind the adjuster too far; and it's easy to strip the tapped thread. So, if you use these, you need to ensure that they are set close to where they need to be before you reassemble the lamp. When you adjust the beam setting on the car be gentle. Then they are likely to be a decent solution to knackered adjusters.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 10 September 2016, 20:08:51
Friday, I assembled two sets of these:


(https://www.dropbox.com/s/69n762u8rdz4yyo/FrontStrutParts%20-%20Copy.jpg?dl=1)


Like this:


(https://www.dropbox.com/s/5tse25bci35y4tn/TheRealUseForCordlessImpacts.jpg?dl=1)


(which is the real use of cordless impacts for DIY use)


into these:


(https://www.dropbox.com/s/ndtb6m3qcud0vb6/FrontStrutAssembled%20-%20Copy.jpg?dl=1)


And to complete the prep for a front suspension rebuild, this morning I fitted a set of polybushes


(https://www.dropbox.com/s/905n3qw1m1s50lb/PolyWishboneBushes.jpg?dl=1)




One tip from this which saves needing extra hands for assembly:


(https://www.dropbox.com/s/3xasotjk8wgkfxl/SupergluetheIsolatorInPlace.jpg?dl=1)


a couple of spots of superglue to hold the rubber isolater in place!

Title: Re: This Week in Wheeler's Workshop
Post by: amba on 10 September 2016, 20:12:49
Headlight beams now fully corrected ,Nick and for the first time in ages headlights both light the road in front of car,not the trees on the n/side and just about the front of the bumper on the o/side.
Top job and thanks
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 10 September 2016, 20:16:38
Remember the jacking adapters?


Turns out they work so well(compared to the stack of washers and pins that were being used), that they want some more pads for the actual jacks. Which I will cut from the bar at the front:


(https://www.dropbox.com/s/ibwsw65cw46rbvu/JackPads%20-%20Copy.jpg?dl=1)


Note the use of engineering grade duct-tape to create a precision fit on the part on the left!


This will be a job for Monday, as I'm ringing twice tomorrow with a visit to the Kent Classic Car Show at Aylesford in between. The plan is to have some beers and a curry if we get the quarter peal of Steadman triples in the afternoon. Or if we don't ;D


I plan on charging £30 each for these bits, which will provide some negotiating room if necessary.
Title: Re: This Week in Wheeler's Workshop
Post by: Weds on 10 September 2016, 20:24:39


This will be a job for Monday, as I'm ringing twice tomorrow with a visit to the Kent Classic Car Show at Aylesford in between. The plan is to have some beers and a curry if we get the quarter peal of Steadman triples in the afternoon. Or if we don't ;D



I'll be at Aylesford with my Porsche 928, stop and say hello if you see me...
Title: Re: This Week in Wheeler's Workshop
Post by: YZ250 on 10 September 2016, 20:53:33
You seem a handy guy on the machines Nick.  :y Are you toolmaker trained or self taught, not particularly relevant but just curious.  :)
Very handy to have the gear to be able to knock stuff up, it's what I miss most about not being on the machines any more.  :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 10 September 2016, 20:53:59


This will be a job for Monday, as I'm ringing twice tomorrow with a visit to the Kent Classic Car Show at Aylesford in between. The plan is to have some beers and a curry if we get the quarter peal of Steadman triples in the afternoon. Or if we don't ;D



I'll be at Aylesford with my Porsche 928, stop and say hello if you see me...


Deal :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 10 September 2016, 21:10:18
You seem a handy guy on the machines Nick.  :y Are you toolmaker trained or self taught, not particularly relevant but just curious.  :)
Very handy to have the gear to be able to knock stuff up, it's what I miss most about not being on the machines any more.  :y


Self taught - I bought and learnt how to use a small lathe because I was fed up with pestering mates for odd jobs. I wish I'd done it while my grandad was alive, as he was a professional machinist. The first thing I made were a custom pair of axle to leaf spring locating pegs: £400 for a £1 part if they had been available ::) Then a small mill for similar reasons. TIG welder, and other stuff, you know how it goes.


Able to knock stuff up is the perfect phrase. I'll happily do mechanical jobs, metalwork, bodywork, simple trimming(I must get my aunt to show me how to use my industrial sewing machine ;D ) because they're all building on basic skills that I started learning as a kid. Unless it's woodwork, where looks like it was nailed together by a pissed amputee but probably won't fall apart is more accurate. I draw the line at electronics and programming: they just give me a headache!
Title: Re: This Week in Wheeler's Workshop
Post by: YZ250 on 10 September 2016, 22:00:03
You seem a handy guy on the machines Nick.  :y Are you toolmaker trained or self taught, not particularly relevant but just curious.  :)
Very handy to have the gear to be able to knock stuff up, it's what I miss most about not being on the machines any more.  :y


Self taught - I bought and learnt how to use a small lathe because I was fed up with pestering mates for odd jobs. I wish I'd done it while my grandad was alive, as he was a professional machinist. The first thing I made were a custom pair of axle to leaf spring locating pegs: £400 for a £1 part if they had been available ::) Then a small mill for similar reasons. TIG welder, and other stuff, you know how it goes.


Able to knock stuff up is the perfect phrase. I'll happily do mechanical jobs, metalwork, bodywork, simple trimming(I must get my aunt to show me how to use my industrial sewing machine ;D ) because they're all building on basic skills that I started learning as a kid. Unless it's woodwork, where looks like it was nailed together by a pissed amputee but probably won't fall apart is more accurate. I draw the line at electronics and programming: they just give me a headache!

Nice one.  :y  You can never have too much equipment, it enables you to make a specialist tool from scratch as you know.  :y  I was lucky that the amount of hub pullers, slide hammers, bearing tools and many other creations that I made were all courtesy of the MOD.  ;)  :)

I was also lucky that I had an apprentice master who was interested in cars. He used to create cars that shouldn't have been, like a MK11 Cortina with Jag engine and running gear,  Land Rovers with Jap engines etc. This was late seventies/early eighties and he was a damn good engineer. He would roll his own arches, weld bits in to make bits fit etc. I learned a lot from him and when he saw me pondering over a car problem he would say "get on with it, it's only a load of metal bits held together with a load of bolts".  ;D  If only life was that simple.  ::)

Title: Re: This Week in Wheeler's Workshop
Post by: Mr Gav on 10 September 2016, 23:22:18
You seem a handy guy on the machines Nick.  :y Are you toolmaker trained or self taught, not particularly relevant but just curious.  :)
Very handy to have the gear to be able to knock stuff up, it's what I miss most about not being on the machines any more.  :y


Self taught - I bought and learnt how to use a small lathe because I was fed up with pestering mates for odd jobs. I wish I'd done it while my grandad was alive, as he was a professional machinist. The first thing I made were a custom pair of axle to leaf spring locating pegs: £400 for a £1 part if they had been available ::) Then a small mill for similar reasons. TIG welder, and other stuff, you know how it goes.


Able to knock stuff up is the perfect phrase. I'll happily do mechanical jobs, metalwork, bodywork, simple trimming(I must get my aunt to show me how to use my industrial sewing machine ;D ) because they're all building on basic skills that I started learning as a kid. Unless it's woodwork, where looks like it was nailed together by a pissed amputee but probably won't fall apart is more accurate. I draw the line at electronics and programming: they just give me a headache!

Hats off to you Nick, I totally admire people that are self taught and are very good at what they do. Proper garden shed engineering in the true British way  ;D

BTW....hope you charged a small fortune for using the ultra rare Z147 paint  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 11 September 2016, 10:14:39
For the first time in ages, I've managed to get up and do something every day this week. Hopefully it will be good practice for when I get around to finding some full time employment.


Monday, I made these:


(https://www.dropbox.com/s/f77wz67gzd143g8/JackAdapters.jpg?dl=1)


They're adapters for jacking the tail of a small aircraft, and apparently they're normally a lot more expensive than the £25 I charged ???

You could always add a couple of zeros to the price and sell them to audiophiles for supporting their equipment. Might need to make up some bull5h1t science for the advert, but... :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 16 October 2016, 19:32:40
We've got to remove a propeller for servicing.


Which lead to being asked to make one of these:


(https://www.dropbox.com/s/bl56nzp3xjtfzhv/HarvardPropWrench.jpg?dl=1)


"but with a smaller hex"


So I had a dig about in my stock, and produced this lot:


(https://www.dropbox.com/s/p8mdnlsdx017syr/PropWrenchParts.jpg?dl=1)


Left to right: mandrel for the 47.5mm AF Hex, Hex machined from 15mm plate and some 2" tube


(https://www.dropbox.com/s/rjp2wcemah1e7ku/MachiningHex.jpg?dl=1)


That's machining the hex using the mandrel held in an ER32 collet block


And then some welding:


(https://www.dropbox.com/s/3pywashy5mstdeu/StimsonPropWrench.jpg?dl=1)


I'll find out if it works tomorrow.
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 16 October 2016, 20:25:32
Locking at that piece of work and guessing how it's going to be used, I think your weld may get stress tested.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 16 October 2016, 20:32:54
We're going to use the same 2 1/2 foot length of bar supplied with the first tool(that is also welded together). It's been used several times and is still straight, so I'm confident hopeful  ;D


Besides, making the tool from a single piece of 60mm bar is not a job for me!
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 16 October 2016, 20:38:37
I'm sure it will be fine Nick, and, if it's not, then you will think of something else.
If something were made from a solid bar, then surely it would just comprise of a 12" long hex with a hole in it? Get cracking.  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: TheBoy on 17 October 2016, 09:50:59
Get cracking.
Is that the noise a weld makes as it fails ;D


(Not that I think it will, as a good weld should be virtually as strong as solid metal, and I know Nick W has done a fair bit of welding :y)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 17 October 2016, 11:05:56
The prop was much tighter than it should have been, and needed a 16stone weight hanging off a 5foot long bar and a lump hammer to undo it. I did have to weld a strap across the open end of the tube.

The tool doesn't look quite such an engineered piece now!
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 17 October 2016, 14:00:37
The prop was much tighter than it should have been, and needed a 16stone weight hanging off a 5foot long bar and a lump hammer to undo it. I did have to weld a strap across the open end of the tube.

The tool doesn't look quite such an engineered piece now!
Come on, you know you wanna show us...please  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 19 November 2016, 21:08:46
Haven't done much lately, just a few bushes, and converted a normal nut to a castle nut.


But this week I was handed a partially disassembled voltmeter, with a cracked glass. Can you do something with that? she said.


So after grumbling about how the clamping ring was badly bent, I used the body of the gauge to draw a circle on a scrap of perspex, and gnawed it off with a hacksaw. Some careful belt sanding brought it close to size, and then draw-filed it to a nice where's my little tappy hammer fit into the body.


At this point it became clear that the rubber sealing ring on the front had a bit missing. Although my O-ring set had one the right diameter it was much too thick. So we had a scratch around in the stores, and found one much too big, but half the the thickness, all in a nice paper envelope with an official AN part number on it. I cut the necessary amount out of it, and superglued it together to make a much smaller ring.


It only took another 20minutes  to straighten the clamping ring and fit all the new pieces together like this:


(https://www.dropbox.com/s/qi3i8wu1w8cufv4/Voltmeter%5B1%5D.jpg?dl=1)


There's just enough clearance for the needle to move!
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 20 November 2016, 11:24:41
a nice where's my little tappy hammer fit

Also called "a machinists fit", I think. Very satisfying when you get it right! (less so if you overcook it a bit and then ruin the new bit trying to dig it back out when it's half way home. Not that I've ever had to do that to anything, you understand..)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 20 November 2016, 12:44:47
a nice where's my little tappy hammer fit

Also called "a machinists fit", I think. Very satisfying when you get it right! (less so if you overcook it a bit and then ruin the new bit trying to dig it back out when it's half way home. Not that I've ever had to do that to anything, you understand..)

I think you're right, but it's less descriptive if you haven't heard the term before.

My usual problem with this sort of thing is having to make another because the last tiny bit of fettling was too much, and the part is now too small. Fortunately, I don't work with expensive materials ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 29 January 2017, 20:04:16
Continuing on from the What did you do to your car today thread, here is my plan for rebuilding the diff/rear subframe mounts. I could fabri-cobble a one-off 'jig' out of scrap MDF in minutes, which would solve the single broken mount I have.



What I intend to build is a bolt together metal jig like this:


(https://www.dropbox.com/s/nh8qaaobvexlrtm/Differential%20Mount%20Mould%20Jig.jpg?dl=1)


that will clamp both metal parts of the failed mount in the correct orientation, and then fill where the rubber used to be with castable polyurethane(the red area, although I shall use black as I'm not 18):


(https://www.dropbox.com/s/ga6bjwesqmt0ut5/Differential%20Mount%20Mould%20Jig%20Urethane.png?dl=1)


Copious use of silicone release spray should make the repaired mounts 'easily' removable ;D
Some further thought suggests building it on a bigger plate, replacing the angle upright with a thicker piece and doubling the clamps. This will enable me to bolt a pair of diff mounts back to back, and repair both with one mix of urethane. That ought to make THIS  (http://www.ebay.de/itm/Neuer-Omega-B-Dampfungsblock-Hinterachse-rear-subframe-mount-GM-90447197-new/172405878264) sort of thing a lot more affordable!


What do you all think?
Title: Re: This Week in Wheeler's Workshop
Post by: amba on 29 January 2017, 20:09:36
You clever old sod ;)
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 29 January 2017, 20:15:05
I used cardboard, grease proof paper and wax...

Reckon that should do it :D
Title: Re: This Week in Wheeler's Workshop
Post by: Tick Tock on 29 January 2017, 20:16:30
Liking this so far.  :y :y

In years to come when Omegas are down to double figures out there on the road, this is one aspect that could make the difference between a 'saver' or a 'scrapper'. I noticed mine were looking a bit rough around the edges, and careful use of a sharp blade makes them look more tidy, but was of concern for the future.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 29 January 2017, 23:56:13
Liking this so far.  :y :y

In years to come when Omegas are down to double figures out there on the road, this is one aspect that could make the difference between a 'saver' or a 'scrapper'. I noticed mine were looking a bit rough around the edges, and careful use of a sharp blade makes them look more tidy, but was of concern for the future.


Mine both looked OK, until I undid the bolts and the metal outer fell of the O/S mount.


I've ordered the urethane, and if it isn't raining when I get in tomorrow will remove the better mount for a measure-up
Title: Re: This Week in Wheeler's Workshop
Post by: Lazydocker on 31 January 2017, 10:23:45
I'm interested in a set of diff mounts once you have the jig made :y

(Or you could lend me the jig and I'll pour my own)  ::) :D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 31 January 2017, 14:59:00
Once I had the knackered mount off the car I did some redesigning to simplify the jig, and made this out of finest ScrapbiniumTm:


(https://www.dropbox.com/s/rff4oxrhh30m83r/DiffBushJig%5B1%5D.jpg?dl=1)


That's an old Sunbeam gearbox cover, a chunk of 20mm ally plate and a couple of spigots to locate the inner parts of the bushes. It all bolts together to make removing the repaired bushes a bit easier - polyurethane will stick pretty much anything to anything, so I intend to grease every surface I don't want to bond together.


This will enable me to do a pair of bushes at a time, and will be durable enough for lots of use.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 31 January 2017, 15:00:17
Afternoon well spent :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 31 January 2017, 15:36:47
And here's the knackered mount cleaned up and clamped ready for the materials to arrive:


(https://www.dropbox.com/s/pm3tfan7pkwb5w9/DiffBushClamped%5B1%5D.jpg?dl=1)
Title: Re: This Week in Wheeler's Workshop
Post by: annihilator on 31 January 2017, 18:32:45
some guy in germany is doing a similar thing
http://www.ebay.pl/itm/Neuer-Omega-B-Dampfungsblock-Hinterachse-rear-subframe-mount-GM-90447197-new-/172405878264?hash=item282430edf8:g:URwAAOSwENxXm4W1 (http://www.ebay.pl/itm/Neuer-Omega-B-Dampfungsblock-Hinterachse-rear-subframe-mount-GM-90447197-new-/172405878264?hash=item282430edf8:g:URwAAOSwENxXm4W1)
John.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 31 January 2017, 19:07:48
some guy in germany is doing a similar thing
http://www.ebay.pl/itm/Neuer-Omega-B-Dampfungsblock-Hinterachse-rear-subframe-mount-GM-90447197-new-/172405878264?hash=item282430edf8:g:URwAAOSwENxXm4W1 (http://www.ebay.pl/itm/Neuer-Omega-B-Dampfungsblock-Hinterachse-rear-subframe-mount-GM-90447197-new-/172405878264?hash=item282430edf8:g:URwAAOSwENxXm4W1)
John.


Yep, posted that link in an earlier post. But, it's a minimum of 180Euros plus the waiting time and a core charge of another 40Euros. I have about 3 hours in this so far and one of those is removing the mount and cleaning the rubber off it, plus about £15 for the polyurethane. I could have made a one-use jig in 5 minutes from some ply and a handful of screws, but this one will be reusable(I've had a couple of nibbles already) and be easier to remove the repaired mount - I hope! It's about the size of 2 CDs, so I might even post it to people who have the same problem, I haven't decided which yet.
Title: Re: This Week in Wheeler's Workshop
Post by: annihilator on 31 January 2017, 19:19:52
apologies,missed the earlier link.I'm sure quite a few of us would put orders in for them if you have the time.
John. :y
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 31 January 2017, 19:44:17
I would sell refurbished rather than lend the tooling out. I appreciate that this might be a slightly misanthropic approach, but you don't need to sell them at silly prices.

Equally you could try different compounds for varying rigidity to suit individual tastes... this bepoke approach could be priced accordingly  ;)

By using mould release on the components you could sell the inserts, negating the need for exchanging old parts... simply send the core off for the end user to fit. :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 31 January 2017, 19:52:53
I would sell refurbished rather than lend the tooling out. I appreciate that this might be a slightly misanthropic approach, but you don't need to sell them at silly prices.

Equally you could try different compounds for varying rigidity to suit individual tastes... this bepoke approach could be priced accordingly  ;)

By using mould release on the components you could sell the inserts, negating the need for exchanging old parts... simply send the core off for the end user to fit. :y


In order:
complete parts is probably the way I'd go. We have a similar idea for refurbishing MGF displacers on an exchange basis.


Too much buggering about. You get what you get.


Looking at the shape of the central mounting block, I don't think it will extract and then fit easily. And I would much rather both parts were bonded together like the originals; the whole mount would need to be wider to stop it pulling apart.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 31 January 2017, 20:03:40
1. Concept is sound.

2. Fair dos, just a thought, although possibly 15 years too late...

3. You're setting the the centre in three planes... even underload it won't budge. Centre piece bolts to the subframe, and the carrier holds it tight to the chassis. The only variable is how clean the purchaser can get the metal work in order that they fit the moulding perfectly otherwise you get play, and play means catastrophic wear...

Thinking it through, you're right ;) although the concept is sound, there are simply too many variables :-\
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 02 February 2017, 18:10:06
The polyurethane arrived today.


So when I got in from work, I applied lots of vaseline to the jig and parts of the mount I don't want bonded together, mixed about 150g of material, and poured it in.


It's now curing in front of the fire:


(https://www.dropbox.com/s/w7oemk656x3as8k/DiffMountCuring%5B1%5D.jpg?dl=1)


It's a small thing, but I should have ordered some black pigment, which would make the finished part look a bit better.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 02 February 2017, 19:07:55
That looks allwight ;)

Sorry, couldn't help myself :-[
Title: Re: This Week in Wheeler's Workshop
Post by: biggriffin on 02 February 2017, 20:29:42
https://www.elichem.co.uk/p-4-anti-roll-bar-repair-resin.aspx
Title: Re: This Week in Wheeler's Workshop
Post by: X30XE on 02 February 2017, 21:51:11
The polyurethane arrived today.


So when I got in from work, I applied lots of vaseline to the jig and parts of the mount I don't want bonded together, mixed about 150g of material, and poured it in.


It's now curing in front of the fire:


(https://www.dropbox.com/s/w7oemk656x3as8k/DiffMountCuring%5B1%5D.jpg?dl=1)


It's a small thing, but I should have ordered some black pigment, which would make the finished part look a bit better.

doood sweet m8. how many horsepowers will it add in white??   :)
Title: Re: This Week in Wheeler's Workshop
Post by: ronnyd on 02 February 2017, 22:37:56
Are you infringing any patent rights or anything. ???
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 02 February 2017, 22:42:05
Are you infringing any patent rights or anything. ???
Nope, because nobody else makes them new and these are simply refurbishment of the original component ;)

As opposed to a blatant copy trying to be passed off as a genuine article...
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 03 February 2017, 00:36:44
Are you infringing any patent rights or anything. ???




How? I've taken a oppsed part that I already own, and repaired it using common materials and decades old techniques. If they were still​ available, I would have just bought one.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 03 February 2017, 06:15:42
No different to refurbishing wishbones ;)
Title: Re: This Week in Wheeler's Workshop
Post by: biggriffin on 03 February 2017, 19:53:40
Are you infringing any patent rights or anything. ???

really. :o
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 03 February 2017, 20:29:42
I removed all the bolts, and the part came off the jig easily:


(https://www.dropbox.com/s/1s2b039qhucqkp0/DiffMountCompleted%5B1%5D.jpg?dl=1)


I don't need to be quite so generous with the release agent, as the surface finish isn't brilliant. That won't affect how well it works, but it's no more effort to make a better looking part. The metal outer could do with a coat of paint, although it isn't going to get one.


I'll fit it tomorrow, along with the front springs which should restore the car's ride and ground clearance.
Title: Re: This Week in Wheeler's Workshop
Post by: biggriffin on 04 February 2017, 08:57:58
I do hope nick, that when you test these non gm parts you are  fully aware of the risks you are taking for the membership, please ensure you wear the correct safety equipment, and then we shall need a full non-senseical report in gobbledygook. ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 04 February 2017, 09:11:04
I could start a new organisation with one rule; just do the job in the way that is most efficient to you.


I would call it Pragmatists Club, but shortening it to PC might lead to some confusion ;D
Title: Re: This Week in Wheeler's Workshop
Post by: TheBoy on 04 February 2017, 09:31:07
That's looking good Nick W.  Will be interested what they are like on the car :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 04 February 2017, 09:49:26
That's looking good Nick W.  Will be interested what they are like on the car :y


Dirtier ;D


It's just a prototype repair caused  by the unavailability of new replacements, and the high cost of tired secondhand parts. Using secondhand rubber mounts smacks of desperation to me. The lack of voids in a stable material suggest it ought to be durable which is my main requirement. You've probably noticed I've only done one, as that's all I need so far.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 04 February 2017, 17:21:38
I do hope nick, that when you test these non gm parts you are  fully aware of the risks you are taking for the membership, please ensure you wear the correct safety equipment, and then we shall need a full non-senseical report in gobbledygook. ;D


Trev, it is a gm part - Good Make :y


Needing a slight tweak to make the second bolt fit, it's on the car.


Here's the full report: it works.
Title: Re: This Week in Wheeler's Workshop
Post by: biggriffin on 04 February 2017, 18:29:10
I do hope nick, that when you test these non gm parts you are  fully aware of the risks you are taking for the membership, please ensure you wear the correct safety equipment, and then we shall need a full non-senseical report in gobbledygook. ;D


Trev, it is a gm part - Good Make :y


Needing a slight tweak to make the second bolt fit, it's on the car.


Here's the full report: it works.
 

 8)  ;)
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 04 February 2017, 18:34:06
I do hope nick, that when you test these non gm parts you are  fully aware of the risks you are taking for the membership, please ensure you wear the correct safety equipment, and then we shall need a full non-senseical report in gobbledygook. ;D


Trev, it is a gm part - Good Make :y


Needing a slight tweak to make the second bolt fit, it's on the car.


Here's the full report: it works.
Oh no, no, no. You can't say that until you've stress tested it. Drop it off at Jamie's tomorrow for a QC test.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 04 February 2017, 18:50:44
If I was worried about stress testing it, I've a mate who is far harder on mechanical stuff than anyone on this forum. ;D


Considering how much better the back of the car is now, I'm wondering how long the mount was broken.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 04 February 2017, 19:08:27
Or how long the other side lasts... but at least you can now fix that the same day :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 19 February 2017, 23:50:41
This weekend's job was supposed to be modifying the first MGF hydragas displacer so that we can refill them with nitrogen.
I had all the parts; a displacer, some metal bodied high pressure schrader valves, and some bosses tapped 1/8BSP(actually pneumatic fittings). The plan was to turn the fittings to a convenient size, drill a corresponding hole in the top of the displacer and TIG the two together. But some cretin ordered brass instead of steel fittings, so that plan is postponed.


That meant I couldn't put off fitting the milling spindle to the lathe any longer:


(https://www.dropbox.com/s/ydxqd9zy88kmz4b/VerticalSlideFitted%5B1%5D.jpg?dl=1)
That's the vertical slide for my original mini-lathe with some extra tapped holes, all on a scratch built mount.


Add an ER11 spindle motor(£80 off Ebay, including the mount, power supply and set of collets)


(https://www.dropbox.com/s/g88ypi58c1sf8bz/MillingMotor2%5B1%5D.jpg?dl=1)


and


(https://www.dropbox.com/s/ir5vq2ytvewybuj/MillingMotor%5B1%5D.jpg?dl=1)




Now I can drill cross holes, mill keyways, slots, hexheads etc and drill PCDs without having to transfer the part to the mill.


Like this quick and dirty testpiece, indexing the chuck jaws by eye:


(https://www.dropbox.com/s/z6ksj42ihw7ijzw/MakingTestPiece%5B1%5D.jpg?dl=1)


Next job is a stepper-motor headstock dividing attachment, then I can start making the wheels for a simple clock
Title: Re: This Week in Wheeler's Workshop
Post by: henryd on 20 February 2017, 10:51:09
Very impressive Nick :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 26 February 2017, 19:14:07
This little hole is an MOT failure:


(https://www.dropbox.com/s/9loxju8394oeso3/LittleHole%5B1%5D.jpg?dl=1)


So I cut it out and had a poke about behind it:


(https://www.dropbox.com/s/o3njh3624uryz2s/CrustyMess%5B1%5D.jpg?dl=1)


Leading to this:


(https://www.dropbox.com/s/75qs9i6ugm4apdl/CutOut%5B1%5D.jpg?dl=1)


A load of cutting and welding later:


(https://www.dropbox.com/s/2e9r4wpneh1t9r5/MostlyRepaired%5B1%5D.jpg?dl=1)


meant I could finally do the 10minute job I started with >:(


None of this is helped by having to remove the seat cushion, various trim pieces, wiring, sound deadening and seam sealer so that they don't get cut through/set alight. There's also a crusty hole in the sill just in front of the jacking point, but that's not visible with the sill cover in place. So I'll get a new sill(both, probably) and replace them in the summer when I'm not working to a deadline.

At least changing the headlamp washer pump was a two minute job :y Looking back, I don't think they've ever worked in the six years I've owned the car.
Title: Re: This Week in Wheeler's Workshop
Post by: X30XE on 26 February 2017, 19:49:12
Yeah... see the thing is... I've never learnt to weld so... I'm gonna have to adopt you.. DAD... and you're gonna have to help me fix this...

 :)

(http://i605.photobucket.com/albums/tt133/011011011/20170226_132609_zpstywhdutn.jpg)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 02 April 2017, 18:56:23
This week's jobs:


MGF wheel bearing:


(https://www.dropbox.com/s/9hsseyzv0aa4vjm/MGFwheelBearing%5B1%5D.jpg?dl=1)


That was the easy bit; it took 8 tons of pressure to push the hub out :o


And I made this blanking plug for the auxiliary fuel tank hose on a Yak18, as we can't buy them:


(https://www.dropbox.com/s/61xqxxa26r3smsr/FueltankHoseBlank%5B1%5D.jpg?dl=1)
It's M24x1.5, cut on a piece of 1" hex bar. That's the first thread I've done just by the numbers, without being able to try the mating part, hopefully it will work
Title: Re: This Week in Wheeler's Workshop
Post by: Lizzie Zoom on 02 April 2017, 20:15:38
That looks very impressive :y

In my time I have done some die and tapping but nothing on that scale!

I remember it being very satisfying. 8)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 02 April 2017, 20:52:48
M24x1.5 dies start at about £60, and would need a big die holder and a lot of effort to turn it.
That was single point threaded in the lathe.
Title: Re: This Week in Wheeler's Workshop
Post by: Lizzie Zoom on 02 April 2017, 20:57:26
M24x1.5 dies start at about £60, and would need a big die holder and a lot of effort to turn it.
That was single point threaded in the lathe.

I rather suspected a lathe would be involved. If I had the space I would love one of them :D ;)
Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 02 April 2017, 21:25:58
And I made this blanking plug for the auxiliary fuel tank hose on a Yak18, as we can't buy them:

 :-* :-* :-* :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 16 April 2017, 21:29:50
I got home earlier than I expected to from the quarter peal, and decided that I've put this job off for long enough:


(https://www.dropbox.com/s/6xs19woad4avkyl/DisplacerBoss%5B1%5D.jpg?dl=1)


that's a high pressure schraeder valve and threaded boss to weld onto an MGF suspension displacer like this:


(https://www.dropbox.com/s/lyrun7n20lwij4a/repairedDisplacer%5B1%5D.jpg?dl=1)


the next step is to recharge it with 25bar of nitrogen, do the same to the other 3, and fit them to the car. Which should make the thing handle and ride properly again.


And I made a new pin to repair the shears that you can see in the last picture. Apparently they're still new, as she's only had them twenty years ::)
Title: Re: This Week in Wheeler's Workshop
Post by: Lincs Robert on 16 April 2017, 21:42:19
What's a quarter peal in your world?  8)

In mine we did 2 today. Are we in the same world? I suspect so.

How many have you done? I've done 426 .......
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 16 April 2017, 21:45:05
The last two were Grandsire Caters.


I've done about twenty since I started ringing again 18months ago.
Title: Re: This Week in Wheeler's Workshop
Post by: Lincs Robert on 16 April 2017, 22:02:35
The last two were Grandsire Caters.


I've done about twenty since I started ringing again 18months ago.

Good stuff. How long did you stop for? I've been doing it since 2004, mainly ring on 6 due to there being a lot of 6 bell towers up this way. I've covered to 2 triples quarters and trebled to 1, find rope sight much more difficult on 8 than 6. I've done one peal, plain bob minor inside, when my grandson was born - but didn't enjoy it and doubt whether I'll do any more.

I spent some time in hospital earlier this year so am steadily returnin - but taking it easy so as not to overdo it.

 :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 16 April 2017, 22:12:39
I stopped for about 26 years, mainly because my shifts were erratic. I promised myself that when I stopped shift work I'd take it up again.


I haven't rung any peals, and don't expect to; the combination of a bad back(from warehouse work and driving trucks) and a broken leg that healed 20mm short I doubt I could stand still for three and half hours.
Title: Re: This Week in Wheeler's Workshop
Post by: Lincs Robert on 16 April 2017, 22:20:08
Well keep up the good work. I suspect that anyone else reading this will think we are talking swalahi!

If you find yourself up this way then PM me and you can grab a tower up here.

All the best ......
Title: Re: This Week in Wheeler's Workshop
Post by: ronnyd on 16 April 2017, 22:45:25
My dear old Dad was a keen Campanologist.
Title: Re: This Week in Wheeler's Workshop
Post by: Lincs Robert on 17 April 2017, 07:54:02
My dear old Dad was a keen Campanologist.

You could take it up. Never too late - I was 48 before I started  :y
Title: Re: This Week in Wheeler's Workshop
Post by: ronnyd on 19 April 2017, 13:52:35
I,m 72 with a dodgy right arm. ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Migv6 le Frog Fan on 19 April 2017, 14:09:20
I'm 57 with dodgy everything. Just got some nasty chest pains carrying my trolley jack into my shed, so can add to the list now.  ::) ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Lazydocker on 19 April 2017, 14:14:22
I'm 57 with dodgy everything. Just got some nasty chest pains carrying my trolley jack into my shed, so can add to the list now.  ::) ;D

57? Christ on a bike, you had a hard paper round :D :D :D

 :P  ::)
Title: Re: This Week in Wheeler's Workshop
Post by: Migv6 le Frog Fan on 19 April 2017, 15:16:39
I'm 57 with dodgy everything. Just got some nasty chest pains carrying my trolley jack into my shed, so can add to the list now.  ::) ;D

57? Christ on a bike, you had a hard paper round life:D :D :D

 :P  ::)

Theres no denying it.  :(

 ;D ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Lincs Robert on 19 April 2017, 18:29:19
I,m 72 with a dodgy right arm. ;D

Age is no problem, but you really need both arms!
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 19 April 2017, 19:00:03
I,m 72 with a dodgy right arm. ;D

Age is no problem, but you really need both arms!
I can immediately think of two people here who might beg to differ... ;)
Title: Re: This Week in Wheeler's Workshop
Post by: Lincs Robert on 19 April 2017, 19:17:13
I,m 72 with a dodgy right arm. ;D

Age is no problem, but you really need both arms!
I can immediately think of two people here who might beg to differ... ;)

?
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 19 April 2017, 19:38:25
I,m 72 with a dodgy right arm. ;D

Age is no problem, but you really need both arms!
I can immediately think of two people here who might beg to differ... ;)


Are they ringers too?  :o
It's possible to ring one handed(it's possible to ring two bells at once, but very few people can do it), but I would suggest that most who do didn't learn that way.
Title: Re: This Week in Wheeler's Workshop
Post by: Lincs Robert on 19 April 2017, 20:14:27
I,m 72 with a dodgy right arm. ;D

Age is no problem, but you really need both arms!
I can immediately think of two people here who might beg to differ... ;)


Are they ringers too?  :o
It's possible to ring one handed(it's possible to ring two bells at once, but very few people can do it), but I would suggest that most who do didn't learn that way.

I know someone who does this on a regular basis- frightens the hell out of me!
There was an episode of Midsomer which featured a ringing competition- ringers getting killed all round, in the end the winning team was a team of 3 people ringing 6 bells! The episode was called "ring our your dead".

I'm not sure what DG means & hope he will enlighten us .......
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 19 April 2017, 20:40:54
Webby and Elite lover have a pair of hands between them ;)

Had forgotten that you were discussing campagnology :-[  ::)
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 19 April 2017, 20:47:22
Didn't know about Elite Lover, but you've got to take your hat off to young Webby. He just gets on with things, he's a good lad.

FFS....Don't tell him I said that.  :-X
Title: Re: This Week in Wheeler's Workshop
Post by: Migv6 le Frog Fan on 19 April 2017, 20:54:47
Wot he said. ^  :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 02 July 2017, 21:39:54
I've been doing a lot of ringing recently so my workshop time has consisted of not making a clock ;D


But Richard's MGF project needs to move along, so he's bought some bits. These consist of three more displacers to repair/recharge, and because its got a head gasket issue we're going to upgrade it from the stock 118hp spec.


So, we have the head, cams, ECU and bigger throttle body off a 135hp car:


(https://www.dropbox.com/s/k7r02jgitnjkiot/AsRemoved.jpg?dl=1)


These are supposed to benefit from matching the inlet ports to the manifold, and the impression on the gasket confirms that: stock ports:


(https://www.dropbox.com/s/7r4j659uoydwgee/StockIntakePorts.jpg?dl=1)


and marked out:


(https://www.dropbox.com/s/9xdfzwwmk9zlnyg/StockPort.jpg?dl=1)


About 20minutes with the die grinder:


(https://www.dropbox.com/s/rf3vs8z737hjdto/EnlargedPorts.jpg?dl=1)


I also removed the step in the short turn near the valve seats as best I could. Once I've got some stones for the Dremel, I'll open up the holes for the water jacket too.


Finally for today, I cleaned up each valve in the lathe using some emery cloth and 400grit (no longer)sticky DA discs:


(https://www.dropbox.com/s/i1fijm2kbrgbc3j/CleaningValve.jpg?dl=1)


I left my drill at work and I'm NOT lapping 16 valves by hand, so that can wait until Tuesday.


The last headwork I did was on a Lycoming engine; these K-series parts are tiny ;D
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 03 July 2017, 12:13:35
But Richard's MGF project needs to move along, so he's bought some bits. These consist of three more displacers to repair/recharge, and because its got a head gasket issue we're going to upgrade it from the stock 118hp spec.

Surprise! ;)

Lathe envy, btw. Lathe envy. I bet your Warco has a lot less play in it than my Myfords :)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 04 July 2017, 13:42:45

Lathe envy, btw. Lathe envy. I bet your Warco has a lot less play in it than my Myfords :)


I only bought it 3 1/2 years ago to replace a mini-lathe, so that had better be the case
The 5" centre height, 30mm spindle bore, 1100w variable speed motor and power cross-slide(which is particularly good for parting off) make it a lot more usable. Well worth the £1100 it cost, I wish I had space to upgrade the mini mill.
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 04 July 2017, 15:54:28
I know that's not particularly expensive for a lathe, but it's still the total cost of both my Myfords combined ;D That said, I'd get more use out of a single, expensive lathe than I would my Myfords, I suspect - especially one, which has pretty catastrophic play in the compound slide which leads to the tooling (esp. if carbide) 'digging' in on facing operations with interesting results!

Perhaps I should chop them both in (still a healthy market) for one newer one..

I'd still love an old Bridgeport, though  :D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 11 November 2017, 19:20:48
I've made a number of bits for work, but they're just boring round stuff.


I have been acquiring some bits though:


(https://www.dropbox.com/s/7i6yw93ckb1kinc/CNCparts%5B1%5D.jpg?dl=1)


That's a standalone 4 axis CNC controller, stepper motor, driver, coupling and mount plus a 12mm ballscrew with bearings. The rest of the bits are in the box behind. The plan was to get this


(https://www.dropbox.com/s/5d6kh4s7gq6sk7y/BareMill%5B1%5D.jpg?dl=1)


converted before Christmas, but I suspect the fettling of my new car will prevent that. The welding will probably start tomorrow.
Title: Re: This Week in Wheeler's Workshop
Post by: ronnyd on 11 November 2017, 21:03:41
Have you got a designated workshop Nick, or is it part of your garage? After a life of working on centre lathes and milling machines, i now don,t feel a need to start doing it in retirement. :D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 11 November 2017, 21:19:42
Garage? Dedicated workshop? Off-road parking? What are they? ;D


My cars have always lived in the street, and my tools are in the cellar; which is home to  the fridge, freezer, storage, coats, indoor washing line and the door we use most of the time. I keep the MIG in the front porch, hydraulic press on the back court and a load of small stuff in the outside bog.


That's the real reason for converting the mini-mill to CNC, if I had the space I would buy a small turret mill for the productivity increase I'm after.
Title: Re: This Week in Wheeler's Workshop
Post by: Mr Gav on 11 November 2017, 21:50:45
Garage? Dedicated workshop? Off-road parking? What are they? ;D


My cars have always lived in the street, and my tools are in the cellar; which is home to  the fridge, freezer, storage, coats, indoor washing line and the door we use most of the time. I keep the MIG in the front porch, hydraulic press on the back court and a load of small stuff in the outside bog.


That's the real reason for converting the mini-mill to CNC, if I had the space I would buy a small turret mill for the productivity increase I'm after.

I like your enthusiasm Nick, proper British back yard engineering  :y
Title: Re: This Week in Wheeler's Workshop
Post by: ronnyd on 11 November 2017, 22:18:19
Garage? Dedicated workshop? Off-road parking? What are they? ;D


My cars have always lived in the street, and my tools are in the cellar; which is home to  the fridge, freezer, storage, coats, indoor washing line and the door we use most of the time. I keep the MIG in the front porch, hydraulic press on the back court and a load of small stuff in the outside bog.


That's the real reason for converting the mini-mill to CNC, if I had the space I would buy a small turret mill for the productivity increase I'm after.
Blimey, i admire your ingenuity  :o :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 15 November 2017, 12:01:55
I fitted a replacement battery to the new toy so it now starts on the button. Then I refitted all of the loose bits of dash that the PO hadn't bothered doing after installing a new heater matrix. I also connected the two hoses that he had joined together for some reason. Now the heater works, which is quite important in November.

I've also ordered a pair of sills to sort the crusty originals, and a bonnet latch so I can lose the hideous bonnet pins. Nor do I see any need for the radiator fan switch to be bypassed for a manual one; I'll buy a new switch to be sure and reinstate it. Taking chances with cooling on a K-series is bloody stupid.

I'd forgotten just how much fun small cars with decent size engines are, it's impossible to get out of this thing without a big smile.
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 15 November 2017, 12:12:18
Small car with K series..hmm..

Can't be an Elise, the sills are plastic fibreglass.
Can't be a Caterfield, there's no need for a heater in a car with no roof.

MGTF?
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 15 November 2017, 12:47:02
Small car with K series..hmm..

Can't be an Elise, the sills are plastic fibreglass.
Can't be a Caterfield, there's no need for a heater in a car with no roof.

MGTF?

No roof increases the need for a good heater!

Good guess on the MGTF, but wrong. I think the TF changes spoilt the earlier car. And it isn't one of those either.
Title: Re: This Week in Wheeler's Workshop
Post by: Viral_Jim on 15 November 2017, 12:58:06
Left field suggestion:

Rover Tomcat with a targa roof?  :-\
Title: Re: This Week in Wheeler's Workshop
Post by: Field Marshal Dr. Opti on 15 November 2017, 13:00:45
Stimson Scorcher? :)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 15 November 2017, 13:03:43
Left field suggestion:

Rover Tomcat with a targa roof?  :-\

I know where there is a good cheap one, but no. And I'd buy a turbo Astra coupe if in the market for that sort of thing.
Title: Re: This Week in Wheeler's Workshop
Post by: BazaJT on 15 November 2017, 18:44:52
Rover 75?
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 15 November 2017, 19:03:10
Rover 75?


Small car? And they're hardly suitable as a toy ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 15 November 2017, 19:07:07
Stimson Scorcher? :)


I'm slightly disappointed that I had to google that.
It's certainly left field
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 15 November 2017, 19:26:15
Metro or Maestro?
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 15 November 2017, 19:34:18
Metro or Maestro?


K-series in a Maestro seems like a lot of work, when the T-series turbo ought to be a bolt in. And I've had a Montego turbo.


No, it's this:


(https://www.dropbox.com/s/f3p00f1hykanbz0/Metro%5B1%5D.jpg?dl=1)
Title: Re: This Week in Wheeler's Workshop
Post by: Migv6 le Frog Fan on 15 November 2017, 20:10:02
Well, it isn't the ugliest car in your street. That's for certain.  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 15 November 2017, 20:46:51
I can’t see your pictures, Nick, who are you using to host them?
Title: Re: This Week in Wheeler's Workshop
Post by: YZ250 on 15 November 2017, 20:51:16
I can’t see your pictures, Nick, who are you using to host them?

Dropbox...... but I can't see them either so I used the 'quote' button to find where they were hosted.   ;D

Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 15 November 2017, 20:59:45
I can’t see your pictures, Nick, who are you using to host them?

Dropbox...... but I can't see them either so I used the 'quote' button to find where they were hosted.   ;D
:y

Sorry I looked now  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 15 November 2017, 21:03:32
Well, it isn't the ugliest car in your street. That's for certain.  ;D


When everybody is at home we've a fine supply of ugly: another Multipla, a Voyager, two 500s - one of them an L which competes with the Juke that another neighbour has just acquired, an Alfa and my mother's Focus. What we need is an aging Omega to add a touch of shabby gentility. No, there's one of those too ;D
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 16 November 2017, 09:02:55
Good lord Nick.. I can only assume someone paid you to take it away? ;D

I had one, once, as a company car.. mine was the 1.4D devoid of any kind of power. Still managed to spin it into a ditch at 17, though that might have been because the front subframe was, prior to that event, two halves of a subframe no longer attached to each other.. only the best BL quality parts.

(I too can't see the pictures without playing the quote-the-post-copy-the-link-remove-the-end-bit game)
Title: Re: This Week in Wheeler's Workshop
Post by: amba on 16 November 2017, 09:56:40
No pictures here either,and If I look out of the loft window I can almost see your road  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 16 November 2017, 10:03:05
Good lord Nick.. I can only assume someone paid you to take it away? ;D

I had one, once, as a company car.. mine was the 1.4D devoid of any kind of power. Still managed to spin it into a ditch at 17, though that might have been because the front subframe was, prior to that event, two halves of a subframe no longer attached to each other.. only the best BL quality parts.

(I too can't see the pictures without playing the quote-the-post-copy-the-link-remove-the-end-bit game)

Power isn't a problem, as it has the 1.8VVC engine. And all of the GTI suspension parts that are necessary for such conversions.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 16 November 2017, 10:26:45
Thank God for that. Now I can see it, I am relieved to see that it isn't a purple cabriolet  :D
Title: Re: This Week in Wheeler's Workshop
Post by: Field Marshal Dr. Opti on 16 November 2017, 10:59:56
I can’t see your pictures, Nick, who are you using to host them?

I'll help you out.

Nick has posted a picture of a beautiful blue Lamborghini. :)
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 16 November 2017, 11:14:07
I can’t see your pictures, Nick, who are you using to host them?

I'll help you out.

Nick has posted a picture of a beautiful blue Lamborghini. :)
Well... They weigh about the same :D
Title: Re: This Week in Wheeler's Workshop
Post by: henryd on 16 November 2017, 11:55:48
Good lord Nick.. I can only assume someone paid you to take it away? ;D

I had one, once, as a company car.. mine was the 1.4D devoid of any kind of power. Still managed to spin it into a ditch at 17, though that might have been because the front subframe was, prior to that event, two halves of a subframe no longer attached to each other.. only the best BL quality parts.

(I too can't see the pictures without playing the quote-the-post-copy-the-link-remove-the-end-bit game)

Power isn't a problem, as it has the 1.8VVC engine. And all of the GTI suspension parts that are necessary for such conversions.

It must bloody tramp on with that motor in it :o :y
Title: Re: This Week in Wheeler's Workshop
Post by: Migv6 le Frog Fan on 16 November 2017, 12:20:28
Good lord Nick.. I can only assume someone paid you to take it away? ;D

I had one, once, as a company car.. mine was the 1.4D devoid of any kind of power. Still managed to spin it into a ditch at 17, though that might have been because the front subframe was, prior to that event, two halves of a subframe no longer attached to each other.. only the best BL quality parts.

(I too can't see the pictures without playing the quote-the-post-copy-the-link-remove-the-end-bit game)

Power isn't a problem, as it has the 1.8VVC engine. And all of the GTI suspension parts that are necessary for such conversions.

It must bloody torque steer like crazy on with that motor in it :o :y

Fixed.  :D
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 16 November 2017, 12:34:10
Front wheel drive was once unthinkable with anything more than 250bhp, but there are quite a few cars which seem to go in a straight line with it nowadays.
Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 16 November 2017, 12:38:32
Front wheel drive was once unthinkable with anything more than 250bhp, but there are quite a few cars which seem to go in a straight line with it nowadays.

Yep, mostly when you're trying to negotiate a bend. ;)
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 16 November 2017, 12:39:28
Front wheel drive was once unthinkable with anything more than 250bhp, but there are quite a few cars which seem to go in a straight line with it nowadays.
Only by using different length suspension components and  individual wheel braking to counter yaw ::)
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 16 November 2017, 12:59:24
Front wheel drive was once unthinkable with anything more than 250bhp, but there are quite a few cars which seem to go in a straight line with it nowadays.
Only by using different length suspension components and  individual wheel braking to counter yaw ::)
To counter my what?  :-\
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 16 November 2017, 13:20:33
Front wheel drive was once unthinkable with anything more than 250bhp, but there are quite a few cars which seem to go in a straight line with it nowadays.
Only by using different length suspension components and  individual wheel braking to counter yaw ::)

Technically I'd say that any decent car suspension should have different length components - specifically the upper & lower wishbones; anything else is a packaging or financial compromise that results in sub-par handling ;)
Title: Re: This Week in Wheeler's Workshop
Post by: Field Marshal Dr. Opti on 16 November 2017, 13:36:00
Front wheel drive was once unthinkable with anything more than 250bhp, but there are quite a few cars which seem to go in a straight line with it nowadays.

Yep, mostly when you're trying to negotiate a bend. ;)

As a kid I had a Corgi model of the Oldsmobile Toronado from the mid sixties. A nice big 7 litre V8 driven through the front wheels. :y

Great looking car. :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 16 November 2017, 14:21:33
Front wheel drive was once unthinkable with anything more than 250bhp, but there are quite a few cars which seem to go in a straight line with it nowadays.

Yep, mostly when you're trying to negotiate a bend. ;)

As a kid I had a Corgi model of the Oldsmobile Toronado from the mid sixties. A nice big 7 litre V8 driven through the front wheels. :y

Great looking car. :y

Cadillac used the same gearbox with an 8.2l engine bolted to it. 400 lb/ft of torque from about 1000rpm.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 16 November 2017, 14:23:54
Front wheel drive was once unthinkable with anything more than 250bhp, but there are quite a few cars which seem to go in a straight line with it nowadays.
Only by using different length suspension components and  individual wheel braking to counter yaw ::)
To counter my what?  :-\
The effect of torque steer on the rear axle ;)
Title: Re: This Week in Wheeler's Workshop
Post by: Field Marshal Dr. Opti on 16 November 2017, 15:01:30
Front wheel drive was once unthinkable with anything more than 250bhp, but there are quite a few cars which seem to go in a straight line with it nowadays.

Yep, mostly when you're trying to negotiate a bend. ;)

As a kid I had a Corgi model of the Oldsmobile Toronado from the mid sixties. A nice big 7 litre V8 driven through the front wheels. :y

Great looking car. :y

Cadillac used the same gearbox with an 8.2l engine bolted to it. 400 lb/ft of torque from about 1000rpm.

All it needed was Frank Cannon.....or was that a Lincoln Continental?
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 16 November 2017, 15:16:04
More like Boss Hogg
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 16 November 2017, 17:50:11

Power isn't a problem, as it has the 1.8VVC engine. And all of the GTI suspension parts that are necessary for such conversions.

It must bloody tramp on with that motor in it :o :y


You might think that; I couldn't possibly comment ::)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 16 November 2017, 17:52:52
I can’t see your pictures, Nick, who are you using to host them?

I'll help you out.

Nick has posted a picture of a beautiful blue Lamborghini. :)
Well... They weigh about the same :D


Metros are just over 800kg(not much more than a 'lightweight' Elise)
What Lamborghini gets even close to that?
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 17 November 2017, 09:28:42
Metros are just over 800kg(not much more than a 'lightweight' Elise)
What Lamborghini gets even close to that?

Most will be within about 1000kg of that. Just. ;D ;D ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 17 November 2017, 10:32:45
Metros are just over 800kg(not much more than a 'lightweight' Elise)
What Lamborghini gets even close to that?

Most will be within about 1000kg of that. Just. ;D ;D ;D
Especially the full fat Vorsprung durch essen versions  ;D

The Urraco P250 tips the scale at a mere 1,100 kgs which isn't bad considering that it's twice the size of the Metro :o
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 17 November 2017, 10:57:04
Yup, sure I remember my friend with the Gallardo saying it's ~1800kg.

Doesn't feel it, mind, when you're driving it!
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 19 November 2017, 19:04:11
Made a start on the Metro.


This is NOT how to repair a rusty sill:


(https://www.dropbox.com/s/rk13u8lj4unvgct/GrottySill.jpg?dl=1)


Especially as there's another rusty part near the front.


This is what is actually required after cutting out and repairing the grot in the floor:


(https://www.dropbox.com/s/7scgndj809zs0nf/CutOffSill.jpg?dl=1)


A bit of tidying up, £45 and some clamps:


(https://www.dropbox.com/s/s5uqj6q56dy3hvp/SillClampedOn.jpg?dl=1)


And run out of gas just when it's tacked on at the top, and plug welded along most of the bottom:


(https://www.dropbox.com/s/qtwik4f01whvo30/SillTackedOn.jpg?dl=1)


So I ground down the welds that I did manage to do, put the car back on its wheels(it's in the street) and went to the pub. I bought it with the arch repair panel fitted like that; I would have fitted considerably less of it so as not to need so much filler to cover the distortion.


I'll get some more gas in the week so I can finish this repair and make a start on the other side which hopefully doesn't need any work to the floor.
Title: Re: This Week in Wheeler's Workshop
Post by: biggriffin on 19 November 2017, 19:22:46
O dear. The race metro was a joy to work on( turbo)   :o  Next time your up nick will talk. :o
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 26 November 2017, 19:05:11
A days work, and it looks just like it did when I bought it:


(https://www.dropbox.com/s/u7uj1va4n3dzrkz/SillFinished.jpg?raw=1)


I'll do the filler work and paint the whole side over Christmas.


The other side will be next weekends job.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 17 March 2018, 20:49:01
Some new bits:


(https://www.dropbox.com/s/yxpg03iar17rh17/MetroExhausts.jpg?raw=1)


that's the leaky, rattly old Metro GTi exhaust(which I couldn't find a new one of) and a 2.25" aftermarket system. The pic doesn't show the new downpipe and cat that I'd already fitted.


The only snag is the polished stainless tailpipe looks even tackier than I thought it would:


(https://www.dropbox.com/s/04ip9eyllww9mbl/SillyExhaust1.jpg?raw=1)


So I'll probably paint it black so it isn't such an eyesore sometime soon.



Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 18 March 2018, 20:20:39
Wicked, innit?  :D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 27 April 2018, 16:28:03
It's been a week for Rovers.


We fitted 4 Hydragas displacers to a mates MGF, along with bigger brakes front and rear, a cold air intake and I fixed the coolant leak by binning the last spring clip on the car and fitting the Jubilee clip it should have had in the first place.


I've also been nibbling away at the welding on my Metro; the test was booked for 09:00 today. But I found that it had NO brakes, so had to fit the new master cylinder I've had for a while. They managed to test it just after lunch, and after I fitted two new wiper blades plus a headlight bulb(which was working, but producing an unsatisfactory pattern) passed it. It turns out that I also have a coolant leak from a hose join, so will be applying the usual fix to that in the morning. The silly looking exhaust doesn't sound as bad as I expected, so I'm calling it a win. Although I am looking forward to a beer after practice tonight.
Title: Re: This Week in Wheeler's Workshop
Post by: Field Marshal Dr. Opti on 27 April 2018, 16:35:12
Wicked, innit?  :D

Don't forget to wear a back to front baseball cap to complete the image. :D

You'll be on the front cover of Max Power magazine in no time. ;)
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 27 April 2018, 17:47:16
You'll be on the front cover of Max Power magazine in no time. ;)

The granddaddy of lads mags, that..
Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 27 April 2018, 19:21:39
You'll be on the front cover of Max Power magazine in no time. ;)

But it's not a Fawd. :-\
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 02 May 2018, 21:02:32
The Metro's previous owner lost all of the boot trim and I'm trying to make it reasonably civilised, so this needed sorting:


(https://www.dropbox.com/s/2j1oopgyz2nxohe/BareQuarter.jpg?raw=1)


that whole area, including the wheeltub is normally covered with one piece of moulded carpet. That's a bit beyond me, so it was time for some simple trim work.


Multi piece cardboard pattern:


(https://www.dropbox.com/s/tukba3ieh7g2sdr/PaperPattern.jpg?raw=1)


which makes two 3mm ply panels:


(https://www.dropbox.com/s/yyf5172f1g99wsw/PlyPanel.jpg?raw=1)


Glue on some scrim foam:




(https://www.dropbox.com/s/4touwyby9r1sibz/TrimmedScrimFoam.jpg?raw=1)


Cover that in more contact adhesive, and stick on the vinyl:


(https://www.dropbox.com/s/tk1aj04ay8i4nsi/AddVinyl.jpg?raw=1)


A couple of minutes of stretching, gluing and stapling later:




(https://www.dropbox.com/s/ua25xkdhudi7kjt/GluedandStapled.jpg?raw=1)


And the finished piece in place(although not fitted):


(https://www.dropbox.com/s/trcsv5cntsf321x/PanelFitted.jpg?raw=1)


That was all done with leftovers from a previous job, as is the dark grey carpet I'll be using on the wheeltubs and boot floor. If I'd bought materials for this job, I would have matched the existing trim a bit better. Although I will eventually replace the door cards and trim panels with fully fitted ones from a higher spec car.
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 02 May 2018, 21:14:31
The Metro's previous owner lost all of the boot trim and I'm trying to make it reasonably civilised, so this needed sorting:



(https://www.dropbox.com/s/2j1oopgyz2nxohe/BareQuarter.jpg?dl)


that whole area, including the wheeltub is normally covered with one piece of moulded carpet. That's a bit beyond me, so it was time for some simple trim work.


Multi piece cardboard pattern:


(https://www.dropbox.com/s/tukba3ieh7g2sdr/PaperPattern.jpg?dl=1)


which makes two 3mm ply panels:


(https://www.dropbox.com/s/yyf5172f1g99wsw/PlyPanel.jpg?dl=1)


Glue on some scrim foam:




(https://www.dropbox.com/s/4touwyby9r1sibz/TrimmedScrimFoam.jpg?dl=1)


Cover that in more contact adhesive, and stick on the vinyl:


(https://www.dropbox.com/s/tk1aj04ay8i4nsi/AddVinyl.jpg?dl=1)


A couple of minutes of stretching, gluing and stapling later:




(https://www.dropbox.com/s/ua25xkdhudi7kjt/GluedandStapled.jpg?dl=1)


And the finished piece in place(although not fitted):


(https://www.dropbox.com/s/trcsv5cntsf321x/PanelFitted.jpg?dl=1)


That was all done with leftovers from a previous job, as is the dark grey carpet I'll be using on the wheeltubs and boot floor. If I'd bought materials for this job, I would have matched the existing trim a bit better. Although I will eventually replace the door cards and trim panels with fully fitted ones from a higher spec car.
Trying to make the images appear but no joy.
Title: Re: This Week in Wheeler's Workshop
Post by: Marks DTM Calib on 03 May 2018, 07:57:13
If using drop box you have to modify the final part of the link and change ?dl=0 to ?raw=1
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 03 May 2018, 08:33:25
If using drop box you have to modify the final part of the link and change ?dl=0 to ?raw=1


I know. And did so.
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 03 May 2018, 09:00:35
They never appear for me, either.. unless I quote the post and manually go to each link.

Erm.. which I invariably CBA to do  :-[ :-X
Title: Re: This Week in Wheeler's Workshop
Post by: reggill on 03 May 2018, 22:50:54
Impressive work. Very insightful to look back through these posts
Title: Re: This Week in Wheeler's Workshop
Post by: Marks DTM Calib on 04 May 2018, 11:14:53
If using drop box you have to modify the final part of the link and change ?dl=0 to ?raw=1


I know. And did so.

No you didn't, I edited it  :y (you changed the =0 to =1 but the ?dl was not changed to ?raw)  :y :y :y

The quote STEMO made is as per the original post (if you quote it you can see the original text)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 04 May 2018, 11:20:58
If using drop box you have to modify the final part of the link and change ?dl=0 to ?raw=1


I know. And did so.

No you didn't, I edited it  :y (you changed the =0 to =1 but the ?dl was not changed to ?raw)  :y :y :y

The quote STEMO made is as per the original post (if you quote it you can see the original text)


Fair enough, but that's exactly how I've posted every other picture here and on other sites. Considering that the links are pasted direct from Dropbox's copy link they shouldn't need to be altered at all
Title: Re: This Week in Wheeler's Workshop
Post by: Marks DTM Calib on 04 May 2018, 12:12:50
If using drop box you have to modify the final part of the link and change ?dl=0 to ?raw=1


I know. And did so.

No you didn't, I edited it  :y (you changed the =0 to =1 but the ?dl was not changed to ?raw)  :y :y :y

The quote STEMO made is as per the original post (if you quote it you can see the original text)


Fair enough, but that's exactly how I've posted every other picture here and on other sites. Considering that the links are pasted direct from Dropbox's copy link they shouldn't need to be altered at all

Its a known quirk of dropbox  :y

I have edited quite a few posts for this
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 04 May 2018, 13:04:33
A quirk. Where's my bullshit dictionary?


Ah yes,


 Quirk -  a fault or flaw that annoys the shit out of anyone who expects stuff to work as advertised.
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 04 May 2018, 18:40:28
If using drop box you have to modify the final part of the link and change ?dl=0 to ?raw=1


I know. And did so.

No you didn't, I edited it  :y (you changed the =0 to =1 but the ?dl was not changed to ?raw)  :y :y :y

The quote STEMO made is as per the original post (if you quote it you can see the original text)


Fair enough, but that's exactly how I've posted every other picture here and on other sites. Considering that the links are pasted direct from Dropbox's copy link they shouldn't need to be altered at all
I've never been able to see your pics, Nick, just a small, square box.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 16 May 2018, 21:33:11
I'm sick of looking at this poorly done repair:


(https://www.dropbox.com/s/ywwpdhk8e8bl1m7/Start.jpg?raw=1)


I would have cut the panel considerably smaller, and not welded it as close to the bodyline. Which would have meant less distortion to sort with filler and sanding:


(https://www.dropbox.com/s/ys2yjeji8ew3man/FilledandFlatted.jpg?raw=1)


Two coats of Green Ti filler-primer applied with a roller




(https://www.dropbox.com/s/ab9uuyat29c91w1/GreenTI.jpg?raw=1)




I've since flatted this down to 600grit, and it's ready for colour. Which I'll do over the weekend when I've bought it.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 19 May 2018, 17:50:55
Today's little job was to paint the Metro.


So I removed the rear window, threw some bodymask over the whole car, cut out the quarter panel and taped the edges down:


(https://www.dropbox.com/s/jhfw4w1l3unb91r/Masked%20ForPaint.jpg?raw=1)


about 5 minutes of actual painting and I had this:


(https://www.dropbox.com/s/pkvtw0cxffga715/Painted.jpg?raw=1)


I also painted the replacement NSF wing.


It's come out OK, hopefully there's enough paint to polish out the defects. But refitting the window and wing is the priority; I'll do that when I get home from ringing tomorrow
Title: Re: This Week in Wheeler's Workshop
Post by: henryd on 19 May 2018, 18:47:25
Today's little job was to paint the Metro.


So I removed the rear window, threw some bodymask over the whole car, cut out the quarter panel and taped the edges down:


(https://www.dropbox.com/s/jhfw4w1l3unb91r/Masked%20ForPaint.jpg?raw=1)


about 5 minutes of actual painting and I had this:


(https://www.dropbox.com/s/pkvtw0cxffga715/Painted.jpg?raw=1)


I also painted the replacement NSF wing.


It's come out OK, hopefully there's enough paint to polish out the defects. But refitting the window and wing is the priority; I'll do that when I get home from ringing tomorrow

Filler work is looking good Nick,not seeing many ripples  in that  :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 19 May 2018, 19:00:47

Filler work is looking good Nick,not seeing many ripples  in that  :y


There's still some distortion noticeable along the bodyline. I decided not to apply another coat of filler primer, which is a mistake. Still, it looks a lot better than when I bought it :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 23 May 2018, 20:54:20
I've got to remove the rubbing strip from the door, but this looks a lot better:


(https://www.dropbox.com/s/hbcna2ju66xzapp/NSPainted-01.jpg?raw=1)


I did jetwash the whole car, which is probably the first time it's been cleaned in year, and apply some gel to all of the black plastics. And I've the sill covers from a Rover 100 that makes that area look a lot more finished.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 23 May 2018, 20:58:21
Very nice job 8)
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 24 May 2018, 08:50:00
I think my old Metro might have been the same colour.. sadly mine also came with the 1.4L naturally aspirated Diseasel engine ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 07 April 2019, 20:07:57
It's Ian's garage actually, but we've been busy with my 3.0l manual and his MGB:


(https://www.dropbox.com/s/samaf7q3y8xzf0p/IMG_20190407_155355.jpg?raw=1)


Bulkhead is stock.


engine mounts made and installed:


(https://www.dropbox.com/s/qb5gia69k4quka0/IMG_20190407_154551%20%281%29.jpg?raw=1)


the gearbox mount is stock Omega with two drilled holes into the MGB crossmember, no further work required :o


We've got to make exhaust manifolds, which will be MGB RV8 style, down through the inner wings. A small diameter alternator where the normal belt tensioner should fit, with an idler pulley on the other side where the PAS pump was should drive it all - the water pump being driven off the back of the belt is a nuisance.


MGB RV8 radiator, and a new water transfer pipe.


We need complete bagpipes and throttle body before we go much further, and a gearlever for the manual gearbox. I'll be making an adapter to fir a double UJ propshaft and slider joint.


It will get a Discovery fuel pump and return fitted to a new MGB fuel tank.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 07 April 2019, 20:31:40
Nice looking job 8)

Refreshing to see an MG that isn't Russet/Red/BRG :y
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 07 April 2019, 21:21:08
Wow
what will you be doing for an ECU  :-\ using the Omega brain or "aftermarket" 
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 07 April 2019, 22:31:57
Wow
what will you be doing for an ECU  :-\ using the Omega brain or "aftermarket"


Completely stock except for a K&N air filter and no cats. And that's only because there isn't room for the filter box, stock manifolds or downpipes.


The idea is that it gives more power than any stock Rover that are now extremely expensive to buy, rebuild(they're always tired) and fit. So far, this install has cost about £15 for the mount materials, and £50 for a Vectra sump. Plus the £250 he paid me for the engine and gearbox ::) The exhausts are going to be costly, but they are for a Rover too - we'll probably use MGB V8 systems to save time and effort. Rovers also require an expensive diff change, but stock MGB diff and wheel diameter is very close to stock Omega gearing. Ian reckons that selling the original running gear will cover about half the cost of installing the V6.
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 08 April 2019, 07:49:43
Very interesting  :)
so have you considered instrumentation ? omega clocks  :-\ or will there be some complex wiring to work out to use MG dash or again an aftermarket solution ?
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 08 April 2019, 09:11:23
Nice! What is going on with that crossmember, though? It looks like it's been attacked by the bottom pulley (not that engine, obviously)..
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 08 April 2019, 18:16:11
Very interesting  :)
so have you considered instrumentation ? omega clocks  :-\ or will there be some complex wiring to work out to use MG dash or again an aftermarket solution ?


Omega clocks?? No room for them, don't have them, too much hassle trying to get them to work, as the only bit that works off the ECU loom is the rev counter. MGB wiring is very simple, with a cable driven speedo, 4 cylinder rev counter and a capillary oil pressure gauge.


And the Omega speedo is driven off the ABS sensors, not the gearbox.


So we're going to use aftermarket to make it easy: RALLYDESIGN (http://www.rallydesign.co.uk/index.php?cPath=412_1824_1825) That gets around all of the issues of mismatched sensors to the gauges, keeps all the gauge faces looking the same(a mix of cheap used gauges looks shit) and gets everything working quickly. Not expensive either.


The crossmember notch was necessary for the pulley, but Ian did insist on doing the welding with a 90amp gasless Mig. A coat of paint and the air intake over the top will deal with the aesthetics


I'll install the pickup for the speedo into the prop to gearbox adapter.
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 08 April 2019, 18:44:35
As the omega  OBD2 port is part of the fusebox, did you get the loom between the OBD2 and engine ecu  or is that another problem   :-\

sorry for the questions , just genuinely interested  :-[
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 08 April 2019, 18:50:16
As the omega  OBD2 port is part of the fusebox, did you get the loom between the OBD2 and engine ecu  or is that another problem   :-\

sorry for the questions , just genuinely interested  :-[


I'll look, but I think it's part of one of the connectors. The port is attached to the fusebox, I don't think it's part of it. I don't have an Omega to check.  I know Ian's had it all powered up, with blink codes, so that's not difficult.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 08 April 2019, 18:55:16
You're talking about running the odd wire from the ecu plug to the dash, hardly groundbreaking, but being able to read a wiring diagram helps :y

The Omega is pretty simple from an electrickery point of view  :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 08 April 2019, 19:01:17
You're talking about running the odd wire from the ecu plug to the dash, hardly groundbreaking, but being able to read a wiring diagram helps :y

The Omega is pretty simple from an electrickery point of view  :y


Only two we care about are the rev counter and water temp. Both are easy, and we probably wouldn't bother with the rev counter if the dash didn't already have a hole for it.


The awkward bits of the job will be making the exhaust manifolds and sorting the belt drive; not difficult, just a lot of fiddly fabrication. The systems are easier to make, but he'll just buy existing Rover ones if they're not too loud. Plenty of V8 cars about to decide on that, and if they are we'll make them too.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 08 April 2019, 19:15:33
My reply was in Dave's direction ;)

I was pleasantly surprised by how relatively straightforward wiring an LS lump into an Omega. ;)

That MG project looks to be a well thought out one that should improve markedly over the original offerings 8)
Title: Re: This Week in Wheeler's Workshop
Post by: Andy H on 08 April 2019, 20:29:22
You're talking about running the odd wire from the ecu plug to the dash, hardly groundbreaking, but being able to read a wiring diagram helps :y

The Omega is pretty simple from an electrickery point of view  :y


Only two we care about are the rev counter and water temp. Both are easy, and we probably wouldn't bother with the rev counter if the dash didn't already have a hole for it.


The awkward bits of the job will be making the exhaust manifolds and sorting the belt drive; not difficult, just a lot of fiddly fabrication. The systems are easier to make, but he'll just buy existing Rover ones if they're not too loud. Plenty of V8 cars about to decide on that, and if they are we'll make them too.
Having messed around with some Rover V8s and then messed around with some Omega V6s my subjective impression is that the Omega is LOUD.

My theory is that the Rover is in a low state of tune and has pushrods slowly opening one exhaust valve per cylinder whereas the Omega is overhead cam and can open two exhaust valves per cylinder a lot quicker (and let the noise out faster).
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 08 April 2019, 21:35:21
My opinion is that everyone makes exhaust systems far bigger than is necessary for the power output, and then fit silencers that don't. My Metro is only 145hp, yet the system is 2" which is good enough for 200hp. It's not only loud but the sound is horrible.


As each system on the MGB will only have to deal with 100hp, 1.5" pipes will be plenty especially if we fit two big silencers in each side. Using that size pipe means tighter radius bends, which makes it easier for tight fitting systems. It's a road car, a cruiser and it needs to be quiet.
Title: Re: This Week in Wheeler's Workshop
Post by: Andy H on 08 April 2019, 22:12:49
I think the hardest task is going to be finding somewhere under the car to locate silencers with enough volume to provide significant attenuation.

The single thing which provides the biggest drop in sound level is linking left & right systems together - easy on a Range Rover but probably impossible in an MG :-\
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 09 April 2019, 08:57:58
So we're going to use aftermarket to make it easy: RALLYDESIGN (http://www.rallydesign.co.uk/index.php?cPath=412_1824_1825)

Not Smiths Instruments? Am disappoint.  :P ;) ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 09 April 2019, 10:39:31
So we're going to use aftermarket to make it easy: RALLYDESIGN (http://www.rallydesign.co.uk/index.php?cPath=412_1824_1825)

Not Smiths Instruments? Am disappoint.  :P ;) ;D
There's a guy near me that makes very nice looking Smiths instruments that actually work have modern electronics behind them IIRC.

EDIT: Not sure if his firmware simulates that wobbly speedo needle when travelling at less then 20 MPH though. ;D
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 09 April 2019, 10:48:15
 ;D

Smiths have their own stepper driven range now - have done for a while AFAIK.. it's what I have in the Cobra. If I ever finish wiring the damn things in. So many wires, so little space.
Title: Re: This Week in Wheeler's Workshop
Post by: Field Marshal Dr. Opti on 09 April 2019, 10:51:43
So we're going to use aftermarket to make it easy: RALLYDESIGN (http://www.rallydesign.co.uk/index.php?cPath=412_1824_1825)

Not Smiths Instruments? Am disappoint.  :P ;) ;D
There's a guy near me that makes very nice looking Smiths instruments that actually work have modern electronics behind them IIRC.

EDIT: Not sure if his firmware simulates that wobbly speedo needle when travelling at less then 20 MPH though. ;D

Wobbly speedo needle?.........a sure sign you are at the wheel of a British classic. :y
Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 09 April 2019, 12:00:45
So we're going to use aftermarket to make it easy: RALLYDESIGN (http://www.rallydesign.co.uk/index.php?cPath=412_1824_1825)

Not Smiths Instruments? Am disappoint.  :P ;) ;D
There's a guy near me that makes very nice looking Smiths instruments that actually work have modern electronics behind them IIRC.

EDIT: Not sure if his firmware simulates that wobbly speedo needle when travelling at less then 20 MPH though. ;D

Wobbly speedo needle?.........a sure sign you are at the wheel of a British classic. :y
If you get to the wobbly speedo phase, it's a good day. :y
Title: Re: This Week in Wheeler's Workshop
Post by: Field Marshal Dr. Opti on 09 April 2019, 12:32:18
So we're going to use aftermarket to make it easy: RALLYDESIGN (http://www.rallydesign.co.uk/index.php?cPath=412_1824_1825)

Not Smiths Instruments? Am disappoint.  :P ;) ;D
There's a guy near me that makes very nice looking Smiths instruments that actually work have modern electronics behind them IIRC.

EDIT: Not sure if his firmware simulates that wobbly speedo needle when travelling at less then 20 MPH though. ;D

Wobbly speedo needle?.........a sure sign you are at the wheel of a British classic. :y
If you get to the wobbly speedo phase, it's a good day. :y


The speedo on my Triumph 1500 would swing wildly between 40 and 110. So top speed was 110 MPH........ :D
Title: Re: This Week in Wheeler's Workshop
Post by: Field Marshal Dr. Opti on 09 April 2019, 12:33:46
.......not long after the cable broke. :)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 09 April 2019, 17:31:32
;D

Smiths have their own stepper driven range now - have done for a while AFAIK.. it's what I have in the Cobra. If I ever finish wiring the damn things in. So many wires, so little space.


that's what I bought for the Avenger, they're lovely.


Ian was stuck in the thinking of 25 years ago; a lashup of wiring, adapters and wishful thinking to produce a setup that sort of works, some of the time. Not to mention jumpy needles, inaccurate readings on inadequately marked dials.
Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 09 April 2019, 19:47:41
This is the guy I was thinking of.. Not desperately cheap, but...

http://farringdoninstruments.com/index.html (http://farringdoninstruments.com/index.html)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 09 April 2019, 22:22:39
This is the guy I was thinking of.. Not desperately cheap, but...

http://farringdoninstruments.com/index.html (http://farringdoninstruments.com/index.html)


and I thought the Smiths were on the pricey side of acceptable! You can buy the whole set for just one of those.....
Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 10 April 2019, 12:28:43
This is the guy I was thinking of.. Not desperately cheap, but...

http://farringdoninstruments.com/index.html (http://farringdoninstruments.com/index.html)


and I thought the Smiths were on the pricey side of acceptable! You can buy the whole set for just one of those.....
Indeed. I guess that's the price of paying an enthusiast in a business unit with rent to pay. No doubt, if you wanted a special kind of needle wobble to be implemented for your application, he'd be happy to do you a special firmware build, though. ;)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 11 May 2019, 16:20:29
Ian's been cracking on with the MGB; he's sourced a gearlever, which almost fits through the original hole, mocked up the accessory drive(without the tensioner pulley, PAS pump and AC compressor), got a radiator and started thinking about the manifolds. We still need some muti-rams and AFM if anyone can help?


I've been sorting the Cathedral's set of handbells. The expensive bit of English bells(assuming they're not cracked) is the leather handles. Fortunately ours are good, but many of the clappers needed work. So I've made nylon washers(much better than the leather that's still used on new ones) to adjust where they screw into the bell, sorted a couple of loose pivots, tightened the spring rivets and straightened a couple of shafts.


As you can see, these are not complicated:


(https://www.dropbox.com/s/qhbbtytqdfb2ppl/BellParts-01.jpg?raw=1)


(https://www.dropbox.com/s/tt4f3xk3fo42cvn/BellRepaired-01.jpg?raw=1)


The clappers now align with the handles so they ring properly in both directions, and they're a lot less rattly. A good couple of hours work

Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 11 May 2019, 16:29:02
Got a MAF for 2.5/3.0 if that's any use?
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 11 May 2019, 16:39:38
Got a MAF for 2.5/3.0 if that's any use?


Yes :y
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 11 May 2019, 16:55:55
Pm your address and I will get it posted on Monday.  :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 12 May 2019, 18:17:26
We've been discussing the next step in MGB project now the alternator is sorted:


(https://www.dropbox.com/s/ptbzjff9kpdui15/59325884_2867169613323269_5551599809695055872_n.jpg?raw=1)


Alternator is reverse mounted because of the shape of the chassis rails and inner wing; the direction the water pump turns is the reason for the bracket which contains the original idler pulley and a smooth Toyota one to retain enough belt wrap. New pulleys will be used, along with a 6pk1440 belt. The tube sticking out the bottom is part of the new radiator transfer tube as there's no room for the route of the old one. He's got multi rams coming, and a V8 radiator which gives a decent amount of space for them. We'll make a new lower for them IF necessary. It will require an aftermarket air filter alongside/in front of the radiator as required.


None of the stock V6 exhaust manifolds fit, so we have laser cut flanges and will order a load of 1 1/4" bends to make headers with the collectors in the inner wings V8-style. That's likely to be the worst bit of the whole job. I hate doing exhausts, but at least there's only 3 primaries to fit. Per side ::)


Stock Omega gearlever needed the MGB hole to be widened, but the cover fits as does the gaiter. So it will look stock with the leather gear knob complete with the correct shift pattern. Which is a bonus.


next time the engine comes out we'll make a custom flexi-hose to plumb to the MGB clutch master cylinder. One of the advantages of hydraulic clutches in swaps is that making them work is easy plumbing.


With that lot done, we'll sort the fuel system(new tank and Range Rover in-tank pump) and then it will be onto why won't it start!
Title: Re: This Week in Wheeler's Workshop
Post by: Sir Tigger KC on 12 May 2019, 18:53:49
That will be an awesome MGB!  8)  :y 
Title: Re: This Week in Wheeler's Workshop
Post by: henryd on 12 May 2019, 19:03:15
That will be an awesome MGB!  8)  :y

Certainly better than the asthmatic Buick/Rover donkey :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 12 May 2019, 19:10:04
That will be an awesome MGB!  8) :y

Certainly better than the asthmatic Buick/Rover donkey :y


Fits better too. The fifties style of swept up and pinched in chassis rails to mount the crossmember cause most of the problems with vee engines. Rovers are both long, and wide across the exhausts for such a small capacity. I would have used a big four cylinder engine to avoid them, but it's not my car.
Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 12 May 2019, 22:36:07
That alternator looks like it could happily power a small village.  :o
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 12 May 2019, 22:45:48
That alternator looks like it could happily power a small village.  :o


Smaller and shorter than the stock Omega, and lower output at 80amp. That's more than it needs, but as it's off a Focus it's a common, cheap part that he had under the bench. We're trying to keep modified parts to a minimum. Regular service or consumable parts must always be standard.


Original MGB is a basic 35amp Lucas. The local specialist doesn't sell less than 45amp ones, which is what I bought for Deb's old 1300.
Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 13 May 2019, 09:29:28
That alternator looks like it could happily power a small village.  :o


Smaller and shorter than the stock Omega, and lower output at 80amp. That's more than it needs, but as it's off a Focus it's a common, cheap part that he had under the bench. We're trying to keep modified parts to a minimum. Regular service or consumable parts must always be standard.


Original MGB is a basic 35amp Lucas. The local specialist doesn't sell less than 45amp ones, which is what I bought for Deb's old 1300.

Fair enough. Just looked quite large, probably because they're not normally sticking out of the front. ;D

If it'll fit and it's cheap, then fine. There are probably more compact options, such as the little Denso ones fitted to some jap cars, but the price is kept high by all the kit car types chasing them. ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Marks DTM Calib on 13 May 2019, 09:38:23
That alternator looks like it could happily power a small village.  :o


Smaller and shorter than the stock Omega, and lower output at 80amp. That's more than it needs, but as it's off a Focus it's a common, cheap part that he had under the bench. We're trying to keep modified parts to a minimum. Regular service or consumable parts must always be standard.


Original MGB is a basic 35amp Lucas. The local specialist doesn't sell less than 45amp ones, which is what I bought for Deb's old 1300.

Check carefully the specs, many more modern alternators are not self contained and often need a LIN connection from the ECU to manage output volts
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 13 May 2019, 17:33:56
That alternator looks like it could happily power a small village.  :o


Smaller and shorter than the stock Omega, and lower output at 80amp. That's more than it needs, but as it's off a Focus it's a common, cheap part that he had under the bench. We're trying to keep modified parts to a minimum. Regular service or consumable parts must always be standard.


Original MGB is a basic 35amp Lucas. The local specialist doesn't sell less than 45amp ones, which is what I bought for Deb's old 1300.

Check carefully the specs, many more modern alternators are not self contained and often need a LIN connection from the ECU to manage output volts


That's in hand.


We did look at the Denso units, but cost and the need to fit a wider pulley were issues. Small issues admittedly, and we would still have had to reverse mount it. The alternator in the pic already had the correct 6 rib pulley
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 27 May 2019, 15:39:27
Some time ago, I painted some 16" steel Picasso wheels for a friend's Capri.


He's now got a VVC Metro, and because the car is a sleeper wants some steel wheels bigger than the stock 5x13s. So, he scrounged 5 unused 5.5x14" MGF spares from the specialist he works for occasionally. But they're black, and black wheels always look shit:


(https://www.dropbox.com/s/hu5h7uwn4yd7dnr/StockMGFWheel.jpg?raw=1)


I cleaned, scotchbrited and wiped them over with thinners ready for paint:


(https://www.dropbox.com/s/tklku38vs5kyd9t/PreparedMGFWheel.jpg?raw=1)


A couple of coats of Aluminium Silver wheel paint(a stock wheel colour, RAL 9007) and some 2pack clear later:


(https://www.dropbox.com/s/paixpq91by1mnim/MGFWheelPainted.jpg?raw=1)


The 'workshop':


(https://www.dropbox.com/s/2o362hi7kogl1zv/PaintingMGFWheels.jpg?raw=1)




All done with 200ml of the paint left over from the Capri wheels and a similar amount of clear, sprayed with a cheap HVLP touchup gun and my 30 year old compressor.



Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 10 June 2019, 22:11:08
After a change of plan, we've started on the exhaust headers:


(https://www.dropbox.com/s/ysvpzolre5wrimo/IMG_20190610_202629.jpg?raw=1)


they're not going out through the inner wings, but as block huggers so we can avoid cutting the car. The strap you can see bolted to the block is where the steering shaft runs, so we can do more of the work with the engine out of the car. This is fiddly enough as it is without making it harder still. The other side ought to be easier, as there's a much bigger gap between the oil filter and engine mount than between the starter and mount.
Title: Re: This Week in Wheeler's Workshop
Post by: henryd on 11 June 2019, 09:11:17
After a change of plan, we've started on the exhaust headers:


(https://www.dropbox.com/s/ysvpzolre5wrimo/IMG_20190610_202629.jpg?raw=1)


they're not going out through the inner wings, but as block huggers so we can avoid cutting the car. The strap you can see bolted to the block is where the steering shaft runs, so we can do more of the work with the engine out of the car. This is fiddly enough as it is without making it harder still. The other side ought to be easier, as there's a much bigger gap between the oil filter and engine mount than between the starter and mount.

Are you going to lag the pipes as it looks in the pic like its really close to the starter
Title: Re: This Week in Wheeler's Workshop
Post by: Andy H on 11 June 2019, 09:15:30
After a change of plan, we've started on the exhaust headers:


(https://www.dropbox.com/s/ysvpzolre5wrimo/IMG_20190610_202629.jpg?raw=1)


they're not going out through the inner wings, but as block huggers so we can avoid cutting the car. The strap you can see bolted to the block is where the steering shaft runs, so we can do more of the work with the engine out of the car. This is fiddly enough as it is without making it harder still. The other side ought to be easier, as there's a much bigger gap between the oil filter and engine mount than between the starter and mount.
That should keep the starter and solenoid nice and toasty. ;)

Will there be space to extract the starter if it needs some TLC without pulling the manifold off? :-\
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 11 June 2019, 17:34:34
It is close to the starter. But there is nowhere else for the pipes to run: we can't bring them out any further because the steering shaft is in in the way and that runs next to the chassis rail.


We'll wrap the starter, and maybe add a heatshield to the end if we think it's necessary.


Lagging manifolds is ugly, expensive, rarely does anything useful and doesn't last long. So, no, we'll not be doing that.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 17 June 2019, 22:46:01
Got a bit more done yesterday:


(https://www.dropbox.com/s/aio5dafceyiquqm/header2.jpg?raw=1)


and fitted:


(https://www.dropbox.com/s/8w6tl6nknz5kmp4/header.jpg?raw=1)


and yes, I know I need more practice
Title: Re: This Week in Wheeler's Workshop
Post by: Andy B on 17 June 2019, 22:56:16
....

and yes, I know I need more practice

That's what TIG is all about ..... practice , practice & more practice  :y (and glasses/lens if you need them   ;))
Title: Re: This Week in Wheeler's Workshop
Post by: Diamond Black Geezer on 18 June 2019, 09:53:50
Handmade Wheeler tubular Omega V6 manifolds coming to an etsy shop near you  :y

I'm no expert but those manifolds look like things of beauty, very nice.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 18 June 2019, 17:30:28
Handmade Wheeler tubular Omega V6 manifolds coming to an etsy shop near you  :y

I'm no expert but those manifolds look like things of beauty, very nice.


You do not want to know how much time there is in these(this, as we haven't started the passenger side one yet), or the cost of the materials and consumables. The only reason to build headers like this for a road car is because there is no alternative. We won't make the systems, but fit off the shelf V8 ones.
Title: Re: This Week in Wheeler's Workshop
Post by: Diamond Black Geezer on 18 June 2019, 17:58:33
Handmade Wheeler tubular Omega V6 manifolds coming to an etsy shop near you  :y

I'm no expert but those manifolds look like things of beauty, very nice.


You do not want to know how much time there is in these(this, as we haven't started the passenger side one yet), or the cost of the materials and consumables. The only reason to build headers like this for a road car is because there is no alternative. We won't make the systems, but fit off the shelf V8 ones.


Among my many crimes I have done acrylic/oil paintings. I did a commission for a friend once, and someone commented how much they liked my work, and said proudly "I'd pay fifty quid for that"... :-\

If I charged minimum wage you don't get very many hours for that, and certainly not even close to how many hours it took me, research, trying out angles which work best, composition, getting the colour/light balance, standing back after hours and deciding you hate it, and it doesnt look 'right' and redoing almost all of it.... etc...

Please read my comment as being ironic, as I can well appreciate the vast time and skill involved in doing these, skill and time doesnt get valued enough sadly.  :y
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 19 June 2019, 11:10:32
Handmade Wheeler tubular Omega V6 manifolds coming to an etsy shop near you  :y

I'm no expert but those manifolds look like things of beauty, very nice.


You do not want to know how much time there is in these(this, as we haven't started the passenger side one yet), or the cost of the materials and consumables. The only reason to build headers like this for a road car is because there is no alternative. We won't make the systems, but fit off the shelf V8 ones.

I think the cheapest quote I've had for a set of headers for the Cobra was £1200, the average about £1600 .. which would probably all go up once they saw the lack of space ;D but .. that does make a compelling case for DIY.
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 19 June 2019, 11:34:41
Handmade Wheeler tubular Omega V6 manifolds coming to an etsy shop near you  :y

I'm no expert but those manifolds look like things of beauty, very nice.


You do not want to know how much time there is in these(this, as we haven't started the passenger side one yet), or the cost of the materials and consumables. The only reason to build headers like this for a road car is because there is no alternative. We won't make the systems, but fit off the shelf V8 ones.

I think the cheapest quote I've had for a set of headers for the Cobra was £1200, the average about £1600 .. which would probably all go up once they saw the lack of space ;D but .. that does make a compelling case for DIY.
Whip it down to Nick, he'll knock you some up in half an hour.  :)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 19 June 2019, 11:48:24
Handmade Wheeler tubular Omega V6 manifolds coming to an etsy shop near you  :y

I'm no expert but those manifolds look like things of beauty, very nice.


You do not want to know how much time there is in these(this, as we haven't started the passenger side one yet), or the cost of the materials and consumables. The only reason to build headers like this for a road car is because there is no alternative. We won't make the systems, but fit off the shelf V8 ones.

I think the cheapest quote I've had for a set of headers for the Cobra was £1200, the average about £1600 .. which would probably all go up once they saw the lack of space ;D but .. that does make a compelling case for DIY.
Whip it down to Nick, he'll knock you some up in half an hour.  :)


I know I've mentioned this before, but I hate dealing with exhausts whether that's changing a broken hanger to fabricating new parts. So I only ever replace entire systems, and buy them whenever possible.


And Aaron doesn't want to pay me £1600 to build his headers in the street outside my house :)
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 20 June 2019, 10:51:19
And Aaron doesn't want to pay me £1600 to build his headers in the street outside my house :)

 ;D ;D Indeed ;) Although I likely will pay someone - because once you add the cost of a decent TIG welder on top of the materials, you're getting close to just paying someone who actually knows what they're doing with the glue gun (instead of me)..

Speaking of, I popped over to Ollie at Olliminium yesterday (he's going to modify the unused ally fuel tank) - he's based at Bicester Heritage and I reckon that place is worth a wander around just to see what's lurking.. a proper little mass of low-volume automotive manufacturers/restorers/etc. The only other place I've seen so many pre-1930 vehicles in one place is Goodwood!
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 20 June 2019, 11:05:46
And Aaron doesn't want to pay me £1600 to build his headers in the street outside my house :)

 ;D ;D Indeed ;) Although I likely will pay someone - because once you add the cost of a decent TIG welder on top of the materials, you're getting close to just paying someone who actually knows what they're doing with the glue gun (instead of me)



the welding is the easy bit! Cutting the tubes so they not only fit in the space, but are still round and join each other correctly is difficult. Fortunately for this job, it's what Ian enjoys. And it's in his garage, so I don't need to get involved too much.
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 20 June 2019, 11:09:25
That too! Much easier if you have a decent metal chop-saw and/or band saw .. neither of which I have, so I'd be trying to hand cut everything with a grinder..
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 20 June 2019, 11:18:57
That too! Much easier if you have a decent metal chop-saw and/or band saw .. neither of which I have, so I'd be trying to hand cut everything with a grinder..


Marker pen, hacksaw, belt sander in the vice, and files. Lubricated with plenty of workshop Anglo-saxon.
Title: Re: This Week in Wheeler's Workshop
Post by: biggriffin on 20 June 2019, 14:41:52
Handmade Wheeler tubular Omega V6 manifolds coming to an etsy shop near you  :y

I'm no expert but those manifolds look like things of beauty, very nice.


You do not want to know how much time there is in these(this, as we haven't started the passenger side one yet), or the cost of the materials and consumables. The only reason to build headers like this for a road car is because there is no alternative. We won't make the systems, but fit off the shelf V8 ones.

I think the cheapest quote I've had for a set of headers for the Cobra was £1200, the average about £1600 .. which would probably all go up once they saw the lack of space ;D but .. that does make a compelling case for DIY.


There's a new member on here who makes exhausts and headers,, 456lbs. Might be able to help,and he's not far from you Aaron.
Title: Re: This Week in Wheeler's Workshop
Post by: aaronjb on 20 June 2019, 15:12:05
There's a new member on here who makes exhausts and headers,, 456lbs. Might be able to help,and he's not far from you Aaron.

Aye  :y I've made a mental note of his name .. once there's an engine in there to join exhausts to, anyway :)
Title: Re: This Week in Wheeler's Workshop
Post by: TheBoy on 20 June 2019, 17:15:59
Speaking of, I popped over to Ollie at Olliminium yesterday (he's going to modify the unused ally fuel tank) - he's based at Bicester Heritage and
I hope you switched your engine off, seeing as the local council are trying (somehow) to make it an offence to keep the engine running whilst stationary...


Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 21 August 2019, 12:55:37
A number of small jobs recently:


Rover 216 tourer sill/arch repair, the brief was "don't buy anything it's only a £100 car", so I folded new sections for the lower sills, and welded them along a body line, plus bent a new section for the lower arch under the bump strip. Some grinding and a thick coat of underseal later and it looks decent - it's a basic MOT repair, but that's no reason for it to look shit.


Made 8 of these window keeps to replace broken ones:


(https://www.dropbox.com/s/r69mrsvel8nirl6/windowkeeppattern.jpg?raw=1)


(https://www.dropbox.com/s/2mz74x773rr9t1h/p_20190821_113713.jpg?raw=1)


She needed 4, asked for 6, and the bit of 6mm thick aluminium I had provided 8. I made one about 3 years ago with a hacksaw and file; these were done in the mill.


Wire hose clamp tool because I was bored, and it might be useful:




(https://www.dropbox.com/s/lrsajk4c0nunyfg/wireclamptool.jpg?raw=1)


It's more likely to be used tieing poles together, but will do in a pinch. That's how fluid hoses were clamped before Cmdr Robinson invented the Jubilee clip over 100 years ago.


Hydragas pump - the £18 pump is meant for testing central heating systems - but with the addition of a low-loss Schraeder connector it works well. Those are about £50, this one was found in a scrap box and the 1/8NPT connecting thread was stripped. It needed an adapter to the M14x1.5 thread on the hose, so I machined one from brass and soldered the two bits together:


(https://www.dropbox.com/s/fdf391u7x0ugk7n/pumpadapter.jpg?raw=1)


And then folded a cover for the thing out of some stainless sheet just to keep the crap out of it.



Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 31 August 2019, 17:54:04
The MGB runs LINK (https://youtu.be/MWX7HRTtEjM)
Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 31 August 2019, 18:03:09
The MGB runs LINK (https://youtu.be/MWX7HRTtEjM)

Idle speed needs work, but  8)

 :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 31 August 2019, 18:24:41
The MGB runs LINK (https://youtu.be/MWX7HRTtEjM)

Idle speed needs work, but  8)

 :y


no induction forward of the throttle bodies, as he's still thinking of deleting the multi-rams. And we need to install the radiator and plumbing before we can do any of that work
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 31 August 2019, 18:26:06
 :) It's always great when you hear an engine run after you've been playing with it's bits  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 31 August 2019, 18:36:45
:) It's always great when you hear an engine run after you've been playing with it's bits  ;D


All we've actually done is take bits off it ;D ; all of the wiring, timing belt, inlet manifold are exactly how somebody else took it out of an MV6 about ten years ago. I bought it like that and am pleased to know it actually works
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 31 August 2019, 18:48:50
so it's running on new a ecu or still the factory GM  :-\
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 31 August 2019, 18:54:59
so it's running on new a ecu or still the factory GM  :-\


Stock Omega. The whole point of doing this is to keep as many standard parts as possible. We made new exhaust manifolds and alternator mounts simply because there isn't room for stock ones. The radiator will be stock MGB V8; the fuel pump is stock Subaru fitted into an MGB tank; the gearbox mount is stock Omega bolted to the MGB crossmember - you get the idea.
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 31 August 2019, 19:08:31
so retaining the multi ram etc makes sense ,as the GM ecu would control it all and get the best out of the engine without spending a fortune and faf about ironing out flat spots etc  :-\
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 31 August 2019, 19:13:24
so retaining the multi ram etc makes sense ,as the GM ecu would control it all and get the best out of the engine without spending a fortune and faf about ironing out flat spots etc  :-\


Exactly. It's effective, self-contained and reliable. And it was all included in the £250 he paid me for the engine and gearbox.
Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 31 August 2019, 19:19:22
so retaining the multi ram etc makes sense ,as the GM ecu would control it all and get the best out of the engine without spending a fortune and faf about ironing out flat spots etc  :-\


Exactly. It's effective, self-contained and reliable. And it was all included in the £250 he paid me for the engine and gearbox.

.. and it'll be plenty of power for the MGB chassis to be dealing with without any Barry Boy induction mods. ;)
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 31 August 2019, 19:36:48
no doubt GM spended* a fair few dollars on R&D back in the day
ask if he has a similar budget to redesign the intake  ;D

*spended is not what I typed  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 31 August 2019, 19:48:29
no doubt GM spended* a fair few dollars on R&D back in the day
ask if he has a similar budget to redesign the intake  ;D

*spended is not what I typed  ;D


We do have to make a new lower box(the plastic part that the multi-rams and AFM sit on) because there's a number of other components that want that space. But we'll try to keep the volume as close as possible.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 31 August 2019, 20:12:54
The MGB runs LINK (https://youtu.be/MWX7HRTtEjM)
Nicely done :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 29 December 2019, 15:31:11
Yesterday's job, about 350mm of 25mm bar with M20 threads on each end pictured with the broken part:


(https://www.dropbox.com/s/e6ynrmmyiphy54u/OldandNewHeadbolts.jpg?raw=1)




Removing the broken off bit took some drilling, milling, filing and 30minutes on the gas stove to break the Loctite before I could finally unwind the remaining thread with some pliers:


(https://www.dropbox.com/s/3cuhgj99n01kjjm/UnwindingThread.jpg?raw=1)


And here's the whole assembly stopping the freezer from floating away :y


(https://www.dropbox.com/s/v0ul8rt3ljkz9rr/RepairedClapper.jpg?raw=1)


thats a 0.75m length of cast steel that fell out of the bell on Monday........








Also done recently was an Omega to standard prop UJ adapter for Ian's MGB


(https://www.dropbox.com/s/jbuu86gvqfz5sbu/propadapter.jpg?raw=1)


which is now running, idling and capable of moving under its own power. Which is nice ;D
sounds good through the single exhaust system meant for a MGB V8
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 01 January 2020, 12:58:07
Just spent 90 minutes fitting the repaired clapper, most of which involved filing the bolt to fit in a cast slot in ths headstock. I did that by clamping  the bolt to the bell frame and used a bastard file, along with repeated checks. Traditional fitter's job. The clapper itself is bloody heavy to hold up whilst trying to get the gudgeon pin to start. Next step is to adjust the twiddle pins so that the bell strikes evenly, but that will wait until the Loctite has gone off.


While we were in the belfry, we changed a couple of tired ropes, checked the stays for damage(we've a learner that doesn't know his own strength) and did the basic safety checks for this year
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 01 January 2020, 14:59:55
I thought it was a gear shifter off some sort of heavy plant  :-[
so, a bell clanger then  ;D
on the prop of the MGB ,are you putting the 6 bolt prop donuts in ,as per BMW,Onega etc ?
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 02 January 2020, 11:16:22
I thought it was a gear shifter off some sort of heavy plant  :-[
so, a bell clanger then  ;D
on the prop of the MGB ,are you putting the 6 bolt prop donuts in ,as per BMW,Onega etc ?


you can't use them when the diff moves, as the distance between the flanges changes and the angles are too much for the donuts to accomodate - they just tear apart. That's why traditional props have a UJ at each end, and either slide on the gearbox output shaft or incorporate a sliding joint. That's what the MGB uses so Ian's new prop is basically a brand new MGB prop that's been made slightly longer to take up the difference in gearbox length. UJs are standard parts(British cars normally use one of two common sizes), as is the slider, so  custom props are cheap and easily available. This one was about £170 from the local specialist who normally make them for trucks, heavy plant and other machinery. Just like when you buy bearings, pulleys and drive belts, they don't ask what it's off, but work from your supplied dimensions or the broken parts.


It's called a clapper. Unless the bell isn't tuned very well ;D
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 02 January 2020, 11:31:14
I thought it was a gear shifter off some sort of heavy plant  :-[
so, a bell clanger then  ;D
on the prop of the MGB ,are you putting the 6 bolt prop donuts in ,as per BMW,Onega etc ?


you can't use them when the diff moves, as the distance between the flanges changes and the angles are too much for the donuts to accomodate - they just tear apart. That's why traditional props have a UJ at each end, and either slide on the gearbox output shaft or incorporate a sliding joint. That's what the MGB uses so Ian's new prop is basically a brand new MGB prop that's been made slightly longer to take up the difference in gearbox length. UJs are standard parts(British cars normally use one of two common sizes), as is the slider, so  custom props are cheap and easily available. This one was about £170 from the local specialist who normally make them for trucks, heavy plant and other machinery. Just like when you buy bearings, pulleys and drive belts, they don't ask what it's off, but work from your supplied dimensions or the broken parts.


It's called a clapper. Unless the bell isn't tuned very well ;D
Yep, hence the saying "goes like the clappers". 🙂
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 02 January 2020, 11:40:40
I thought it was a gear shifter off some sort of heavy plant  :-[
so, a bell clanger then  ;D
on the prop of the MGB ,are you putting the 6 bolt prop donuts in ,as per BMW,Onega etc ?


you can't use them when the diff moves, as the distance between the flanges changes and the angles are too much for the donuts to accomodate - they just tear apart. That's why traditional props have a UJ at each end, and either slide on the gearbox output shaft or incorporate a sliding joint. That's what the MGB uses so Ian's new prop is basically a brand new MGB prop that's been made slightly longer to take up the difference in gearbox length. UJs are standard parts(British cars normally use one of two common sizes), as is the slider, so  custom props are cheap and easily available. This one was about £170 from the local specialist who normally make them for trucks, heavy plant and other machinery. Just like when you buy bearings, pulleys and drive belts, they don't ask what it's off, but work from your supplied dimensions or the broken parts.


It's called a clapper. Unless the bell isn't tuned very well ;D
Yep, hence the saying "goes like the clappers". 🙂


which is actually slowly - bells do not turn very quickly, it would be about 40RPM if they travelled a full circle. And that small clapper can't move far as I can't get my shoulders in the mouth of the bell, its weight is what does the work.
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 02 January 2020, 11:47:52
I think the day probably originated as the sound of lots of clappers going all at once, as in a very loud peal with lots of bells. You would probably get lots of notes in less than a second. Well, a few notes in less than a second.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 02 January 2020, 12:00:40
I think the day probably originated as the sound of lots of clappers going all at once, as in a very loud peal with lots of bells. You would probably get lots of notes in less than a second. Well, a few notes in less than a second.


one bell strikes at a time, maybe half a second apart if they're small and being rung quickly. Larger numbers(10 or more) will have more time between them as the overall speed is dependent on the largest - you can't make the 30cwt tenor at Rochester turn as quickly as the 5cwt treble, but you do want an even gap between each bell.
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 02 January 2020, 12:37:36
That was supposed to say 'saying' not 'day'.
Title: Re: This Week in Wheeler's Workshop
Post by: Sir Tigger KC on 05 January 2020, 00:09:08
Yep, hence the saying "She goes like the clappers". 🙂

FTFY Uncle STEMO!  :y
Title: Re: This Week in Wheeler's Workshop
Post by: Marks DTM Calib on 09 January 2020, 07:33:58
you can't use them when the diff moves, as the distance between the flanges changes and the angles are too much for the donuts to accomodate - they just tear apart. That's why traditional props have a UJ at each end, and either slide on the gearbox output shaft or incorporate a sliding joint. It's called a clapper. Unless the bell isn't tuned very well ;D

Omega uses a sliding joint  :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 09 January 2020, 10:59:34
you can't use them when the diff moves, as the distance between the flanges changes and the angles are too much for the donuts to accomodate - they just tear apart. That's why traditional props have a UJ at each end, and either slide on the gearbox output shaft or incorporate a sliding joint.
 It's called a clapper. Unless the bell isn't tuned very well ;D

Omega uses a sliding joint  :y


true, but it has a lot less travel than is required for a live axle.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 05 April 2020, 13:05:08
Ian has been busy fitting enough parts to MOT the car for this year's show season. Which is now cancelled.


Here is a stock X30, driving, with all the Omega junk removed and other bits moved(alternator, MAF, multirams) to suit the installation:


(http://https://www.dropbox.com/s/yawpubak1642kl5/IMG_20200327_201101.jpg?raw=1)(http://https://www.dropbox.com/s/yawpubak1642kl5/IMG_20200327_201101.jpg?raw=1)
Title: Re: This Week in Wheeler's Workshop
Post by: henryd on 06 April 2020, 10:46:18
Ian has been busy fitting enough parts to MOT the car for this year's show season. Which is now cancelled.


Here is a stock X30, driving, with all the Omega junk removed and other bits moved(alternator, MAF, multirams) to suit the installation:


(http://https://www.dropbox.com/s/yawpubak1642kl5/IMG_20200327_201101.jpg?raw=1)(http://https://www.dropbox.com/s/yawpubak1642kl5/IMG_20200327_201101.jpg?raw=1)

Pics  ???
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 06 April 2020, 11:35:26
Ian has been busy fitting enough parts to MOT the car for this year's show season. Which is now cancelled.


Here is a stock X30, driving, with all the Omega junk removed and other bits moved(alternator, MAF, multirams) to suit the installation:


(http://https://www.dropbox.com/s/yawpubak1642kl5/IMG_20200327_201101.jpg?raw=1)(http://https://www.dropbox.com/s/yawpubak1642kl5/IMG_20200327_201101.jpg?raw=1)

Pics  ???
I can't see Dropbox pics either, it's a bloody nuisance.
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 06 April 2020, 11:37:58
(https://i.ibb.co/BBtkPm0/FE1436-DE-5-A17-4-E15-B9-C2-78-D347-EC49-D0.png) (https://ibb.co/gJ3Y7Gk)
Title: Re: This Week in Wheeler's Workshop
Post by: Viral_Jim on 07 April 2020, 01:11:25
Lovely neat job that  :y

Loving the updates on this build :)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 07 April 2020, 11:53:33
Lovely neat job that  :y

Loving the updates on this build :)


neat was important, so we've only modified parts where absolutely necessary.


So it has a stock Omega engine loom spliced into the car, with the EML and immobiliser working(the ignition pickup fits inside the stock MGB housing, and the chip goes into a Discovery key). We only made the exhaust manifolds, water rail and alternator mounts because there was no way of fitting stock parts. That made both the EGR and SAI redundant; Ian's made cheater circuits to remove all of the hardware especially the vacuum lines.The new water rail feeds the stock MGB bypass valve and heater box, which does away with more vacuum accessories.


It took me a while to convince him to keep the multirams, although the lower box that the AFM attaches to didn't fit. We needed to move that anyway as the water rail and alternator had to fit in that space. The new box is made from 75mm soil pipe and fittings(which are true 90° unlike drain pipe) bonded together, with the guts of the AFM screwed in. Air filter is a K&N in front of the radiator, he'll live with a shorter AFM life if that happens. Connecting hoses are stock. Throttle cable is Vectra with an adaptor to take up the extra 30mm length. This was quicker and easier than shortening the cable, and means that another stock cable will fit if necessary


Radiator is stock MGB V8, with a threaded boss for the fan switch - manually switched cooling fans are an abomination - in the stock location, with a completely unmodified Omega top hose joining them!


I made an adaptor to fit a stock MGB UJ to the Omega gearbox flange. The custom prop is basically stock MGB, but longer to take up the space the overdrive unit occupied. Gearlever is stock Omega with the reverse lockout removed(there's another inside the gearbox), through the stock MGB hole, trim, console and gaiter. Ian drilled a hole in the side of the bell housing to fit the clutch hose(stock MGB pedal and master cylinder), I would have kept the stock top location, even though it is a little busy there.
Title: Re: This Week in Wheeler's Workshop
Post by: 456lbft on 26 June 2020, 14:49:52
Great to see V6s getting a second chance at life, and not having to lug a bi heavy body around anymore.  Keep the updates coming. I look forward to shows opening up, so we can all see what's been going on in other people's sheds!
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 26 June 2020, 15:13:51
Quote
Ian drilled a hole in the side of the bell housing to fit the clutch hose(stock MGB pedal and master cylinder), I would have kept the stock top location, even though it is a little busy there.
That top routing keeps it clear of the cats, but if they've gone, there's probably a bit more space for the feed to be routed down to the side, especially if it lends itself better to the MGB geography...
Title: Re: This Week in Wheeler's Workshop
Post by: Field Marshal Dr. Opti on 26 June 2020, 15:58:31
With only roughly 1000KG of MGB to drag around that should go like shit off a shovel. :y
Title: Re: This Week in Wheeler's Workshop
Post by: Migv6 le Frog Fan on 26 June 2020, 17:01:52
I imagine it will still handle like an MGB though.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 26 June 2020, 17:13:43
Front end should be lighter ;)
Title: Re: This Week in Wheeler's Workshop
Post by: Migv6 le Frog Fan on 26 June 2020, 17:25:53
Really ? V6 lighter than a B series four ? Even so, the handling was dire with S4 or V8, due to the suspension design being centuries old.
Title: Re: This Week in Wheeler's Workshop
Post by: VXL V6 on 26 June 2020, 17:35:25
Looks great  :y

Lot of work gone into that installation.  :)
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 26 June 2020, 18:32:45
Really ? V6 lighter than a B series four ? Even so, the handling was dire with S4 or V8, due to the suspension design being centuries old.
Upon investigation, there's not much in it... 181kgs for the 4pot boat anchor vs 190ish* for the V6 ;)

* The 3.0 V6 turbo version that SAAB used is 197kgs.
Title: Re: This Week in Wheeler's Workshop
Post by: Migv6 le Frog Fan on 26 June 2020, 20:33:00
It does look a lovely installation though.  :y Would be even nicer in a Chevette.  :)
Title: Re: This Week in Wheeler's Workshop
Post by: 456lbft on 27 June 2020, 09:05:41
It does look a lovely installation though.  :y Would be even nicer in a Chevette.  :)
V6 is shorter than a 4 pot too, and unusually narrow V angle helps a bit too as long as you don't have a steering box to get around...
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 27 June 2020, 10:13:05
It does look a lovely installation though.  :y Would be even nicer in a Chevette.  :)
V6 is shorter than a 4 pot too, and unusually narrow V angle helps a bit too as long as you don't have a steering box to get around...


the problem with engine swaps in a lot of fifties cars(MGB underbody wasn't new) is that the front chassis rails sweep up and inwards to mount the suspension. That doesn't really matter with a tall, inline engine but is right where the exhaust manifolds need to be on a vee motor. DOHC heads make that worse, as do the very wide Rover heads - Rover V8s are only common swaps in the UK due to their ubiquity, they're actually long, tall wide, underpowered compared to their bulk, and not very durable. And the 'alternatives' were even worse; Essex V6 for example.

When comparing the weights, don't forget the gearboxes: four speed with an additional chunk of overdrive both in cast iron compared to a shorter aluminium cased five speed. Swapping the massive V6 flywheel four cylinder one would make another difference. Although we've fitted the back of the engine in the stock location, the front pulley is about where the front axle line lies. This changes the weight distribution, as the car currently sits higher than normal on its standard front springs.

MGB suspension is double wishbone front with decent geometry, and there's nothing wrong with parallel leaf springs. The biggest problem is that it's all a bit cramped under there. This car is intended as a GT, so with appropriate front springs, thicker oil in the front dampers and telescopic rears(Escort ones I bought by mistake 20years ago) plus 4pot calipers on bigger, vented discs(an off the shelf upgrade as Ian wants to keep the stock alloy wheels) it will be plenty good enough. The car's small size, light weight(even small modern cars are ridiculously heavy), impressive power to weight and torquey power delivery will make for seriously usable performance. If it were my car, I would have used a 2.2 four cylinder.
Title: Re: This Week in Wheeler's Workshop
Post by: 456lbft on 28 June 2020, 22:24:41
speaking from experience, the Rover is a nightmare for making exhaust manifolds because the head face is vertical, not even slightly angled downwards.  So you have to start with a 135degree bend to tuck it into the block. These days we can bend them on a very tight radius with no kinking or loss in cross-section, but that certainly wasn't possible as easily back when I started in the eighties.  Triumph Stags with Rover engines in were a common swap back then. The Omega V6 in an MBG sounds much more sensible by comparison.
Title: Re: This Week in Wheeler's Workshop
Post by: Field Marshal Dr. Opti on 29 June 2020, 15:38:46
Really ? V6 lighter than a B series four ? Even so, the handling was dire with S4 or V8, due to the suspension design being centuries old.

Apparently the MGC handled even worse.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 30 June 2020, 08:20:02
Really ? V6 lighter than a B series four ? Even so, the handling was dire with S4 or V8, due to the suspension design being centuries old.

Apparently the MGC handled even worse.


there's not much MGB under an MGC.....
Front structure, gearbox tunnel, suspension and steering are all very different to accomodate the boat anchor masquerading as an engine. Supposedly, the press demonstrators had incorrectly inflated tyres for some reason; fixing that makes a big difference
Title: Re: This Week in Wheeler's Workshop
Post by: 456lbft on 07 July 2020, 14:46:08
Really ? V6 lighter than a B series four ? Even so, the handling was dire with S4 or V8, due to the suspension design being centuries old.

Apparently the MGC handled even worse.


there's not much MGB under an MGC.....
Front structure, gearbox tunnel, suspension and steering are all very different to accomodate the boat anchor masquerading as an engine. Supposedly, the press demonstrators had incorrectly inflated tyres for some reason; fixing that makes a big difference
Wasn't it an Austin Healey engine, iron head and all. I can hardly lift the head alone of one of them, and yet a bare rover V8 block and heads is easy (or was 10 years ago before bulging discs and sciatica..)
Title: Re: This Week in Wheeler's Workshop
Post by: Keith ABS on 07 July 2020, 19:55:34
It does look a lovely installation though.  :y Would be even nicer in a Chevette.  :)
Much nicer in a Manta Albs :y :y
Title: Re: This Week in Wheeler's Workshop
Post by: Migv6 le Frog Fan on 07 July 2020, 21:22:28
Nah, Manta always looked a bit big and cumbersome to me compared to the Chevette. All personal preference of course.
I need to speak to you soon Keith about hire of ABS cam locking kit. :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 08 July 2020, 09:32:30

Wasn't it an Austin Healey engine, iron head and all. I can hardly lift the head alone of one of them, and yet a bare rover V8 block and heads is easy (or was 10 years ago before bulging discs and sciatica..)


it was just BMC's six cylinder engine as used in their big cars and trucks, but in a slightly higher state of tune.


The twin-cam MGA engine would have made the MGB a much better car, if the design hadn't been so crap. Something that Triumph continued with their slant engine family(which includes the Stag V8) and especially the Sprint cylinder head. If those had been better designed and engineered(angled head bolts for instance), BL would not have been reliant on the B-series, Rover V8 and Triumph six throughout the seventies.
Title: Re: This Week in Wheeler's Workshop
Post by: Olympia5776 on 08 July 2020, 11:05:26
That's an incredibly nice and very interesting conversion  Nick.
I had a two year old MGB GT back in the day and loved it for the short time I owned it . With retirement looming and my E24 long since fully restored I've been looking at the GT's again with a view to doing a restomod on one , stock exterior with modern drivetrain .
This is food for thought .
Keep us updated if you would please .
Don
Title: Re: This Week in Wheeler's Workshop
Post by: 456lbft on 14 July 2020, 14:46:55
It might be possible to build a fast 'B for less than one of these:-
https://www.frontlinedevelopments.com/vehicle/mg-le50/ (https://www.frontlinedevelopments.com/vehicle/mg-le50/)
I do know someone who has all the facilities to build one himself, and he bought one from them, so they must be good.
Title: Re: This Week in Wheeler's Workshop
Post by: Viral_Jim on 14 July 2020, 15:19:28
It might be possible to build a fast 'B for less than one of these:-
https://www.frontlinedevelopments.com/vehicle/mg-le50/ (https://www.frontlinedevelopments.com/vehicle/mg-le50/)
I do know someone who has all the facilities to build one himself, and he bought one from them, so they must be good.

Yikes! for £85k+ you'd have to REALLY want one. Still, nostalgia is a powerful draw I suppose.  :-\
Title: Re: This Week in Wheeler's Workshop
Post by: Sir Tigger KC on 14 July 2020, 20:54:26
It might be possible to build a fast 'B for less than one of these:-
https://www.frontlinedevelopments.com/vehicle/mg-le50/ (https://www.frontlinedevelopments.com/vehicle/mg-le50/)
I do know someone who has all the facilities to build one himself, and he bought one from them, so they must be good.

Yikes! for £85k+ you'd have to REALLY want one. Still, nostalgia is a powerful draw I suppose.  :-\

That's fab!  :y  But yes, a rich boys toy.  :'(
Title: Re: This Week in Wheeler's Workshop
Post by: Kevin Wood on 15 July 2020, 23:04:03
It might be possible to build a fast 'B for less than one of these:-
https://www.frontlinedevelopments.com/vehicle/mg-le50/ (https://www.frontlinedevelopments.com/vehicle/mg-le50/)
I do know someone who has all the facilities to build one himself, and he bought one from them, so they must be good.

Yikes! for £85k+ you'd have to REALLY want one. Still, nostalgia is a powerful draw I suppose.  :-\

That's fab!  :y  But yes, a rich boys toy.  :'(

If I had that sort of money to splash on a toy it wouldn't be going anywhere near a "2 door Morris Oxford", MX-5 engined or not..  ;)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 31 July 2020, 20:15:06
Ian let me know that the MGB passed its MOT retest**, and it will be taxed tomorrow. Then we'll find out how well it goes :y


** it failed on the rear brake balance. Which was fixed by making the mk3 version of the handbrake cable to drum linkage to go around the new exhaust.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 31 July 2020, 21:35:29
Nice one :y

Much fettling left to do?
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 31 July 2020, 22:33:44
Nice one :y

Much fettling left to do?


The original interior is very poor, except for the seats which are Mx5. That's easy, new door cards/carpet/headlining are available new for sensible money. Dynamat will be used where ever possible. Noisy, vibrating cars are deeply unpleasant.


The car had been painted before he bought it but it was never brilliant, and is covered in garage rash. They didn't paint the roof as it was going to have a new vinyl roof. And whoever reskinned the doors did a terrible job. We'll deal with all of that over the winter once the car has been debugged.


Mechanically, its stock or common upgrades and all new/rebuilt so no real worries there. Although some experimentation with the front springs might be necessary once they've settled. At least we'll have a good starting point, as they're new and stock. Cutting off a couple of coils might be enough.


Which leaves the conversion: the fuel pump(Impreza in MGB tank) needs proving, as does the cooling system in use and the drive belt brackets. The radiator is a new V8 one, so it's easily up to the job. Other heat management(shields, vented bonnet) might be necessary. Engine loom is unmolested Omega, except for the power plug. It no longer has SAI, EGR, HBV or any other vacuum systems that aren't essential.


Some new tyres would be a good idea.....
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 31 July 2020, 22:59:34
A couple of weekends still to go them...  :D

At least it can be road tested to help the process :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 31 July 2020, 23:05:33
A couple of weekends still to go them...  :D

At least it can be road tested to help the process :y


That was the intention. It looks OK from the other side of the road, and the shabby interior is better than bare metal. We can sort out any problems it might have before blowing it apart for paint. A pair of Stag alloys for the back would be good to try before then.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 02 August 2020, 14:51:46


Mechanically, its stock or common upgrades and all new/rebuilt so no real worries there. Although some experimentation with the front springs might be necessary once they've settled. At least we'll have a good starting point, as they're new and stock. Cutting off a couple of coils might be enough.


Which leaves the conversion: the fuel pump(Impreza in MGB tank) needs proving, as does the cooling system in use and the drive belt brackets. The radiator is a new V8 one, so it's easily up to the job. Other heat management(shields, vented bonnet) might be necessary. Engine loom is unmolested Omega, except for the power plug. It no longer has SAI, EGR, HBV or any other vacuum systems that aren't essential.


Some new tyres would be a good idea.....




(https://www.dropbox.com/s/etbkfctrukzc9r2/MGBMOTD2.jpg?raw=1)


Now on the road!


It sits in heavy traffic with the cooling fan switching properly and the needle in the centre of the gauge(which agrees with the ECU sensor). Underbonnet temp seems lower than an Omega so no issues there.


It starts and idles perfectly. It's reasonably quiet inside the car, even with no interior. Except for the fuelpump, which isn't covered - a false bootfloor should sort that. It had an erratic clonk from the NSR, which is a loose shock droplink. The new, aftermarket speedo has an erratic sticky needle - a phone call to the supplier when they're open is on the list.


Clutch and gearbox are good - they were unknown from when I bought them.


Stance is good, slightly nose down with normal MGB clearance. It's on four new 185/70 14 Avons.


Mx5 seats are comfortable.




It's utterly effortless, pulls like a train from under 30mph in fifth. First gear is a little lower than you'd ideally want in such a light car, but it's nowhere near as bad as a T9 equipped RS2000. And a 3.7 diff instead of the 3.9 would fix it if OCD enough.



Title: Re: This Week in Wheeler's Workshop
Post by: Sir Tigger KC on 02 August 2020, 22:56:17
Awesome!  8)
Title: Re: This Week in Wheeler's Workshop
Post by: TheBoy on 03 August 2020, 18:44:48
Cracking :y
Title: Re: This Week in Wheeler's Workshop
Post by: Auto Addict on 03 August 2020, 18:49:30
Fantastic :y
Title: Re: This Week in Wheeler's Workshop
Post by: 456lbft on 03 August 2020, 21:22:16
 :y I would love to hear that.  Have you gone for a 2 into one or a dual pipe exhaust set up?
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 03 August 2020, 21:52:35
:y I would love to hear that.  Have you gone for a 2 into one or a dual pipe exhaust set up?


It's off the shelf, 2 into 1 for a Rover. Ian had to lengthen the crosspiece slightly.


There's not much room under an MGB, and he's planning on a Panhard rod which further reduces the space over the axle. Plus, single systems are cheaper and quieter which is important on road cars!
Title: Re: This Week in Wheeler's Workshop
Post by: 456lbft on 04 August 2020, 13:22:41
:y I would love to hear that.  Have you gone for a 2 into one or a dual pipe exhaust set up?


It's off the shelf, 2 into 1 for a Rover. Ian had to lengthen the crosspiece slightly.


There's not much room under an MGB, and he's planning on a Panhard rod which further reduces the space over the axle. Plus, single systems are cheaper and quieter which is important on road cars!
2 into 1 much better for sound quality, and I'm sure you're not short of power now!
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 09 August 2020, 21:41:57
Today, I've done something ghastly: worked on a VW :o


Back in March, my neighbour asked why his camper wasn't starting. Some faffing about in the dark suggested that the starter was knackered, and it turned out that whoever fitted it last had managed to bugger up the shaped top bolt, so removing it took ages.


He managed to get  a new one in the week, so we(I) fitted it. And that's why Borstal reverberated to the flatulent sound of a 1700 flat four with an air leak.


It's been a while since I've done anything to one of these heaps, and I had forgotten how utterly shit they are. There isn't enough beer to persuade me to actually drive the thing......
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 09 August 2020, 21:58:06
worth a far amount those Nazi wagons  :P
maybe they will pay you in boiled sausages  :(
i'm not a fan of vans ,even modern ones ,let alone an 80 year old design
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 09 August 2020, 22:13:42
worth a far amount those Nazi wagons  :P
maybe they will pay you in boiled sausages :(
i'm not a fan of vans ,even modern ones ,let alone an 80 year old design


James is a New Zealander, so lamb would be more likely ;D


It's a few beers job.
Title: Re: This Week in Wheeler's Workshop
Post by: Marks DTM Calib on 10 August 2020, 11:30:47
Today, I've done something ghastly: worked on a VW :o


Back in March, my neighbour asked why his camper wasn't starting. Some faffing about in the dark suggested that the starter was knackered, and it turned out that whoever fitted it last had managed to bugger up the shaped top bolt, so removing it took ages.


He managed to get  a new one in the week, so we(I) fitted it. And that's why Borstal reverberated to the flatulent sound of a 1700 flat four with an air leak.


It's been a while since I've done anything to one of these heaps, and I had forgotten how utterly shit they are. There isn't enough beer to persuade me to actually drive the thing......

Horrific things, the type 1 flat 4 is a joke of a power unit, crap in every way
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 10 August 2020, 11:51:56

Horrific things, the type 1 flat 4 is a joke of a power unit, crap in every way


The only place flat engines make any sense is aeroplanes. And even then, they sound like a proper engine with the plug leads on wrong. Although modern engine technology has reduced their advantages down to just one: their low height.
Title: Re: This Week in Wheeler's Workshop
Post by: Marks DTM Calib on 10 August 2020, 12:14:50
Every type 1 I have worked on has the same faults:

Crap crank case design which moves around the mains (magnesium alloy) so they are shot at sub 50K and cant be-rebuilt successfully.
Oil feed is non existent to one bank of cylinder heads - fixed at the type 4..........can be drilled through if you can weld the above crap alloy casing.
No oil filter as standard
Crap cooling, they are really an oil cooled unit with an oil/air heat exchanger that does most of the work - the cast fins do only a low percentage of the real cooling
Rubbish oil pressure, so not enough flow to cool and lube them well.
Terrible ignition system
All aftermarket parts are inherently crap

The only fix is to bin it and fit a type 4!  ;D ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Migv6 le Frog Fan on 10 August 2020, 12:33:59
You forgot to mention that they put the valves too close together in the heads so they crack between the valve seats.
Quite a few people seem to love them, but I will never understand why.  ::)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 10 August 2020, 13:04:28
Every type 1 I have worked on has the same faults:

Crap crank case design which moves around the mains (magnesium alloy) so they are shot at sub 50K and cant be-rebuilt successfully.
Oil feed is non existent to one bank of cylinder heads - fixed at the type 4..........can be drilled through if you can weld the above crap alloy casing.
No oil filter as standard
Crap cooling, they are really an oil cooled unit with an oil/air heat exchanger that does most of the work - the cast fins do only a low percentage of the real cooling
Rubbish oil pressure, so not enough flow to cool and lube them well.
Terrible ignition system
All aftermarket parts are inherently crap

The only fix is to bin it and fit a type 4!  ;D ;D


Those are hardly unusual problems for an engine designed in the thirties! Compare it to the sidevalve Ford or  Morris engines which are its real competitors. The VW engine's real problem is that it should have been replaced a good thirty years earlier, like its contemporaries.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 20 August 2020, 19:54:06
On the bench today:


(https://www.dropbox.com/s/ihtaghcbh4dfvis/damagedVVChead2.jpg?raw=1)


and for those who didn't spot the reason why it's not bolted to an engine:


(https://www.dropbox.com/s/n5d59jhe4cnxgez/BentVVCvalves.jpg?raw=1)


the intake valves on #1&2 cylinders are bent where the pulley slipped on the front mechanism(it's a k-series VVC head)


What I haven't shown is the other head I was supplied that has 8 bent valves due to a broken timing belt.


So the plan is to strip both heads, and use the second one(which was free) to provide the valves and a complete undamaged VVC mechanism:


(https://www.dropbox.com/s/87budxddh5pgcy2/VVCmechanism.jpg?raw=1)


With that little lot out of the way, it's straightforward head work:


(https://www.dropbox.com/s/kb1e0mokcm6klqn/partiallystrippedVVChead.jpg?raw=1)




while the head is apart, I'll do a little tidying up in the valve throats, cut the valve heads back by 30degrees, blend the steps in the chambers, clean the cam followers and use the best 16, remove the flash from the water jacket holes, match the inlet manifold to the ports(it already has a good aftermarket exhaust manifold) and replace the stem seals.


Then the fun starts - refitting the inlet cam(s) and the VVC mech.


Perhaps the new apprentice will help; Yves seemed fascinated by the work so far:


(https://www.dropbox.com/s/evq7suw4lbglfbj/Apprentice.jpg?raw=1)
Title: Re: This Week in Wheeler's Workshop
Post by: Keith ABS on 20 August 2020, 20:25:42
 Would this be out of your Metro Nick?
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 20 August 2020, 20:31:52
Would this be out of your Metro Nick?


Different one that's even sneakier: tidy five door, 14" steel wheels, quiet exhaust, stock ride height, leather interior, all the factory toys. He bought it as finished, but we've had to rewire it, fit the cooling system, interior, make an exhaust, uprate the brakes, and undo all sorts of shitty work. Pretty much what you expect from banger racers: if it starts, it's finished. And this happened a week after getting it on the road.
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 20 August 2020, 21:21:15
No £50 machine shop head skim  :P
do you flat off heads yourself on a plate ?
or is it a ye olde fibre n fire ring headgasket ?
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 20 August 2020, 21:52:53
No £50 machine shop head skim  :P
do you flat off heads yourself on a plate ?
or is it a ye olde fibre n fire ring headgasket ?


Nothing wrong with the head surface, so we're leaving it well alone. There's not much available deck height on these or any other modern aluminium head. This one has clearly been rebuilt fairly recently, as it has an overheating telltale sticker on it. I suspect that was when the cam pulley was badly fitted and damaged. The locating roll pin and hole are mangled, the adjusting hub seems really loose and there's rusty dust in the centre bolt hole. All of that is why none of the inlet cam mechanism is going back in.


I don't have a big enough mill to skim heads myself, so would have it done professionally. It needs to be geometrically correct which makes doing it by hand a highly skilled job - skills I don't have and don't have the time or need to develop. Although I wish I'd asked Grandad to demonstrate them.


Recent redesigned gaskets combined with accurate shimming of the liner heights, reduce HG failure to other causes. Besides, a VVC in a R100 is not working hard!
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 03 September 2020, 21:02:43
I've been getting on with the head(s):


dismantled the spare head(which had a number of bent valves from a broken timing belt) so I had a full set of valves, undamaged VVC mechanism, and a replacement cam followers for the ones that failed this test


 (https://www.dropbox.com/s/r54i7m3hnppvp3i/CheckingCamFollowers-01.jpg?raw=1)


cleaned the valves


(https://www.dropbox.com/s/nnpard8ou80n1kg/CleanedValve-01.jpg?raw=1)


mildly ported the head; blended the short side to a radius, unshrouded the valve to chamber, removed the machining step into the chamber for the seat inserts, tapered the valve guide bosses, opened the exhaust ports to better match the aftermarket manifold, removed the casting flash from the water jacket into the combustion chamber jacket and lapped in the valves -


(https://www.dropbox.com/s/dmagktrrveyu93u/MildlyPortedHead-01.jpg?raw=1)


after jet washing everything I refitted the valves with new stem seals


(https://www.dropbox.com/s/te5fyj3i91cdv6z/ReadyToReassembel-01.jpg?raw=1)


(https://www.dropbox.com/s/tye2370bf0qyml4/RefittedValves-01.jpg?raw=1)


flipped it over and put the cam followers in, then laid out the intake cam apparatus:


(https://www.dropbox.com/s/szs58a7fcib3i33/VVCMechsReadyToFit-01.jpg?raw=1)


which was much easier than I expected :o
All assembled, rear timing belt installed, front cam aligned and waiting for a new pulley:


(https://www.dropbox.com/s/5sdl18iyzzj7ng6/ReassembledHead-01.jpg?raw=1)


collected by the owner to fit at the weekend.



Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 03 September 2020, 21:13:15
nice work  8)
it's been a while since i had to do a head , thankfully   :)
I have fat fingers and valve collets are hard to find when the spring goes ping and fires them across the room  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 03 September 2020, 21:24:40
nice work  8)
it's been a while since i had to do a head , thankfully   :)
I have fat fingers and valve collets are hard to find when the spring goes ping and fires them across the room  ;D


blob of grease on the end of the valve stem. Stick the collet to a small screwdriver with a tiny blob of grease. Push the collet on to the valve stem, and do the same with the other half. Squeeze the collets together with tweezers. Let off the spring compressor slowly -  a screw type is better as you can watch what's going on, and correct it. K-series parts are tiny, compared to Lycoming ones....


I keep telling myself that when I do grow another pair of hands, they'll be small girly ones ;D
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 04 September 2020, 09:21:52

I keep telling myself that when I do grow another pair of hands, they'll be small girly ones ;D

NO  :o
the CPU and operating system is problematic/temperamental at best ,devoid of any logic ,unable to follow the simplest of instruction  :P
Title: Re: This Week in Wheeler's Workshop
Post by: amba on 04 September 2020, 09:25:35
And normally high maintenance costs  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 04 September 2020, 09:33:32
And normally high maintenance costs  ;D
oh dear , someone who obviously looks at his bank statements and does the maths
that's a slippery slide  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: amba on 04 September 2020, 14:47:03
Trouble with having too many females in the family.....Wife/Daughters/Grand Children....its all a very slippery slope  :(
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 04 September 2020, 22:49:02
Trouble with having too many females in the family.....Wife/Daughters/Grand Children....its all a very slippery slope  :(
The first two are self inflicted. Grandchildren are an obvious side effect of the first two :D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 09 September 2020, 15:50:55
Had some parts left over, a welder and was bored:


(https://www.dropbox.com/s/zg3idnbza3ykvus/WeldedPart.jpg?raw=1)


knocked up a carbon fibre base and a plaque


(https://www.dropbox.com/s/2ayym8t6g70tkvd/Base.jpg?raw=1)




producing a 'Fingyornament  8)


(https://www.dropbox.com/s/xga2ijmbs29in5h/Ornament.jpg?raw=1)
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 09 September 2020, 19:11:52
something to hang all your spring hose clamps on so you don't loose any   :P
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 27 October 2020, 19:11:09
This was unexpected:


(https://www.dropbox.com/s/f0cixjff66rfd4i/coolingpressuretester.jpg?raw=1)


which is a cooling system pressure test set.


I didn't buy it, a friend had bought one that was supplied with an adapter that leaked. That was the adapter he bought it for, so complained to the supplier. We could have fixed the leak(the QR fitting into the adapter), but it was brand new. Instead of replacing the faulty adapter they made a couple of derisory offers of £2 and £3 refunds. After some justified whinging, they just sent  him a complete new set.


Except they sent two new sets, so I've gained a useful new tool and he has spares ;D  We both wish he'd ordered the one that vacuum bleeds an empty cooling system......
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 27 October 2020, 19:48:16
You can't have everything  :D

Vac filled systems seem to be more prevalent  :-\
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 27 October 2020, 20:01:59
You can't have everything  :D

Vac filled systems seem to be more prevalent  :-\


Just think how much time you've spent groping Omega hoses following the OOF recommended procedure. Then there are difficult(and critical) to bleed systems like MGFs, where knowing that half a dozen stokes of a pump and turning a knob would do 95% of the job in seconds.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 22 November 2020, 16:40:15
I didn't expect to use the pressure tester so soon.
My sister turned up with the Focus to take Mum shopping, with the complaint that the heater doesn't work and there's a funny smell.


A quick pump on the tool(and empty coolant bottle >:( ) showed a hairline crack on one of the small plastic coolant pipes.


As a temporary repair I'd hoped to slip a bit of hose over it, but both the pipe and T-piece were really brittle:


(https://www.dropbox.com/s/iv421n76cs8l9dd/DamagedParts.jpg?raw=1)


That T-piece comes complete with the both hoses and the plastic pipe complete with QR fittings, and I can't get one until the end of the week.


So £1 acquired this better sized bit of hose and the correct size clamps:


(https://www.dropbox.com/s/zxzajh57s8dkp82/Hose.jpg?raw=1)


A few minutes on the lathe:


(https://www.dropbox.com/s/9z4ld90hhl86zzh/TurnedParts.jpg?raw=1)


my last piece of silver solder, must get some more and practice a bit:


(https://www.dropbox.com/s/lhzxz46awzj7ctb/Soldered.jpg?raw=1)


and the completed repair:


(https://www.dropbox.com/s/0aivudtww0cxyf2/FinishedRepair.jpg?raw=1)




I've just got back from road testing it, no leaks and the heater works. So that's good for now; I'll still order a new hose, as I have doubts about the rest of the plastic pipe.
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 22 November 2020, 16:50:51
Tidy  :)
I've "temporarily fixed *" many coolant and Vac pipe leaks with stock plumbing fittings i carry

* temporary fix = i'll get round to a proper fix IF  * fails before car gets sold/scrapped  :-X  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 22 November 2020, 17:12:20
That repair would probably outlast the car :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 22 November 2020, 17:13:24
Over 40 years ago, on holiday in Normandy, Mum's Avenger split two(of four) heater hoses. As the cottage was miles from anywhere(although Rods2 would recognise the hamlet name) Dad made a temporary repair using ordinary and very old garden hose. Which was still on it when the car was traded in for  a new one four years later.....
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 22 November 2020, 17:16:32
That repair would probably outlast the car :y


It's 16mm diameter brass with an 8mm hole through the middle. It ought to outlast me. I cut the plastic pipe back to what seems good material but I don't trust it. As this is the feed for the water-cooled turbo, it's important. And such a common failure that there is an upgraded part.


That's when I'll top up the anti-freeze
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 26 November 2020, 23:01:34
Not in Wheeler's Workshop, but the garage down the road: a bright green Holden Maloo, probably for an MOT. They had a HSV last week.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 05 December 2020, 14:48:56
Today, some jewellery.


broken earing from my sister:


(https://www.dropbox.com/s/r5p8yw5l7k0nvb3/BrokenEarring.jpg?raw=1)


so I cleaned both bits with a wire brush in the Dremel, added some flux, refilled my 'Heat Tool' with butane and soldered the two bits together:


(https://www.dropbox.com/s/442i3vapdv0bsuv/repairedearring.jpg?raw=1)




So that's Christmas sorted :y

Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 17 April 2021, 19:43:34
More years ago than I want to remember, I started making a simple hacksaw from a magazine article to be powered by a wiper motor. Last year I found I found it behind a cupboard


(https://www.dropbox.com/s/9xzypjvvqt6v4j4/incompletesawframe.jpg?raw=1)
 
and resolved to finish the thing. That was taken after I'd cleaned it and checked the frame still slides along the arm.


Some cutting, machining and welding of various scrap I had lying about, plus scrounging an MGF wiper motor and linkage:


(https://www.dropbox.com/s/qe4a9crc9arkvcx/PivotArm.jpg?raw=1)


(https://www.dropbox.com/s/7y1zw4p5bumi4hr/ClampParts.jpg?raw=1)


Produced this (almost) finished tool:


(https://www.dropbox.com/s/y27dqijrltb1coe/Completed.jpg?raw=1)


There's even some Omega content: the upright that holds the pivot was cut from an Omega towbar.


It works, albeit slowly, when connected to a battery charger and cuts through steel bar which was my requirement.


To finish it needs wiring with a switch and fuse. I'll paint it when I've finished the wheeling machine I started at a similar time.
Title: Re: This Week in Wheeler's Workshop
Post by: ronnyd on 17 April 2021, 19:57:03
Reminds of the ancient one i used to use at my last job.  :y
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 17 April 2021, 22:24:12
Hmm.....when it's raised from the slider, which I presume it is when resting on the piece of work to be cut, does it not 'rock', rather than a smooth back and forth motion?
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 18 April 2021, 09:24:00
Hmm.....when it's raised from the slider, which I presume it is when resting on the piece of work to be cut, does it not 'rock', rather than a smooth back and forth motion?


the frame that hold the blade can only slide along the pivoting arm, as it's constrained by two more pieces of the tube you can't see in the photo. The whole assembly - frame, pivot arm, motor, mount and linkage - pivots. This means the cut starts short and at a steep angle, and gets longer and shallower as it progresses. That's typical of powered hacksaws but is a design compromise. They're intended to be simple, robust(proper commercial ones!), cheap and compact; a mechanism that keeps the cut parallel would be a lot more complicated. It's a roughing out tool that can be left unattended to munch through large stock. More sophisticated cutting is done on bandsaws.
Title: Re: This Week in Wheeler's Workshop
Post by: ronnyd on 18 April 2021, 16:00:53
Hmm.....when it's raised from the slider, which I presume it is when resting on the piece of work to be cut, does it not 'rock', rather than a smooth back and forth motion?


the frame that hold the blade can only slide along the pivoting arm, as it's constrained by two more pieces of the tube you can't see in the photo. The whole assembly - frame, pivot arm, motor, mount and linkage - pivots. This means the cut starts short and at a steep angle, and gets longer and shallower as it progresses. That's typical of powered hacksaws but is a design compromise. They're intended to be simple, robust(proper commercial ones!), cheap and compact; a mechanism that keeps the cut parallel would be a lot more complicated. It's a roughing out tool that can be left unattended to munch through large stock. More sophisticated cutting is done on bandsaws.
Agree with that Nick. Worked at my best job for 25 years. Started off with a Hacksaw type, (it was there when i started). Suggested buying a bandsaw and they bought a Startright automatic one. Great piece of kit. Even used to leave it running when i left off on short billets and it switched off when it tripped the microswitch on the barfeed.  The clamping vice had rollers to feed the bars out to the workstop.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 18 April 2021, 17:01:24
That's a horizontal bandsaw, and is a step up for cutting off lengths of stock.


Then there are vertical bandsaws that are used for cutting shapes, which would be much more useful to me. But even a small metal cutting saw takes up much more space than I have and is extremely costly. Most of the smaller machines are intended for cutting wood, so tend not to be robust enough and run far too fast.
Title: Re: This Week in Wheeler's Workshop
Post by: ronnyd on 19 April 2021, 18:00:04
The worst, (or funniest), part of fitting a new bandsaw blade was untwisting it. I used to drop it on the floor and stand well back.  :D
Title: Re: This Week in Wheeler's Workshop
Post by: Viral_Jim on 20 April 2021, 20:10:57
I subscribe to a few YT woodworking channels and this seems to be the approved method.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 26 April 2021, 23:29:02
Some time ago, poster on another forum suggested that 3D CAD makes designing things complicated, and requires months of training to produce something simple like a crankshaft. I thought at the time he had that back to front, and when reminded of it decided it warranted a quick look. A few minutes in Fusion360 produced this, from one dimensioned sketch(visible in the pic), 3 extrudes and a mirror operation:


(https://www.dropbox.com/s/fjwpytigqpswta7/Crank%20Web.jpg?raw=1)


another few minutes and three jointed copies later I had something that looked like it would work:


(https://www.dropbox.com/s/8vt3jy5knis33sx/CrankWebs.jpg?raw=1)


Then things got a bit out hand, and I ended up with a mostly working(F360 doesn't have a follower joint) CAD model of a 60cc DOHC water cooled, wet liner engine that with a little extra work could make a working prototype:


(https://www.dropbox.com/s/h8tjfj004thal2m/Whole%20Engine.jpg?raw=1)


(https://www.dropbox.com/s/iarvw3rk883c8fy/Cutaway.jpg?raw=1)


It's about 165mm long, 185 high and F360 reckons it will weigh about 4kg which seems a bit low to me.




These are pretty


(https://www.dropbox.com/s/yrskthhfi30put2/Throttle%20Bodies.jpg?raw=1)


If we don't start ringing soon, I'll end buying several blocks of aluminium and a chunk of 50mm steel bar ;D
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 27 April 2021, 06:32:45
A fancy drawing board. The thing you have to keep going back to when stuff doesn't work.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 27 April 2021, 12:09:30
A fancy drawing board. The thing you have to keep going back to when stuff doesn't work.


Sometimes, it shows problems as proved by these sectional views


(https://www.dropbox.com/s/6jug5fjn43qa0cn/cutaway2.jpg?raw=1)




(https://www.dropbox.com/s/i0mgr5xx8oqdx6e/Front%20Section.jpg?raw=1)


As it stands, the only way to create the block's water jacket is with a cored casting. Considering the amount of metal that would have to removed for the other features from a large, expensive, solid block, that would be a sensible way to proceed. Making both parts of each main bearing cap bolt in would make machining them and the block easier.


As modelled, there's no good way to get the curved ports in the head without another casting. Changing them to angled ports and throats would remove this need, although continuing the water jacket to surround the combustion chambers would put it back. The head needs to 5mm longer at each end to prevent the headbolt counterbore breaking out. This would make the nose on the cam boxes redundant and make the water jacket surround the end cylinder liner if carried into the block.


There are no crank or rod bearings, although there is space for them. Nor is there any oiling system; I'd probably use an external pump for the main and cam bearings, driven off the water pump belt. Splash oiling for the conrods and pistons. The water pump is currently empty, and needs some serious thought to make it work.


I modelled the sump using surfaces for some practice and to make it look like a stamped sheetmetal part, but if actually building this thing I would hollow it out of a block or add it to the casting list.


It's easy to say that this would be an electronically managed engine, but scale injectors are an entirely different matter. Ignition systems are available. I've a friend who built a 180cc OHV V8, and getting the carburation even working, let alone well, was the hardest part of the build.


I suspect it will need domed pistons, instead of the flat top ones shown, to get enough compression to actually work.


It has a 25mm bore on 35mm centres, and a 30mm stroke
Title: Re: This Week in Wheeler's Workshop
Post by: TheBoy on 28 April 2021, 17:14:54
I keep toying with those cheap nasty small CNC machines you can get, in order to convert some of my designs into something a little stronger than 3d printer plastic.

But I know I'll be disappointed with it's capabilities, so keep talking myself out of it.

But the flip side is that during the ongoing climate where I don't want to go to busy pubs and eateries, I'd probably only spend the money on RC Planes/Drones/Cars/Trucks instead...


//TB wanders off pondering again...
Title: Re: This Week in Wheeler's Workshop
Post by: Sir Tigger KC on 28 April 2021, 18:12:02
I keep toying with those cheap nasty small CNC machines you can get, in order to convert some of my designs into something a little stronger than 3d printer plastic.

But I know I'll be disappointed with it's capabilities, so keep talking myself out of it.

But the flip side is that during the ongoing climate where I don't want to go to busy pubs and eateries, I'd probably only spend the money on RC Planes/Drones/Cars/Trucks instead...


//TB wanders off pondering again...

I'm sure you could find something suitable on Ebay?  ;D  :P
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 28 April 2021, 18:31:18
I keep toying with those cheap nasty small CNC machines you can get, in order to convert some of my designs into something a little stronger than 3d printer plastic.

But I know I'll be disappointed with it's capabilities, so keep talking myself out of it.



Think of them as very low power/rigidity routers. So, if most of your jobs would be small profiles machined from thin, soft, sheet materials(including aluminium) then they're a good start. But as you say the limitations are probably greater than the majority of the work you'd finish.


I have an equivalent of THIS  (https://www.machinemart.co.uk/p/cl-cmd300-mill-drill/?da=1&TC=GS-060710300&gclid=CjwKCAjwj6SEBhAOEiwAvFRuKH7IBG6PLQVRiFEgRo66l1MnTDPgp17KMTPmpvDGCad6EoiHDHpdrhoCT50QAvD_BwE&gclsrc=aw.ds)and the engine block shown here is too big for it. Milling on the lathe is similarly restrictive. I must get around to fitting the CNC parts I have for my my mill.


 I mentioned the V8 a friend built:


(https://www.dropbox.com/s/b83viat5ym3gd5g/v8block%20%281%29.jpg?raw=1)


Although he did the finish machining on a bigger benchtop mill, it was roughed out on the CNC machine he uses at work, to reduce the amount of time and potential mistakes. That's quite important when the billet cost over £150. And if you want to get the job done in one lifetime ::)
Title: Re: This Week in Wheeler's Workshop
Post by: Migv6 le Frog Fan on 28 April 2021, 23:11:21
That is a thing of beauty.  :y 8)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 28 April 2021, 23:31:17
That is a thing of beauty.  :y 8)


It looks better in the 'display stand'


(https://www.dropbox.com/s/pfx0p5s2682k9i3/Dragster.jpg?raw=1)
Title: Re: This Week in Wheeler's Workshop
Post by: Migv6 le Frog Fan on 29 April 2021, 13:19:00
That looks superb.  8) 8)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 29 April 2021, 13:24:57
That looks superb.  8) 8)


You should see what happens in between projects, when he gets bored :o
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 25 May 2021, 14:11:51
This week, 'can you stop the wheel falling off my RC car?'


This is what's left of the rear axle:


(https://www.dropbox.com/s/k3xlb1ofsoht9c8/brokenaxle.jpg?raw=1)


That broken bit is a hex, and the screw should hold the wheel on. There should be one on the other end too, but it's missing.



Maxwell is six and the car was £30 from a toyshop, so spares aren't available.


The axle is 9mm diameter, hollow and I don't like the screws.


So some scrap 10mm bar and a bit of machining produced two new ends complete with M4 retaining screws:


(https://www.dropbox.com/s/u8w9de3gcv3ffnx/NewEnds-3.jpg?raw=1)


Epoxied in place:


(https://www.dropbox.com/s/jfn09ebeoyvh7fn/RepairedAxle-3.jpg?raw=1)


That ought to sort it :y
Title: Re: This Week in Wheeler's Workshop
Post by: Raeturbo on 25 May 2021, 15:16:23
Good job👍
Title: Re: This Week in Wheeler's Workshop
Post by: ronnyd on 25 May 2021, 15:24:49
That's good to see, a well used workmate. 8) Axle repair ain't bad either.  :y
Also, what was it like drilling out the axle to fit the stubs that you turned?
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 25 May 2021, 15:39:11
That's good to see, a well used workmate. 8) Axle repair ain't bad either.  :y


It's one of the £15 cheapies that I've had for about twenty years. I'll have to replace the tops again soon - I have another couple of pieces of decking...
Title: Re: This Week in Wheeler's Workshop
Post by: TheBoy on 25 May 2021, 18:13:16
This week, 'can you stop the wheel falling off my RC car?'


This is what's left of the rear axle:


(https://www.dropbox.com/s/k3xlb1ofsoht9c8/brokenaxle.jpg?raw=1)


That broken bit is a hex, and the screw should hold the wheel on. There should be one on the other end too, but it's missing.



Maxwell is six and the car was £30 from a toyshop, so spares aren't available.


The axle is 9mm diameter, hollow and I don't like the screws.


So some scrap 10mm bar and a bit of machining produced two new ends complete with M4 retaining screws:


(https://www.dropbox.com/s/u8w9de3gcv3ffnx/NewEnds-3.jpg?raw=1)


Epoxied in place:


(https://www.dropbox.com/s/jfn09ebeoyvh7fn/RepairedAxle-3.jpg?raw=1)


That ought to sort it :y
I don't think I could do that on any of my 6S RC cars, they'd rip it to shreds ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 25 May 2021, 18:22:11

I don't think I could do that on any of my 6S RC cars, they'd rip it to shreds ;D


As they cost more than £30, I suspect that your axles don't have integral gears on 2mm thick tubes, and drive stubs that are much thinner than that. They also have bigger motors than the basic DC thing that's been used in small toys for decades.


I think you'd be surprised at what a properly used Loctite will do; it's replaced a lot of light press-fits.
 
And you're not six, although you break things as if you are...

Title: Re: This Week in Wheeler's Workshop
Post by: TheBoy on 25 May 2021, 18:38:22
I think you'd be surprised at what a properly used Loctite will do; it's replaced a lot of light press-fits.
Loctite's superglue only sticks rubber. And skin. ;D

 
you're not six, although you break things as if you are...
Eternal youth, my friend, that's what I have. I am, according to Mrs TB, still 5 ;D
Title: Re: This Week in Wheeler's Workshop
Post by: TheBoy on 25 May 2021, 18:57:22
This happened at the weekend, and I just childishly found it funny.
https://www.youtube.com/watch?v=1r31va0WmHY
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 25 May 2021, 20:28:50
I think you'd be surprised at what a properly used Loctite will do; it's replaced a lot of light press-fits.
Loctite's superglue only sticks rubber. And skin. ;D

 


Something like Loctite 638 would assemble axles for your toys :y
Title: Re: This Week in Wheeler's Workshop
Post by: Andy B on 25 May 2021, 21:36:59
....

Loctite's superglue only sticks rubber. And skin. ;D

We have a pretty good flavour of Loctite at work. 326  :-\ I'll send you some if you want   ;)

Title: Re: This Week in Wheeler's Workshop
Post by: TheBoy on 26 May 2021, 10:12:31
I think you'd be surprised at what a properly used Loctite will do; it's replaced a lot of light press-fits.
Loctite's superglue only sticks rubber. And skin. ;D

 


Something like Loctite 638 would assemble axles for your toys :y
I'd actually be impressed if any general adhesive would be strong enough, as it has significant torque.

Think around 150A at 22v, probably bursting to 200-250A from standing start hard acceleration.

I can't get my head around the current requirements.
Title: Re: This Week in Wheeler's Workshop
Post by: TheBoy on 26 May 2021, 10:12:55
fortunately, mine is metal axles, obviously ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 26 May 2021, 10:36:09

Something like Loctite 638 would assemble axles for your toys :y
I'd actually be impressed if any general adhesive would be strong enough, as it has significant torque.




That's not a general adhesive, but one specifically designed for this sort of job. As I wrote earlier, adhesive fits are quickly replacing ones that used to be made by pressing parts together. Parts that are bigger, heavier and under far more load than an RC car.


My repair was done with ordinary 2k epoxy because it doesn't matter, using procedures that match: I 'measured' the bore with using cheap drill bits, machined the spigots and stub axles until they just fit, and the only lengths I measured(with a rule) were the hex and track. I've don't know what plastic the axle is made from, and I think the aluminium rod I used was once part of some racking. This is a job where good enough is a very low bar.
Title: Re: This Week in Wheeler's Workshop
Post by: STEMO on 26 May 2021, 10:45:42
Superglue became widely available after it was found to hold the space shuttle together ok.  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 26 May 2021, 10:51:10
Superglue became widely available after it was found to hold the space shuttle together ok.  ;D


Yes.


Although you do need to be careful which O-rings it gets used on....
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 05 June 2021, 15:00:38
My sister turned up wanting a cable-tie for this:


(https://www.dropbox.com/s/1utz2185qica6kf/Missing.jpg?raw=1)


Her boyfriend has lost the 'nut' that goes on the end, and works like a wormdrive clamp.


A cable tie would work, but I've  a lathe and some 22mm nylon rod, and the 'thread' is a simple 2mm pitch so


(https://www.dropbox.com/s/elfc3tl8mxp5072/NewNut%20.jpg?raw=1)


No real precision there; I drilled a 12mm hole and cut the thread until it just cleaned up, because the tool is a stock V-form and the part has straight sides.


Finished, with a quick knurl and chamfered edges:


(https://www.dropbox.com/s/7acib7cbo22gkze/Repaired.jpg?raw=1)


I should have measured the length, as it could have been a bit shorter

Title: Re: This Week in Wheeler's Workshop
Post by: Field Marshal Dr. Opti on 06 June 2021, 13:23:49
Superglue became widely available after it was found to hold the space shuttle together ok.  ;D

Didn't this happen after people decided it would be fun to apply it to a toilet seat and then see what happened. ::)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 11 July 2021, 15:18:07
I've previously mentioned a friend's VVC Metro that we spent a while correcting all of the 'builder's oppsing awful workmanship. Part of the philosophy was that everything we refitted got cleaned and painted. It's been on the road for a year, and has just failed the MOT on emissions(which is the only real problem), a pair of tyres(disappointing with under 20k miles on them) and both front wheel bearings.


So he dropped these off:


(https://www.dropbox.com/s/69afbb87nobqchv/CrustyHubs.jpg?raw=1)


which were salvaged from a car he paid £35, and has provided all sorts of useful bits. These show that the car had been standing in a field for several years, and it took this to remove the driveshafts:


(https://www.dropbox.com/s/7ry5w288jc5ii2x/PressingOut%20Driveshaft%21%21.jpg?raw=1)


I had intended to press out the hubs and bearings, but it's low on oil. Which meant resorting to a hammer and drift for the hubs and the toolset for the bearings:


(https://www.dropbox.com/s/uo9kr3agvia5ipa/ExtractingWheelbearing.jpg?raw=1)


which left all this scrap:


(https://www.dropbox.com/s/wckct2lo0z8c1i4/TheStuffWeDon%27t.jpg?raw=1)


We couldn't have used the splash shields even if they weren't rotten as they don't fit behind the vented discs.


I degreased, wirebrushed everything then mixed some 2k gloss black and brushed it on


(https://www.dropbox.com/s/99zntgqpakenljd/CleanedandPainted.jpg?raw=1)


(https://www.dropbox.com/s/bqwk9bmtv5ke38e/PaintedUpright.jpg?raw=1)


Puts a nice finish on the cat, too 8)


(https://www.dropbox.com/s/gmxf2jkiwn2fkcq/Jess.jpg?raw=1)


That should save a bit of time next week when he arrives with the car and bearings. I'll make a bracket for the extra MGF engine mount while the car is jacked up.
Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 11 July 2021, 15:22:52
Is the cat in its drying pose?  :D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 20 August 2021, 12:27:06
About three weeks ago, Deb arrived with a broken door handle on her Hyundai.


We couldn't find a used one(there were plenty for the other side) without importing from Spain or eastern Europe for about £50. New ones are about the same.


So she bought 2 new ones, from a Chinese supplier, for £16 delivered:


(https://www.dropbox.com/s/eq12vitq83gqlzm/2New.jpg?raw=1)


The only snag was at least a fortnight delivery time.


Which meant a quick&dirty repair using some M4bolts, 2mm stainless sheet and some epoxy:


(https://www.dropbox.com/s/rhaz7vx68u4fje5/Repaired-1.jpg?raw=1)


I did that without removing the part, and it would probably last for some time. It would always be really ugly.


The new ones arrived yester day, so I fitted the necessary one:


(https://www.dropbox.com/s/08snv16rs8xz8ms/FittingHandle.jpg?raw=1)


One of the things I like about this car is the sensible way it's assembled: all that was needed to change the handle was to remove three screws, and pry the cables off.


The new ones don't have the horrible soft-touch coating, so I'll probably fit the other side to keep the details correct ::)
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 16 August 2022, 12:24:14
Today's job is the clutch on Deb's coupe.


Dismantling everything to get the was straight forward due to good design. There's even room to wedge it in the subframe so that lifting it back up isn't necessary. But I've turned into a weakling over the last couple of years and can't get the gearbox off.
Yet.
I'll have another go when it's stopped raining.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 03 October 2022, 18:25:51
At Easter I had the conversation about restoring a friend's Capri. And for the third year in a row, I told her I wasn't going to do anything until she bought some parts. So now the summer is over, with decent weather and long days with it, the money arrived.


This is what £160 buys:


(https://www.dropbox.com/s/x8sebgh1dftn7cb/NSPanels.jpg?raw=1)


that's the N/S sill, end cap, wheelarch and quarter panel repair. It also needs the windscreen corner and the strut tower strengthener, which are another £70 although I'll probably make the corner. Plus some steel for the repairs to the door pillar, inner arches, floor etc. And the same for the other side. Then a pair of wings at £240 each.
 



Title: Re: This Week in Wheeler's Workshop
Post by: Doctor Gollum on 03 October 2022, 22:37:38
Pretty reasonable all things considered. Certainly it would cost at least as much to buy any other rear wheel drive Coupe that didn't need all that stuff replacing soon.  :y
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 29 November 2022, 19:19:40
It's Christmas soon, so it must be time for another clapper repair ::)


The steeple-keeper mentioned that when he took the muffles off after Rememberance Sunday, that he though the clapper on the tenor was loose. This is a bad thing, and urgently needs investigating.


None of the relevant bolts were loose, but the clapper had about 8mm of vertical play.


So we loosened the headbolt, and dropped it out the bottom:


(https://www.dropbox.com/s/sng87s8p5y9a7lm/Clapper.jpg?raw=1)


The pin is screwed into the clevis, and because the whole thing is 11cwt of vibrating metal, the M20thread  is done up EFT, loctited and has a locknut so a long breaker bar was used with a 30mm socket.


I was expecting to find the either a worn bush, ovalled hole in the clapper or possibly wear in the pin.


I wasn't expecting this:


(https://www.dropbox.com/s/f09cg3ojspwtkzs/P_20221129_123422.jpg?raw=1)


which is 1" diameter, 20mm bore tufnol sleeve, floating in a 33mm hole - both undamaged. The weird thing is there is no trace anywhere of another bush to connect the two and there's less than 2mm of side clearance for it to escape through. All of this, except for the actual bell, is only 16 years old, so shouldn't be showing signs of wear.


It did mean an easy repair; I machined a new middle sleeve from a (too) big chunk of delrin:


(https://www.dropbox.com/s/08woe7hdchmyisc/PinandBushes.jpg?raw=1)


mostly fitted into the clapper


(https://www.dropbox.com/s/x013q3znl52lplj/Repaired.jpg?raw=1)




I've reassembled everything, and it all works correctly so we'll refit before Friday's practice.




But I'm mystified by how this happened, especially as none of the other seven bells have this fault.





Title: Re: This Week in Wheeler's Workshop
Post by: Raeturbo on 29 November 2022, 20:05:16
She gave me water……,🤣🛎
Title: Re: This Week in Wheeler's Workshop
Post by: ronnyd on 29 November 2022, 22:35:00
It's Christmas soon, so it must be time for another clapper repair ::)


The steeple-keeper mentioned that when he took the muffles off after Rememberance Sunday, that he though the clapper on the tenor was loose. This is a bad thing, and urgently needs investigating.


None of the relevant bolts were loose, but the clapper had about 8mm of vertical play.


So we loosened the headbolt, and dropped it out the bottom:


(https://www.dropbox.com/s/sng87s8p5y9a7lm/Clapper.jpg?raw=1)


The pin is screwed into the clevis, and because the whole thing is 11cwt of vibrating metal, the M20thread  is done up EFT, loctited and has a locknut so a long breaker bar was used with a 30mm socket.


I was expecting to find the either a worn bush, ovalled hole in the clapper or possibly wear in the pin.


I wasn't expecting this:


(https://www.dropbox.com/s/f09cg3ojspwtkzs/P_20221129_123422.jpg?raw=1)


which is 1" diameter, 20mm bore tufnol sleeve, floating in a 33mm hole - both undamaged. The weird thing is there is no trace anywhere of another bush to connect the two and there's less than 2mm of side clearance for it to escape through. All of this, except for the actual bell, is only 16 years old, so shouldn't be showing signs of wear.


It did mean an easy repair; I machined a new middle sleeve from a (too) big chunk of delrin:


(https://www.dropbox.com/s/08woe7hdchmyisc/PinandBushes.jpg?raw=1)


mostly fitted into the clapper


(https://www.dropbox.com/s/x013q3znl52lplj/Repaired.jpg?raw=1)




I've reassembled everything, and it all works correctly so we'll refit before Friday's practice.




But I'm mystified by how this happened, especially as none of the other seven bells have this fault.






Lovely stuff to m/c. Piles of plastic swarf everywhere. Not like Tufnol, powdery and stinks of burnt piss.
Title: Re: This Week in Wheeler's Workshop
Post by: Marks DTM Calib on 30 November 2022, 08:42:11
Delrin is a more sensible material choice than tufnol, my only other go to for this application is oil impregnated nylon 6 (which is what we use for brake rigging bushes on the choo choos now).

I would never use Tufnol for that application as it needs regular lube, its more for electrical insulation and can be quite abrasive (hence why it works with lube, it has places to trap oils). I can see that wearing the metal rather than the bush once it picks up a bit of the base to abrade with.

Regarding the original issue, looks like somebody didn't have the correct bush when they were overhauled.......

Title: Re: This Week in Wheeler's Workshop
Post by: ronnyd on 30 November 2022, 09:14:45
Delrin is a more sensible material choice than tufnol, my only other go to for this application is oil impregnated nylon 6 (which is what we use for brake rigging bushes on the choo choos now).

I would never use Tufnol for that application as it needs regular lube, its more for electrical insulation and can be quite abrasive (hence why it works with lube, it has places to trap oils). I can see that wearing the metal rather than the bush once it picks up a bit of the base to abrade with.

Regarding the original issue, looks like somebody didn't have the correct bush when they were overhauled.......


Used to m/c quite a lot of Delrin in my centre lathe turning days. Not much tufnel though. Machining Magnesium was rather 'interesting', always had the sand bucket handily placed. ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 30 November 2022, 09:15:55
Delrin is a more sensible material choice than tufnol, my only other go to for this application is oil impregnated nylon 6 (which is what we use for brake rigging bushes on the choo choos now).

I would never use Tufnol for that application as it needs regular lube, its more for electrical insulation and can be quite abrasive (hence why it works with lube, it has places to trap oils). I can see that wearing the metal rather than the bush once it picks up a bit of the base to abrade with.

Regarding the original issue, looks like somebody didn't have the correct bush when they were overhauled.......


I was slightly surprised by the tufnol bush, but it and the stainless pin it rides on are still unmarked, round and to size. So is the bore in the clapper, as the original machining marks are still visible. That's why I kept them, and made a new spacer to fill the void. It's delrin because I had some, although I would probably have bought something similar. It would definitely have been closer in size, as I probably spent more time backing the live centre off to clear the long strings of swarf - even 4mm DOC takes time to reduce the diameter from 75 to33mm.


The interesting bit is neither of us can explain what was used before the new spacer, as there is no material anywhere around the bell, frame or on the floor. And there's only a 1mm gap at each end for it to escape through.


As I mentioned, this entire installation, apart from the bells(which vary from 140 to nearly 400 years old), was new in 2006 and has had no work since. It's an entirely conventional modern steel frame using standard parts, replacing the wooden one that was condemned in the early '70s. None of the bells I've seen have lubrication for the clapper pins - access is very poor - and the main bearings tend to get it about once a century ::) . They don't turn quickly, and aren't particularly heavy. The clapper can't swing much more than about 30°. Traditionally, most of these parts would have been made by the local blacksmith, and there are still plenty throughout the country that are still in use.


Title: Re: This Week in Wheeler's Workshop
Post by: ronnyd on 30 November 2022, 14:44:16
Delrin is a more sensible material choice than tufnol, my only other go to for this application is oil impregnated nylon 6 (which is what we use for brake rigging bushes on the choo choos now).

I would never use Tufnol for that application as it needs regular lube, its more for electrical insulation and can be quite abrasive (hence why it works with lube, it has places to trap oils). I can see that wearing the metal rather than the bush once it picks up a bit of the base to abrade with.

Regarding the original issue, looks like somebody didn't have the correct bush when they were overhauled.......


I was slightly surprised by the tufnol bush, but it and the stainless pin it rides on are still unmarked, round and to size. So is the bore in the clapper, as the original machining marks are still visible. That's why I kept them, and made a new spacer to fill the void. It's delrin because I had some, although I would probably have bought something similar. It would definitely have been closer in size, as I probably spent more time backing the live centre off to clear the long strings of swarf - even 4mm DOC takes time to reduce the diameter from 75 to33mm.


The interesting bit is neither of us can explain what was used before the new spacer, as there is no material anywhere around the bell, frame or on the floor. And there's only a 1mm gap at each end for it to escape through.


As I mentioned, this entire installation, apart from the bells(which vary from 140 to nearly 400 years old), was new in 2006 and has had no work since. It's an entirely conventional modern steel frame using standard parts, replacing the wooden one that was condemned in the early '70s. None of the bells I've seen have lubrication for the clapper pins - access is very poor - and the main bearings tend to get it about once a century ::) . They don't turn quickly, and aren't particularly heavy. The clapper can't swing much more than about 30°. Traditionally, most of these parts would have been made by the local blacksmith, and there are still plenty throughout the country that are still in use.



Do you reckon that delrin might wear a bit quicker, than say PTFE, due to the former being harder? I know that PTFE is worse to m/c as it picks up around the workpiece. Goes like a rotating Christmas tree.  :D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 30 November 2022, 14:50:41
Don't know, and didn't consider it as I don't have any.


The original tufnol bush is a push fit in the new spacer which is a similar fit in the clapper, so it shouldn't be a problem. Whatever, it's got to be better than 20kg of clapper clonking about.
Title: Re: This Week in Wheeler's Workshop
Post by: Raeturbo on 30 November 2022, 16:53:46
Looks a nice job👍
Title: Re: This Week in Wheeler's Workshop
Post by: Sir Tigger KC on 30 November 2022, 18:19:34
Presumedly when that clapper (or the original clapper) was fitted hundreds of years ago it would have had a leather bush?  ???
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 30 November 2022, 19:06:18
Presumedly when that clapper (or the original clapper) was fitted hundreds of years ago it would have had a leather bush?  ???


More recent ones might have been hardwood, brass or bronze. More than five or six hundred years ago, it would probably have just been a hook and eye but we weren't doing full-circle ringing then. The bells were attached to their bearings differently too.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 03 May 2023, 12:31:11
For some reason I've done a lot of sill repairs lately: 2 MGFs, a ZR and this R100.


The only rot on this R100 is at the rear ends of the sills:




(https://www.dropbox.com/s/rriub0kpce3ekji/OriginalRot.jpg?raw=1)


If there had been any other rust in either the inner or outer sills, he'd have been buying new panels as it's quicker, easier and a better repair to replace the whole thing than several patches.


Some basic template and shaping produced these:


(https://www.dropbox.com/s/jwiy8a1zvqq642r/OuterRepairPanels.jpg?raw=1)


Trimming for those exposed this around the rear subframe mount/sill closer:


(https://www.dropbox.com/s/9qfu7rtdypdo06q/MoreRot.jpg?raw=1)


Which meant another panel


(https://www.dropbox.com/s/l81yyobsqi9360x/InnerRepairPanel.jpg?raw=1)


Doesn't get much more basic than this!


(https://www.dropbox.com/s/o845kkhanik86kg/FoldingOuterRepair.jpg?raw=1)




Door step and inner attached:


(https://www.dropbox.com/s/md8nm1zxjw2dfy5/P_20230502_155217.jpg?raw=1)




The fully welded job:


(https://www.dropbox.com/s/bfous4tmh72tuty/WeldingComplete.jpg?raw=1)


I still need to grind the welds that are visible once the sill cover is refitted, and decide how we're going to finish the blend into the wheel arch, as somebody has already filled that far more than was necessary. If it comes to it, we'll dig out all the filler, redo so that the shape is more original(it looks really 'soft' at the moment) and paint the whole quarter panel. It's a five door car, so that isn't a big piece!


And of course, the other side needs the same work.


This job was payment for a ticket to the recent Goodwood Member's Meeting.


Last week I slimmed down all 16 wheel nuts for the wheel adapters to put Scimitar Wolfrace on his TR7 which was a thoroughly tedious job.




I found a long piece of grotty, large angle iron when tidying the garden recently, so this afternoon's job will be to weld three lengths of it to my cheap bead-roller to stop it twisting in use.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 04 May 2023, 10:25:13
I bought this bead roller about 15years ago when price first dropped below £200:


(https://www.dropbox.com/s/x4wyoomhxf58wqh/BasicBeadRoller.jpg?raw=1)


It's a piece of 10mm thick steel with a slot for the workpiece, and it came with several dies for different beads and steps. The job I bought it for didn't happen and it got abandoned outside for years, which is why it looks like that. As part of my recent Grand Clear UpTm, I cleaned it, freed off the seized shafts, replaced the shitty fasteners and moved to sorting one of the inherent issues.


Which is as soon as you apply tension to the adjuster, the plate twists. It twists even more as you crank the work through the machine. That means most of the effort is wasted and the results are really poor. These things are now really common, and all have the same problem. The Grand Clear UpTm produced some really crusty angle iron that were fence posts for about 50 years, so it's no use for anything important. But a little cutting and welding later:


(https://www.dropbox.com/s/ih47yya3t57o490/StiffenedBeadRoller.jpg?raw=1)


The square tube is simply to keep the ends of the slot flat while welding. Before, the plate could be twisted by hand. It's much more rigid now :y


A sliding rest in the slot will make long straight work easier.


Then a couple of brackets to bolt it to a bench, although a proper stand would be better. Some scrounged gate post welded to a large wheel would work well....






It really needs to be motorised, as large work takes another pair of hands to turn the crank; the favourite for that is a small 12v winch motor and speed controller.


Finally, I'll machine some tipping dies to make starting curved flanges quicker, easier and more accurate. You can buy them, but the £50 they cost will provide plenty of material for several other dies. Making this sort of tooling is one of the reasons I own a lathe.
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 04 May 2023, 12:36:41
Excellent reading  :)
I purchased an eclectic metal snotter /glue gun machine a while ago for such sill repairs
fortunately not had to use it yet  :P
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 04 May 2023, 13:59:26
Before you need to weld on the car, get some lots of practice.


Buy some sheetmetal of the thickness you're going to use, and have it sheared in 150mm squares. Run beads across a couple of them until you're consistently getting tidy looking welds that penetrate, but don't burn through. Then weld various edges together.


If the metal you're welding isn't free of paint/underseal on all four edges, you're going to really struggle. The welding area needs to be clean and shiny fresh off the grinder, it helps if the whole repair is.


Cut as little off as possible until you have the repair fitting well, whether you buy or make it. Templates from thin card are the key to this. Be aware that if you shape around the existing part, your new one will be too big by the thickness of the metal and paint at each bend! That's why I made the door step separately. There's a point where it makes sense to split a big repair into smaller ones, but it's really easy to go too far and end up with lots of welding and grinding of tiny pieces.
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 04 May 2023, 15:31:09
Thanks for the advice  :)

I do intend to have a practice ,I've got some old panels ,sheet etc  :y

I did do TIG, MIG , GAS and stick as part of my engineering diploma years ago  :-X

but not done any FINE bird droppings in a long time ,though I done stick on RSJs etc (got an old heavy transformer snotter for that)

but yes , I'll need plenty of practice and some youtube vids

plus grinding discs and seam sealer  >:D

fortunately nothing on the fleet is too crusty ATM ,

and before you say it .... yes ,I've taken the sill covers off etc and prodded my Omega several times  :D

I've purchased the mig (chinesium tat) in case i need it in the interim period between now and 2035 ,by which time we'll all be flying ECO solar electric hover cars and using the fantastic new public transport systems  ::)

Title: Re: This Week in Wheeler's Workshop
Post by: Marks DTM Calib on 04 May 2023, 16:16:53
Currently sorting the sills on a 2004 Ford Explorer.

Can't get the cills in this country so having to use bent tin......we are 3m of this in and rising.

With a repaired propshaft UJ (usual bearing failure) and proper setup of the handbrake (similar setup to Omega.....and its been adjusted using the cable.....) it might get an MOT.

Even then it will still be a pile of old turds  ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 04 May 2023, 16:29:03
Was it not feasible to order them from the States? A quick Google suggests they're <$100, and the dogleg(a part I really wouldn't want to make) about half that. The sheer amount of time and effort that would save would probably have me refusing to do the job without. Making the multiple bends for such long parts isn't fun even with a suitably long brake.


When I rebuilt the front of one work's Transits, a new wheel-arch and sill were non-negotiable even though he didn't want to spend the £70 per side.
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 04 May 2023, 16:42:08
I'll need plenty of practice and some youtube vids

plus grinding discs and seam sealer  >:D

fortunately nothing on the fleet is too crusty ATM ,

and before you say it .... yes ,I've taken the sill covers off etc and prodded my Omega several times  :D



I would have had a full sill fully attached to the car in less time than making these repair panels. It's much easier work too, as they're plug welded along the lower edge and to where the door seals sit - Omegas are the same. That means you only have to attach them in the arch, under the wing and a few mm in the door shuts. If the outer is bad, the inner is likely to need work too, and it's much easier with the skin out of the way.


This was my Metro, but should give some idea:


(https://www.dropbox.com/s/7scgndj809zs0nf/CutOffSill.jpg?raw=1)


(https://www.dropbox.com/s/qtwik4f01whvo30/SillTackedOn.jpg?raw=1)





If removing a full sill, try and blag a plasma cutter to get most of it out the way. Then grind a 10mm(ish) drill bit to a nearly flat tip and drill out most of the spotwelds, splitting what's left with a sharp chisel - a wood working one you don't care about is ideal. That all saves a considerable amount of time, noise, sparks, cutting discs/dust and trips to A&E :y
Title: Re: This Week in Wheeler's Workshop
Post by: Field Marshal Dr. Opti on 05 May 2023, 13:29:39
That Metro reminds me of Triggers broom.

None of it is the original forty year old  car. ::) >:D
Title: Re: This Week in Wheeler's Workshop
Post by: Marks DTM Calib on 05 May 2023, 13:35:59
Was it not feasible to order them from the States? A quick Google suggests they're <$100, and the dogleg(a part I really wouldn't want to make) about half that. The sheer amount of time and effort that would save would probably have me refusing to do the job without. Making the multiple bends for such long parts isn't fun even with a suitably long brake.


When I rebuilt the front of one work's Transits, a new wheel-arch and sill were non-negotiable even though he didn't want to spend the £70 per side.

Sadly not, quotes with shipping and tax were north of £400 and a considerable lead time for those willing to ship (many were not interested)

Have sourced some pre formed steel length which is doing the job pretty well (1m lengths at 2mm thickness), a bit more seam welding needed along the top edge but, the bottom fix is plug welding  :y
Title: Re: This Week in Wheeler's Workshop
Post by: TheBoy on 05 May 2023, 13:45:12
My welding is "artistic" and resembles birdshit :P
Title: Re: This Week in Wheeler's Workshop
Post by: TheBoy on 05 May 2023, 13:46:00
Actually, I appear to have mislaid my hobbyweld cylinder.  God only knows how I've managed to lose that ;D
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 05 May 2023, 16:58:56
That Metro reminds me of Triggers broom.

None of it is the original forty thirty year old  car. ::) >:D


Most of it was the original car.
Title: Re: This Week in Wheeler's Workshop
Post by: dave the builder on 05 May 2023, 17:21:29
Actually, I appear to have mislaid my hobbyweld cylinder.  God only knows how I've managed to lose that ;D
"Cylinders" are taken off you for safety reasons  ;)
Title: Re: This Week in Wheeler's Workshop
Post by: countrywoman on 05 May 2023, 18:37:42
I have a n/s Metro inner sill repair panel left over from when I had a business, didnt think there would be any demand for it now!!
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 24 May 2023, 16:01:32
On to the other side:


(https://www.dropbox.com/s/khp4qtitugcu2j1/OriginalHole.jpg?raw=1)


It was worse than that, and I made the mistake of just extending the small template from the other side to get this bigger outer patch:


(https://www.dropbox.com/s/08ss8sgvhghswuz/OuterPanel.jpg?raw=1)


Why was that a mistake? because by the time I'd made the tapered front edge fit, there wasn't enough metal left to fold the arch return. So I had to resort to the unsatisfactory method of welding it on, which takes longer, doesn't fit as well, isn't adjustable and requires lots of grinding on very thin edges. As you can see, the return isn't at 90degrees, and pulled the panel slightly too. It's just good enough to fit with the plastic sill cover, so I moved onto the inner patch - note how much better the folded flange is:


(https://www.dropbox.com/s/ftfkhs8pdocgr70/InnerRepair.jpg?raw=1)


welded in


(https://www.dropbox.com/s/jqi5ijox4144yl5/InnerAttached.jpg?raw=1)


door step made and adjusted to fit:


(https://www.dropbox.com/s/9qevl5l3y39mqff/StepShaped.jpg?raw=1)


Welded in


(https://www.dropbox.com/s/9moag7cjbal1vr8/DoorStepAttached.jpg?raw=1)


Outer ready to weld:


(https://www.dropbox.com/s/y8ek2jac0jm08zh/OuterClamped.jpg?raw=1)


Tacked:


(https://www.dropbox.com/s/7m5nb6gjy0dc0ne/OuterTacked.jpg?raw=1)


Welded:


(https://www.dropbox.com/s/zz47emvamsvgsfj/FullyWelded.jpg?raw=1)


A load of grinding later:


(https://www.dropbox.com/s/67gzz6me1cniuff/RepairGround.jpg?raw=1)


and in the door shut:


(https://www.dropbox.com/s/wsyp9fm0tp11oy3/DoorShutGround.jpg?raw=1)




I have to discuss with the owner how far we're going to finish this, as it isn't the first time this area has been repaired; the arch has already been filled(not to the correct shape), and the quarter repainted up to the body line. If the arch was original, this repair would only need a wipe of filler, and a flick of paint.

Title: Re: This Week in Wheeler's Workshop
Post by: Raeturbo on 25 May 2023, 00:34:44
Fk nice work, there’s a lot done there for just a smallish patch😱
Title: Re: This Week in Wheeler's Workshop
Post by: Nick W on 25 May 2023, 10:34:39
It would have been quicker to fit a whole sill. But this is going to be sold soon, and we are trying to keep the costs down.


Otherwise the job would have bought both sills and probably the wheel arches, knowing the quarters were going to need to be painted.