DIY Mechanics Fail Stories

DIY Mechanics Fail Stories

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headcase

2,389 posts

219 months

Saturday 8th December 2012
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Put a new set of rings in a 1.3 cavalier as it was bought as a real bad oil burner just to make a few pennies on it. Job done not burning oil any more but what's that rattling noise seems to get louder the more you rev it, then all of a sudden the're was the sound of tinkling metal no rattling sound any more and a loss of power. On closer inspection there was a con rod stuck out the side of the block Doh! Forgot to tighten up the end caps frown. That car was scrapped a few weeks later.

Evoluzione

10,345 posts

245 months

Sunday 9th December 2012
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One of mine:
When I built my first engine in an Alfasud Sprint I had back in the day I was about 18 - 20 and had spent a fortune (relative to my income of about £80 a week!) on it with a lightened and balanced bottom end/flywheel, ported the heads myself and I'd also had the crank re-ground, I asked the machine shop if they had washed it which they had.

I didn't realise at the time that of course it was my job to remove all the particles of grinding material from the oilways inside the crank and reassembled it as it was.
It didn't go for long before it all got washed out by the oil, ground away the crank journals, the big ends knocked ominously and it had to be all done again. There was even more bearing failure problems when I realised I'd purposely put the crank thrust washers in the wrong way round, I reasoned that the groove shouldn't be facing the crank as that didn't look right. This is the groove in the soft metal side of the bearing which holds the oil as opposed to the smooth steel backing of the bearing..... It wore a groove about 1mm deep in the end of the lovely lightened and balanced crank which consequently went in the bin...

Link to pic of crank thrust washers in case you were wondering:

http://www.google.co.uk/imgres?num=10&um=1&amp...





One of someone else's I witnessed:

A particular local criminal lowlife parked his car outside my place whilst visiting my neighbour before then coming across to annoy me.
He then realised said neighbour had locked up and gone leaving this guys car keys in his garage. "Why don't we ring him and he'll come back and get your keys for you?" Says I just wanting to get rid of him.
"No, i'll just hotwire it" Criminal says cockily...

So he borrows some tools and sets about his ignition barrel and steering column for half an hour before firing it up and realising that he can only go forwards and backwards due to the steering lock. As he can't break it on his own he asks me to come and help him, so he gets behind the wheel and I get hold of it from the passenger seat. We get hold and start to turn, as neither of us are lightweights it starts to revolve surprisingly easily.


Until it snaps clean off in his hands.

The shocked look on his face was somehow made even better by the fact that the airbag light on the now completely disconnected wheel is still flashing as if to say "Help me!".
Laugh? Well this guy's a hot headed Eastern European crim, so I tried not to for about three seconds, but still my bottom lip began to tremble and I just couldn't stop, before long I really was rolling on the floor laughing with aching sides and tears rolling down my cheeks, I don't think I've laughed so much in ages.
I was still chuckling as he borrowed even more tools, sharpened the steering column like a pencil and bashed the wheel on tight with a lump hammer before attempting to weld it on and driving off.

If there is a lesson to be learned here it's that old Renault 19s aren't very easy to steal..

Jasper Gilder

2,166 posts

275 months

Monday 17th December 2012
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Not one of mine and not DIY. A pro fitter for a major trucking company had a little party piece which was to belt into the workshops and handbrake his steed to a stop over his pit. Fair enough. A few years ago the buildings backing on to the workshops had been refurbed with a swanky new conference room

So chummy decides to pull his party piece - he'd forgotten it was raining and the tyres and floor were wet, so - up to speed - handbrake on - slide, slide Waargh!!!! Truck slides over pit, leaves pit behind, hits workbench at virtually undiminished speed, workbench, now with truck attached to it, makes it's way into middle of swanky new conference room via breezeblock wall

Somehow they made it good in about 48 hours for the arrival of the Chairman to open the conference room, which I used a lot in later years. I've never seen such a badly plastered wall ever!!!

hman

7,487 posts

196 months

Tuesday 18th December 2012
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Evoluzione said:
One of mine:






One of someone else's I witnessed:

A particular local criminal lowlife parked his car outside my place whilst visiting my neighbour before then coming across to annoy me.
He then realised said neighbour had locked up and gone leaving this guys car keys in his garage. "Why don't we ring him and he'll come back and get your keys for you?" Says I just wanting to get rid of him.
"No, i'll just hotwire it" Criminal says cockily...

So he borrows some tools and sets about his ignition barrel and steering column for half an hour before firing it up and realising that he can only go forwards and backwards due to the steering lock. As he can't break it on his own he asks me to come and help him, so he gets behind the wheel and I get hold of it from the passenger seat. We get hold and start to turn, as neither of us are lightweights it starts to revolve surprisingly easily.



If there is a lesson to be learned here it's that old Renault 19s aren't very easy to steal..
dont mean to troll but haven't you just admitted to aiding and abetting TWOC?

Mark Benson

7,544 posts

271 months

Tuesday 18th December 2012
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hman said:
dont mean to troll but haven't you just admitted to aiding and abetting TWOC?
I get the impression that the crim was the owner of the car, he just didn't have the keys.

Super Slo Mo

5,368 posts

200 months

Tuesday 18th December 2012
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I've just remembered one I did (with the help of a mate) about 20 years ago.

My dad, for some reason I never really understood, bought an old Mini automatic for my mum (who refused to drive it), but I spent a bit of time tooling around in it (I was probably only 18 at the time).

Anyway, MOT time came around, and I had noticed the brakes were a bit ineffective, so bought a new set of shoes and, with the valued assistance of the aforementioned mate, whipped the front drums off and fitted the new shoes.

Trouble was, we couldn't get them to balance for love nor money. After a couple of hours faffing, and by now on the verge of being late for the test, we decided they'd 'bed in' eventually, and went up to the local garage, hoping they wouldn't notice.

Anyway, the tester (who also was the garage boss) went through the whole MOT process, then put the car on the rollers. As expected, it gave a bit of an odd result, with one side showing much greater retardation than the other. Next thing we knew, the tester had reversed off the rollers and went bombing off down the road to test the brakes for real. As the brake lights came on, we saw the car swerve violently to the right.

He turned the car around and came steaming back up the hill, going like the clappers (as much as a 1,000 cc auto mini could anyway). He took his hands off the wheel, braked, and the car turned itself straight into his forecourt and pulled up alongside my mate and I who were watching.

'Oh', says I, nonchalantly, 'looks like it's pulling a bit to the right'.

MOT tester chap went completely apest. I got a proper bking and was made to take it away and fix it.

So we did. Off came the right wheel, since that was the problematic brake, a good sized splodge of grease was applied to the shoes, and we went back, with the little mini tracking (reasonably) straight and true under braking.

MOT man asked how we'd fixed it.... 'erm, we just 'adjusted' it a bit', we said . We got a funny look, and a pass certificate.

Fastdruid

8,698 posts

154 months

Tuesday 18th December 2012
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I have plenty for this, mostly bike related. smile

Years ago I was given a non-runner GSX250. Can't remember why but for some reason I wanted to turn over the engine but as it had no plugs in and I'd heard you could blow the ECU if you ran it without spark plugs connected flicked the kill switch to off. It didn't turn over. Spent hours pouring over the wiring, took everything apart, finally took the kill switch apart before realising that if you had the kill switch off it also cut power to the starter...






Fastdruid

8,698 posts

154 months

Tuesday 18th December 2012
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As for car related ones, I got fed up of the sh*t handbrake on the Mondeo, cables were fine so figured it was the adjuster. Took the wheels off drums didn't want to come off. Gave them a good yank and they finally came off. Only to pull the linings off the shoes on the lip. Cue panicked running round on a Sunday trying to find somewhere that was both open and had a set of shoes in stock!

Another time had a front coil spring go (while parked). The HBOL says to undo the pinch bolt that holds the steering knuckle to the damper..... SNAP. Oh c*ck. Two days and many hours later finally manage to extract the broken remains of the bolt that I discovered I didn't need to remove as you don't need to remove the knuckle to remove the strut and swap springs.


Fastdruid

8,698 posts

154 months

Tuesday 18th December 2012
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doogz said:
Fastdruid said:
I have plenty for this, mostly bike related. smile

Years ago I was given a non-runner GSX250. Can't remember why but for some reason I wanted to turn over the engine but as it had no plugs in and I'd heard you could blow the ECU if you ran it without spark plugs connected flicked the kill switch to off. It didn't turn over. Spent hours pouring over the wiring, took everything apart, finally took the kill switch apart before realising that if you had the kill switch off it also cut power to the starter...
The kill switch on my quad bike doesn't do that. It just cuts the spark.

The number of times Laura's had to come get me because the quad bike won't start...

Then when it does, the exhaust is full of petrol, and BANG!
Yep, it varies between bikes which is why I got confused, Honda's don't kill the starter, Suzuki's do (don't know about others). On the other side of that I've also spent ages trying to work out why my Hondas won't start before realising the kill switch is set to off (cue massive BANG when they do).

Mr2Mike

20,143 posts

257 months

Tuesday 18th December 2012
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Mr Happy said:
Muppet here, wondering what was up, slid the battery back out of the way with the engine still running, and had the bright idea to make sure the HT leads were still connected...

Cue a "owyabdwhatthefkwasthat!?!?!" moment, as I took HT voltage to the fingers, and in recoil, bashed my hand off the bonnet!

A ghetto repair involving taking my belt off, wrapping it around the battery to secure it and driving like a nun was swiftly implemented!!
A similar story with my brothers mini, for reasons long forgotten I had to disconnect the coil so pulled out the king lead and started to pull off one of the primary wires. Unbeknown to me the ignition was on, so as soon the the primary wire was disconnected a large spark shot out of the top of the coil and earthed itself through my hand which bloody hurt. Unfortunately, the subsequent muscle spasm saw me dab the wire back onto the coil briefly, giving me another high voltage belt...and another, and another. After 6 or seven shocks I managed to fall backward onto the floor, smashing my head on the bonnet on the way back. A group of young lads walking past were just about wetting themselves frown

Robatr0n

12,362 posts

218 months

Tuesday 18th December 2012
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Posted this up about 4 years ago and thought it'd sit well in this thread:

Robatr0n said:
I popped over to see a friend of mine about 7 years ago to find out that his Dad had recently been involved in a small accident in his VW Passat. He had bought himself a new head light, reflector and a can of blue spray paint to repair it himself but stupidly my mate declared that 'we' would fix it because I knew about cars..

Almost immediately he set about trying to get the lid off off the can of spray paint with a hammer even though I told him he just needed to gently prize it off with a screwdriver. Sadly the hammer technique didn't really work. He kept gently tapping the lid trying but it just wasn't going to budge so he got fed up and gave it a full on whack. Well that did work but it also also pierced the spray can which pretty much exploded in our faces. Both of us were covered in blue paint and looked like a couple of unhappy smurfs.

Next we decided to fit the headlight which would have been alot easier if it wasn't for the fact that all the plastic mountings had snapped when his Dad crashed the car. My mate decided that we could easily fit it with superglue because he didn't want to dissapoint his Dad...

Meanwhile, I decide I'll let him get on with glueing the headlight whilst I try and scrub the blue paint off of my hands, arms and face only to come outside and see my mate on his knees holding the headlight in the place. I told him that it looked great yet he just stayed on his knees holding the headlight. I told him to get up so he did, whilst still holding the headlight. He had managed to glue it to his hands whilst I was in his parent's house washing up! hehe

We couldn't remove it but luckily his Dad was a doctor and had apparently dealt with alot of idiots before so he knew how to remove it. Was pretty amusing to see the look of dissapointment/failure on his face when he saw what a mess we had made of the whole thing.

Needless to say, I've never been asked to help them out since! thumbup

hman

7,487 posts

196 months

Tuesday 18th December 2012
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^^^^ good work!

Slippydiff

14,913 posts

225 months

Wednesday 19th December 2012
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Not really a DIY failure, but amusing all the same . . .

Back in the eighties I worked (very briefly) for a well known (then) Vauxhall/Opel tuner/parts supplier (His surname rhymes with Gaydon . . . . )

He was in the process of building a very potent Nova 1.3 SR for road rallying when I began my employment there.

Whilst he did a lot of bolt on engine upgrades on site, proper engine builds were done by an outside contractor.

I arrived there one Saturday afternoon to find him looking at the freshly installed engine in the Nova (the intention was to get 130Hp out of it using twin 40s, big valve head and a high lift/long duration cam along with a decent exhaust manifold)

He commented it sounded "a bit rattly". "Fire it up then, let's have a listen" I said.

Sure enough when he fired it up, it sounded like a skeleton having a w*nk in a biscuit tin.

I shouted "Knock it off Peter" (for that was his name) he duly switched it off and I started to remove the cam cover to see it there was anything obviously wrong.

Sure enough, with the lid off it became clear why it was so noisy, all the thrust pads between the valve stems and the rocker arm (circled in red in the image below) had been left out ! !

Eight new items duly ordered and fitted on Monday afternoon, and the engine was a peach (and quiet too)



Evoluzione

10,345 posts

245 months

Wednesday 19th December 2012
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hman said:
dont mean to troll but haven't you just admitted to aiding and abetting TWOC?
Needs to go to Specsavers. readit

jimxms

1,633 posts

162 months

Wednesday 19th December 2012
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Slippydiff said:
Sure enough when he fired it up, it sounded like a skeleton having a w*nk in a biscuit tin.
I genuinely LOL'd there

Zoobeef

Original Poster:

6,004 posts

160 months

Tuesday 1st January 2013
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Someone must of done some Christmas tinkering smile

When I first got my car the interior lights didn't work when you opened the doors. Replaced the relay and that fixed it. A few weeks ago they stopped working again so I took the relay out and took it apart, couldn't see anything obviously wrong so left it on the side, then eventually put it back in, nope still not working.
Yesterday while driving I suddenly decided to flick the switch on the lights from off to door. Yes they now work.

I must of turned them to off at some point when I was working on it with the door open. I don't remember though!

The Black Flash

13,735 posts

200 months

Tuesday 1st January 2013
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Dog Star said:
Last year I was doing some work in my garage and doing some grinding and filing (motorbike rack). Obviously I'm not daft and I'm wearing my safety specs. So job finished and I'm clearing up and I've taken the safety specs off and (schoolboy error) I rub my eye and get some (as it turns out) swarf in it.

I ended up trying to ignore the incessant itching and pain, and rubbing the eye more and more. After two days with a blood red eyeball and people going nuts with me the GF takes me to A&E, quite late on so that hopefully it'll be quiet. I end up with a special dye in my eye and something to make the pupil dilate and there are 3 shards of metal properly embedded in my iris (the coloured bit). I have my head stuck in a frame, a strong light shone in it and the nurse manages to pick two of the pieces out with a needle - I could actually feel the slivers pulling out of the jelly of my eyeball vomit The third piece was not having it. She then called a specialist out and (all credit to him - it was nearly midnight at this point) he was there in ten minutes. With an extreme amount of skill he got the last bit out. I have never been so grateful. I then ended up with eyedrops, ointment and a patch on my eye til the scratching healed.

Edited by Dog Star on Wednesday 28th November 08:29
Ah, I've been there hehe. Grinding with goggles on, took them off to look, then "just needs a tiny touch more" which I of course did without the goggles. Cue shards in eye, and a similar trip to A&E for the needle treatment.
"Now don't move your eye" said the Dr as the needle approached. "That would be really bad". He'd turned my eyelid inside out so I couldn't blink, but it's incredibly hard not to look away. Not a great way to spend an hour!

orangesrule

1,463 posts

150 months

Tuesday 1st January 2013
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Last week i was drive out for a pootle with the missus, about 15 miles from home, the car decided it wanted to drop a cylinder nursed the car home. Although i found it weird how it picked up and regained full power, towards the end of the rev range.

I thought it was a spark issue, so removed the coil pack, which had a crack in it. ideal i thought, easy fix i though, i bought the cheapest thing i could get (as im planning to scrap the car in june).

This didn't fix it...so i turned to the HT leads and plugs - but they were only 15k miles old. anyway, when removing one of the ht leads one of the ends of them snapped off....balls.

To cut a long story short...turns out i had a good spark all along and it is infact the the injector on cylinder no.1 is stuck on near fully.

So nearly £70 laters (ht leads, 1 spark plug and coil pack), im trying to source a used injector from a scrappies tomorrow.....fail.

bencollins

3,538 posts

207 months

Tuesday 1st January 2013
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Grew up in the sticks of cumbria, friends from school came out to our cottage one evening/overnight and in the morning we all had a go on my teeny 50cc "motorbike" on the private track that led to road. finally (and reluctantly under much peer pressure) Kevin B gets on, lets out the clutch.

Just then the throttle decides to stick open and he races off, looking back at us with his face paralysed as edvard Munch's "scream". We shouted to pull in the clutch, but by this time he had forgotten which was brake and clutch so was just yanking at everything in blind panic. He pulls in the clutch, with the engine then revving to 1xxxx's rpm so lets out the clutch, bunny hops off out on to the main road, no helmet. this continues, in a bucking bronco stylee, bunny hoppy/clutch in manic braking, now running in a 5 second cycle, for about 3 mins, all the while his "im going to die" expression never changed.

We are watching, near asphyxsiating of laughter, then eventually he switches of the ignition and the bike stutters to a stop, cue car rounding the corner screeching to a halt, where he got a right bking off the driver for being in the road stationary without a helmet, looking like a total space cadet.

great thread btw!

*Al*

3,830 posts

224 months

Tuesday 1st January 2013
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Drained the fuel tank of my daughters 04 Clio, she'd put contaminated petrol in. I used some garden hose to syphon the remaining fuel and swallowed a mouthful of 95 octane, not a nice experience as i also vomited my recently eaten dinner. I could taste and burp petrol for over a day, not nice. frown