Rollpin removal and fitting
Discussion
Over the last couple of days I have been doing my annual car clean. This involves taking the seats out and trying to do it properly to make up for all the neglect for the previous twelve months.
When I fitted my gear change linkage the zinc chromate finish on the rod stopped the bar fitting in the rose joints, so it had to be sanded off. Three years use with very sweaty palms lead to a very rusty knob.
So I needed to remove it to polish it up. I tried using a punch to knock the pin out with no success, as the mechanism is always moving. So I googled for "rollpin removal tool" to see if I could buy a special tool. Stig's website was second on the list but didn't have what I wanted. So I made a variation of his modified G-clamp.
First drill a 4.5mm hole all the way through the end on the g clamp jaw, with it fully closed. Aim to come out in the middle of the clamping face. Continue on to drill partially through the screw.
Next find the broken stem of a 3.2mm drill (if you've built an Ultima you should have plenty of these around.)
By locating the hole in the clamp body on the back of the pin, and the stem of the drill on the other side, pushed in by the screw (which now has a convenient hole to locate it), you can easily drive the roll pin out.
To refit the rollpin you can make another simple mod to your g clamp. Tap the 4.5mm hole with a 5mm tap (hole is a bit oversize, but it works for this application). Fit a 5mm bolt in the back of the clamp, screwed in just enough to leave a couple of mm hole at the clamping face. Put the rollpin in the hole in the g clamp, and squeeze the pin back into the UJ (probably with a bit of wood on the screw side to protect the surface).
When I fitted my gear change linkage the zinc chromate finish on the rod stopped the bar fitting in the rose joints, so it had to be sanded off. Three years use with very sweaty palms lead to a very rusty knob.
So I needed to remove it to polish it up. I tried using a punch to knock the pin out with no success, as the mechanism is always moving. So I googled for "rollpin removal tool" to see if I could buy a special tool. Stig's website was second on the list but didn't have what I wanted. So I made a variation of his modified G-clamp.
First drill a 4.5mm hole all the way through the end on the g clamp jaw, with it fully closed. Aim to come out in the middle of the clamping face. Continue on to drill partially through the screw.
Next find the broken stem of a 3.2mm drill (if you've built an Ultima you should have plenty of these around.)
By locating the hole in the clamp body on the back of the pin, and the stem of the drill on the other side, pushed in by the screw (which now has a convenient hole to locate it), you can easily drive the roll pin out.
To refit the rollpin you can make another simple mod to your g clamp. Tap the 4.5mm hole with a 5mm tap (hole is a bit oversize, but it works for this application). Fit a 5mm bolt in the back of the clamp, screwed in just enough to leave a couple of mm hole at the clamping face. Put the rollpin in the hole in the g clamp, and squeeze the pin back into the UJ (probably with a bit of wood on the screw side to protect the surface).
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