The body off has begun
Discussion
OK not huge progress this weekend - removed the diff. What a pig of a job.
This bolt head which is towards the front of the diff on the driver side (ie towards the front of the car) is difficult to access - not obvious on this photo but you can't get a socket on it as the chassis member is in the way.
There's no problem the other side - because the input shaft on the diff is offset it is close to the chassis this side but there's loads of room the other side. It may be because the mounting rubbers have sagged a bit as well I guess.
The solution was to suspend the diff using straps and my engine crane, then removing the top rubber mounts (pic below) to allow the diff to be jacked up slightly - then the bolt head is clear of the chassis member and presents no further problems.
The rear of the diff has 4 x T50 Torx bolts - so that set of torx drivers I bought from machine mart has come in useful again - I did wince at paying £30 for them and I've said it before but they were worth every penny.
I found the best method was to support the diff using straps and the engine crane then once all bolts were undone I lowered it through the chassis onto the floor.
The diff didn't want to part company with the steel carrier bracket but in the end I persuaded it!
The steel carrier bracket was a bit of a puzzle to get out of the chassis too.
Here she blows! Fastest it's been for ages!
Thats it folks.
Chris
This bolt head which is towards the front of the diff on the driver side (ie towards the front of the car) is difficult to access - not obvious on this photo but you can't get a socket on it as the chassis member is in the way.
There's no problem the other side - because the input shaft on the diff is offset it is close to the chassis this side but there's loads of room the other side. It may be because the mounting rubbers have sagged a bit as well I guess.
The solution was to suspend the diff using straps and my engine crane, then removing the top rubber mounts (pic below) to allow the diff to be jacked up slightly - then the bolt head is clear of the chassis member and presents no further problems.
The rear of the diff has 4 x T50 Torx bolts - so that set of torx drivers I bought from machine mart has come in useful again - I did wince at paying £30 for them and I've said it before but they were worth every penny.
I found the best method was to support the diff using straps and the engine crane then once all bolts were undone I lowered it through the chassis onto the floor.
The diff didn't want to part company with the steel carrier bracket but in the end I persuaded it!
The steel carrier bracket was a bit of a puzzle to get out of the chassis too.
Here she blows! Fastest it's been for ages!
Thats it folks.
Chris
Great Dave - the more the merrier.
Well a little update - my welding stuff has arrived so I'm hoping to get some practice in at the weekend on some scrap and get good enough to weld the seatbelt brackets on that Sean (Trickjohn) sent me. I also need to replace the small brackets on top of the outrigger tube but I need to fabricate them first.
Sorry if you were expecting a big fat update!
Chris
Well a little update - my welding stuff has arrived so I'm hoping to get some practice in at the weekend on some scrap and get good enough to weld the seatbelt brackets on that Sean (Trickjohn) sent me. I also need to replace the small brackets on top of the outrigger tube but I need to fabricate them first.
Sorry if you were expecting a big fat update!
Chris
Well done chris, at least V8S & S3/2/1 have something in common, the diff removal job is a complete arse from start to finish. All my spraying gets finished this friday, then clean the spanners and start assembly, it should go together fairly quickly, however I have wiring issues, radiator fan is on a manual switch and driving lights dont work, windscreen washer bottle is held on with tie wraps broken bolts?? - stuff to be done when the body is back on will slow me down, - weekend work is out due to valentines break (must clean my nails), sometimes things take longer than you can say them, you are doing well - it changes every week, Keep it up.
See you at S Haven.
Best regards
Sean
See you at S Haven.
Best regards
Sean
Yes things are moving - although a bit too slowly for my liking.
Things were different when I was a teenager - if you wanted to fiddle with your car you just went and did it - now I have to balance seeing my kids at the weekend / wifey / work / looking after elderly relatives / the Tiv ends up at the bottom of the pile.
Never mind at least it is happening slowly.
I do feel like I'm getting there now - I've had a few 'what have I started' moments along the way.
Hopefully things will move much quicker once the chassis is sorted & painted, once the welding is done that is!
I'm hoping to be back on the road for the end of April, but if things conspire against me it will just have to take longer - in the project management time/cost/quality triangle I want to be sat in the quality corner!
I intent to have the engine in bits aswell - the head gaskets can start to leak on the V8 at about my mileage (66k) so may as well get that sorted while it is out of the car, need to check the cam too also prone on the V8. The chassis at the front of the car is in great condition mainly due to the amount of oil spraying out of the engine aswell, so new gaskets needed all round! (Sump gasket I think is leaking like a pig).
Chris
Things were different when I was a teenager - if you wanted to fiddle with your car you just went and did it - now I have to balance seeing my kids at the weekend / wifey / work / looking after elderly relatives / the Tiv ends up at the bottom of the pile.
Never mind at least it is happening slowly.
I do feel like I'm getting there now - I've had a few 'what have I started' moments along the way.
Hopefully things will move much quicker once the chassis is sorted & painted, once the welding is done that is!
I'm hoping to be back on the road for the end of April, but if things conspire against me it will just have to take longer - in the project management time/cost/quality triangle I want to be sat in the quality corner!
I intent to have the engine in bits aswell - the head gaskets can start to leak on the V8 at about my mileage (66k) so may as well get that sorted while it is out of the car, need to check the cam too also prone on the V8. The chassis at the front of the car is in great condition mainly due to the amount of oil spraying out of the engine aswell, so new gaskets needed all round! (Sump gasket I think is leaking like a pig).
Chris
Edited by Barkychoc on Wednesday 13th February 09:39
petclub said:
Met an S3 owner from Notts today, Porsche Blue (but looks blue/grey, very nice, unusual), didn't get his name but he says he's coming to S Club.
Is it the new owner of my old car? have a look on here:-http://www.pistonheads.com/gassing/topic.asp?h=0&a...
OK well another boring report I'm afraid.
I bought a MIG welder - and have been practising for a couple of hours today - and though I'm no expert yet with a bit more practice I think I'll be good enough to do the welding myself - so thats Plan A at the moment.
I can recommend http://www.mig-welding.co.uk if you want to have a go yourself.
Chris
I bought a MIG welder - and have been practising for a couple of hours today - and though I'm no expert yet with a bit more practice I think I'll be good enough to do the welding myself - so thats Plan A at the moment.
I can recommend http://www.mig-welding.co.uk if you want to have a go yourself.
Chris
S3 Steve said:
Is it the new owner of my old car? have a look on here:-
http://www.pistonheads.com/gassing/topic.asp?h=0&a...
Yes, that's the one! Most unusual colour (very nice too), IIRC it was his first East Mids meeting. Didn't have much time to chat as we were both about to go.http://www.pistonheads.com/gassing/topic.asp?h=0&a...
Oh Sh!t
After a bit more poking I found more holes
After a bit of headscratching I actually managed to plug the holes with weld, ground them back and then welded a patch over the top. Its not that pretty (so no pic!) but it serves the purpose.
Then managed to do this, pretty pleased with it.
I left some of the sound original thick metal mounting on the tube and welded to that, so I didn't run the risk of blowing holes in the rear tube. Actually got quite a nice weld I think, and its penetrated through too.
Haven't done the rear support yet - Sean thanks for the email I will make sure I weld it on so the trailing arm bolt can come out.
The welding thing actually isn't as hard as I thought it would be - I'm certainly nowhere near expert status but I think I'll get by sorting this out. I won't win any awards for speed either!
Chris
After a bit more poking I found more holes
After a bit of headscratching I actually managed to plug the holes with weld, ground them back and then welded a patch over the top. Its not that pretty (so no pic!) but it serves the purpose.
Then managed to do this, pretty pleased with it.
I left some of the sound original thick metal mounting on the tube and welded to that, so I didn't run the risk of blowing holes in the rear tube. Actually got quite a nice weld I think, and its penetrated through too.
Haven't done the rear support yet - Sean thanks for the email I will make sure I weld it on so the trailing arm bolt can come out.
The welding thing actually isn't as hard as I thought it would be - I'm certainly nowhere near expert status but I think I'll get by sorting this out. I won't win any awards for speed either!
Chris
OK well been welding today. The bracket in the pic above - I welded the vertical bit behind it but the weld looked sh!te so I decided to cut it off and reweld it. I belted it off with a hammer as I thought my crap weld would break. Anyway the original TVR weld broke - mine was stronger! Doh! Anyway rewelded it with a new piece of metal and it looks much better - and bloody strong too if I say so myself.
Will do the other side tomorrow.
Chris
Will do the other side tomorrow.
Chris
Thats great news Dave.
OK now I've finished decorating assembling IKEA furniture and trips to the tip its time for some serious work.
I have welded the other side seat belt mount on today. I had issues with holes in the rear tube under the seat belt mount, and I've also found a small one in one of the side outrigger tubes under the side outrigger mount.
Also here you can see how much thinner the metal has got at the rear of the bracket.
Although thats not the major issue now I've poked away at the rust
Here's welder boy in action!
OK now I've finished decorating assembling IKEA furniture and trips to the tip its time for some serious work.
I have welded the other side seat belt mount on today. I had issues with holes in the rear tube under the seat belt mount, and I've also found a small one in one of the side outrigger tubes under the side outrigger mount.
Also here you can see how much thinner the metal has got at the rear of the bracket.
Although thats not the major issue now I've poked away at the rust
Here's welder boy in action!
Edited by Barkychoc on Sunday 9th March 20:16
TVRleigh_BBWR said:
Get some lap/Flap disc, very good at cleaning up the metal ready for welding.
Will also take down weld to flat if you need anything flush mounted, or you mess up and need to re-weld.
Yep - got one of those - bloody vicious too aren't they - they soon take the weld down to sod all!Will also take down weld to flat if you need anything flush mounted, or you mess up and need to re-weld.
A bit easier to control than a grinder even if the discs are 10 times the price.
Chris
Well mine only cost me about 90p each. the very very thin cutting disc's are about the same price.
You may want to get some 60 and 80 grit ones also, as they are not as agressive.
I'll be doing another up-date tomorrow,
http://www.pistonheads.com/gassing/topic.asp?h=0&a...
You may want to get some 60 and 80 grit ones also, as they are not as agressive.
I'll be doing another up-date tomorrow,
http://www.pistonheads.com/gassing/topic.asp?h=0&a...
it up myself rather than paying someone else to do it!Gassing Station | S Series | Top of Page | What's New | My Stuff