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Post by Zed. on May 17, 2019 13:25:49 GMT
more... I was wondering if an early (6" diff) ppf would work with a later (7" diff) so having spares, I placed a box / prop / diff case & 'spare 1.6 ppf togther  sorta looks good  the ebay bits I collected a few days ago looked like  as you can see, I had a little help   and was watched by the safety-observer Rich. |
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Post by Zed. on May 18, 2019 16:57:28 GMT
Non '5 content... went on a 400 mile roundtrip-roadtrip to the north bit inside the m25..  1960's Chevrolet Corvair engine, flat 6 aircooled of 2.3 - 2.7 L capacity depending on spec (they are a mecano set engine so interchangable parts & capacity)  for projekt-ZaZ  also, yesterday I stripped & mostly de-powered the mk2 steeringrack, will tack-weld the pinion this afternoon (tack-weld as I don't want to put too much heat into the hardened steel that it's made from) Rich. |
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Post by Zed. on May 20, 2019 13:21:06 GMT
so, spent more money....... set of throttlebodies from a 1999 Suzuki Hayabusa  photo from the ebay listing.... had a change of direction from making a cars worth (4 cylinders) from a few sets of Triumph tripple tb's as I decided they 'might' work in the Corvair Zaz now waiting for them to be posted & arrive to be altered & hopefully fit  Rich. |
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Post by Zed. on May 20, 2019 13:28:48 GMT
also, I've started de-rusting parts in my usual concoction of malt vinegar & cheapo died cola, this works suprisingly well as the vinegar has acetic acid & the diet cola has phosphoric acid - also makes you wonder as to what we are eating  I have a mk2 / NB front & rear suspension crossmember that I want to de-rust & paint, I'm considering electrolisis (battery charger & bicarb bath) but also looking for someone local that can sandblast, is one better Rich. |
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Post by Zed. on May 20, 2019 22:40:54 GMT
I'd bought a set of wheels for the tyres (that had been on a '5) and today I decided to try one on my car...  sorta minilite-ish fake splitrims with a deep dish / lip.  bit close to the arch for me, suppose an 8" rim would be a little close (also, bonus 3/4 rear view of Projekt ZaZ )  although I like the dish  but they are not getting used (anyone want 3 1/2 of them?) Rich. |
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Post by noobie on May 21, 2019 11:52:19 GMT
You'll have to be extremely patient using electrolysis on large parts. Sand blasting, even diy stuff with a pressure washer, is much quicker. Pay particular attention to the insides of the A-arm mounts as these are bearing surfaces..paint probably wouldn't survive for any appreciable time.
Instead of doing a poor welding job on the steering column it's worth considering to pin the assembly. If you have a drill press and lathe it's probably the better solution.
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Post by Zed. on May 21, 2019 12:26:26 GMT
I don't mind leaving something 'cook' in a de-rusting tank for a few days / week if the results are worth it but also am working on a vague timeline (sometime this year  ) I'm more concerned with the condition of the wishbones than the crossmembers as wishbones have lots of cavity-space that can be hiding rot - am tempted to buy new lower wishbones BUT £££££!'s maybe I'll make a jig to fabricate some tubular items BUT don't expect that to happen this year as to welding, I have considered alternative methods of securing, pinning is easy as long as the metal's are not hardened as this poses a slight hurdle to overcome (can access spark-errosion tec.) but a quick tack with the hot-glue shouldn't cause issues (no nice continuous-fillet weld for me ) Rich. |
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Post by Zed. on May 22, 2019 10:37:08 GMT
so, another delivery... the hyabusa throttlebodies have arived still fresh with the scent of power (petrol). they are Keihin tb's with 50mm bore at the airfilter side & 42mm bore at the engine side - possibly a bit excessive for a 1.6 '5 engine but hey-ho the injectors will be replaced as I presume a 200mph superbike has injectors suited more to warp-factor9 than part-throttle drivability so it looks like I'll be machining some adapter-bosses to fit the standard mazda-fit Denso units untill I need to look larger (if needed?)   obviously I will be making some adapters to fit the tb's onto the Jenvey / DCOE manifold pattern but thats a story (& some measuring) for another day...... Rich. |
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Post by Zed. on May 23, 2019 15:01:46 GMT
went shoppin earlier, local bearing suppliers in Clydach (yes that is where they are located!) had the diff bearings in stock so £75+vat later & I had 4 new bearings in my hand bearings to fit the later NA & all NB '7" diff' not the earlier 1.6 '6" diff' pinion rear is a 32307 pinion front is a 32206 diff sides are 32008XA (2 required) sorta posting this as a record of parts needed got to order oilseals now as I *might* have forgotten to ask when buying bearings   Rich. |
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Crumpets
Chats A Bit
Insert witty remark here...
Posts: 227 
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Post by Crumpets on May 23, 2019 15:09:30 GMT
What a goldmine of info!
Once you've got everything you should do a "how to" thread with rebuilding a rear diff.
- Crumpets
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Post by Zed. on May 23, 2019 16:44:58 GMT
What a goldmine of info! Once you've got everything you should do a "how to" thread with rebuilding a rear diff. - Crumpets I will be putting a few photo's up but I'm not a good teacher so unless you want to come & watch / photograph & write then it's gonna be limited |
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Post by Zed. on May 23, 2019 17:49:30 GMT
also, I probably won't be completing the diff build for a while as I need a suitable lsd & although I can afford one theres possibly better (I mean more important  ) uses for the money... maybe I'll get round to selling some stuff to 'make space' Rich. |
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Post by Zed. on May 24, 2019 12:20:14 GMT
maybe I'll get round to selling some stuff to 'make space' Rich. nope just arranged to collect another bit of tooling, this time a 'spool-gun' welding set (think mig welding but with the wire on a 'gun' / handset). this is actually a 'spare' as I have an identical set in 240v / single phase but the 'new' one is 440v / 3ph (I have 3ph power in the unit ) why? well, I do a bit of fab work & it was cheap... also amassing bits to build a sand-blasting cabinet, might be big enough to walk in NEXT... Rich. |
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Post by Zed. on May 26, 2019 17:11:47 GMT
Diff 'pigs-head' rust removal time, it was scruffy so I attaacked it with a wire brush, then a rotary wire brush on a drill.... then Buggerit happened & I reverted to my second favourite rust removal method (behind sandblasting) - ACID well, malt vinegar! I regularly destroy a local Aldi or Lidl's stock control as I buy ~24 bottles at a time of their cheapo malt vinegar (acetic acid iirc), this alone works as a good rust remover but can be mixed with tesco's cheapo diet cola (contains phosphoric acid) to make a cocktail of rust-eating proportions - admittedly slowly BUT I've a few days working on other projects so.... I also like phosphoric acid as a de-rusting method but strong phosphoric is getting expensive as is most things that actually work! so, one diff-case, one bucket & a few bottles of vinegar.......  I'll give it a day then agitate with a brush then leave another day untill it looks done not much else to report.... Rich. |
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Post by Zed. on May 26, 2019 18:57:45 GMT
while I'm waiting for the acid to eat it's rust, I decided to press the pinion's rear bearing on, so first check I had the 4.778:1 pinion! then it was cleaned along with the spacer-shim that was fitted to the previous (4.1:1 ratio) pinion in the pigs-head - working on the assumption (I know, I shouldn't assume anything!) that the shim was correct for the case & therefore the pinion's intrusion into the crownwheel   the 'old' 4.1:1 on the left, the 4.778:1 I'm using on the right. note the smaller pinion gear on the 4.778:1. next.....  Dig my way to the press (& find my box of usefull spacers, tubes etc for pressing stuffffffffffffffffff)   sorta out of order as you can see the pinion in the press, note the plastic bag over the bearing to stop crap landing in it when pressing  the magic box of stuff, old bearings, tubes, blocks of metal & nylons and even a large tap (of the thread cutting type)  anyway, back to the job... can see the assembly of the pinion, with the shim then bearing (hopefully the correct way round )  back to the press, shows the bearing is in there  back to the bench, bearing & shim fitted, all those photos for this!  bagged ready for use, the 4.1:1 crownwheel & pinion are not bagged, no use to me so might ebay them? any use to anyone?? more ramblings to come... Rich. |
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) I'm more concerned with the condition of the wishbones than the crossmembers as wishbones have lots of cavity-space that can be hiding rot - am tempted to buy new lower wishbones BUT £££££!'s 
) uses for the money...
le sigh