I've been a naughty boy...

Discussion in 'Show Us Your Bit On The Side' started by theBusmonkey, May 17, 2015.

  1. theBusmonkey

    theBusmonkey Sponsor

    :p:p
     
  2. It's actually quite the opposite of "broken". Very much "fixed". #engineoutjob :eek:
     
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  3. theBusmonkey

    theBusmonkey Sponsor

    :p:p:p:(
     
  4. 8
    there are the 4 others on the support bar:)
     
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  5. Pedantic, it was a joke

    Sent from my Nexus 6 using Tapatalk
     
  6. theBusmonkey

    theBusmonkey Sponsor

    Sadly in my foolishness I seem to have selected the most complicated one of the line!
    As Dicky pointed out, not only is it a syncro but it also has aircon & power steering.
    4 bolts (two already off) and a shed load of hoses containing nasty fluids....all good:D
     
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  7. theBusmonkey

    theBusmonkey Sponsor

    Obviously the pumps need not be disconnected, just unbolted & hung out of the way but TBH it's another job I was hoping to avoid.
     
  8. Leave the compressor hoses connected and disconnect the actually compressor if you can, to save having to refill the AC(sorry teaching you to suck eggs.) Might be able to help out during the week if you want?

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  9. You will repent your sins boy!:)
    :p
     
  10. theBusmonkey

    theBusmonkey Sponsor

    I'll treat you to a shot of the manifold that's been welded on if I can be bothered to get the camera out tomorrow:eek:
    It's going to be a lovely day & Mel & I are bottling wine....choices, choices...not really!
     
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  11. theBusmonkey

    theBusmonkey Sponsor

    So apart from slicing through the coolant hoses & disconnecting the fuel lines it's all ready to be dropped! Nice bloke that he is, @Dicky has offered a hand or two and a huge selection of jacks, stands, and enthusiasm so Wednesday is pencilled in for the extraction.
    Pretty straight forward really & fortunately nothing broke today. The engine bay is now a mass of little bits of scribbled on masking tape lest I forget:rolleyes:

    A picture of my mind...:confused:
    IMG_20170417_162611.jpg
     
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  12. hmm but what type of sealant on the flange!!!
     
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  13. theBusmonkey

    theBusmonkey Sponsor

    ;) Loctite 518 I think but I'll check tomorrow......
     
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  14. theBusmonkey

    theBusmonkey Sponsor

    I can't believe it was back in April that we dropped the engine out. The 19th to be precise!

    Fools fooling . I need to have a word with my brother regarding his lack of sartorial elegance & @Dicky just appears to be messing about!
    IMG_0606 (1).jpg

    However it fell out with no more drama than a broken loom to the distributor that somehow we managed to miss...:fool:

    We bundled it straight across the road & into the workshop of the local machinist who was going to have a go at getting the exhaust studs out.
    & there it stayed for the next 3 weeks whilst I tried to forget about it.

    I'd rather fallen out of love with the old fella as it seemed one thing after another. Mrs Monkey's birthday trip to Wales was a distraction & work has been busy blah blah blah.
     
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  15. theBusmonkey

    theBusmonkey Sponsor

    Eventually our machinist got fed up falling over the engine and to be fair he'd got 6 studs out leaving me with 2 broken ones. On different heads!
    The final straw.

    Now to engineering bods this is an everyday thing, but to me it was game over. New heads, scrap block, scooby conversion, I've been through all the scenarios over the last few weeks but actually haven't done anything about it!

    I once heard that if you use any old excuse....you'll use any old excuse...:rolleyes:

    We reclaimed the sorry lump, took it down my workshop, and promptly tried to forget about it for another week or two. Big G deserves more than this wilful neglect & my conscience finally got the better of me.

    So yesterday Mrs Monkey & I decided to have a go at broken stud extraction.
    Here's the story...

    First I tried burning it into submission. That didn't work!
    IMG_0811.jpg

    So the grinder came out & the stud was cut off flush with the manifold & filed flat across the port
    IMG_0821.jpg

    Centre punched, roughly central...
    IMG_0824.jpg

    ...and drilled out. 4mm to start gradually increasing in size until I lost my bottle. It's a scary thing to do because if you go too deep you're into the water jacket.
    Not a good look, but in any case you feel the drill bottom out when it goes through the stud.
    IMG_0828.jpg

    The old zorst has been blowing for some time & eroded the gasket sealing surface. I'll have to dress this flat with a hand file to give the new gasket half a chance of sealing...
    IMG_0832.jpg
    ......
     
  16. theBusmonkey

    theBusmonkey Sponsor

    ....
    I then ran an M6 tap down the hole and was left with a thin layer of metal filling the old threads...
    IMG_0833.jpg

    ...which came out with a little persuasion from a tiny chisel like an apple peeling.
    IMG_0851.jpg


    The other one was attacked in the same way
    IMG_0858.jpg

    Despite being pretty central with the punch, the drill ran off a bit...
    IMG_0863.jpg

    But not too worry as it meant the stud came out, with a bit more brute force, in one chunk!
    IMG_0864.jpg

    Heritage do an M8 to M10 repair stud, so 2 of those are apparently winging their way over to be tapped into suitably sized holes and all is good in the world again:D
     
    Last edited: Jun 4, 2017
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  17. theBusmonkey

    theBusmonkey Sponsor

    hahaha, I've got a massive collection of bits to bolt on and modify and build and and and...
    and finally have the enthusiasm back again! I guess we all go through it one way or another & it just takes a bit of effort rather than too much thought.

    Anyway, back on track now. We're up to the garage in your village on July 1st to get Mr Monkey's Marge MOT'd. We're planning on going to Cadwell Park for the scooter and historic bike racing that weekend so the plan is to swap Chip for the Beetle for a few weeks.
    You about for cookies?
     
  18. Great work, I have 2 I've fallen out of love with, get your ass to Manchester.
     
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