tag:blogger.com,1999:blog-14052237895261433832024-03-18T22:46:01.876+01:00Greasy GregIn a world full of family sedans and soccer mum SUVs, somebody got to take care of them go-fast 'n' kill yourself wheels...Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.comBlogger447125tag:blogger.com,1999:blog-1405223789526143383.post-16105688754665048032024-03-17T20:00:00.002+01:002024-03-18T22:45:31.057+01:00Project Volksrad - something abouts prophets, mountains and stopping<p><i> "If the prophet does not come to mountain, the mountain will come to the prophet"... and it better not have early 1980ies Honda Goldwing integral brakes -</i> 1st book of Greg, the Goldwing sermons, p. 1200.</p><p>With the plug wires hooked up correctly and a handful of fresh ones, which (added bonus) actually were long enough to route them properly things started to look a lot better on the engine front. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0ZPKt69U9_vrsdVxKkex4b9NMvQvOmstbNSQVRt5fBPq_6zavJKrZcj8NXoJNeHRxslnsw_ZBup5uplqICn4yMeYMHqRaZ-MaFb4SOUU7V18tIj-FF3bF4ioV_omfxCJAR592ygrGwnbBkH-s4mnUy-wuHaX5dcfyfL1-0yntgfo81VnTlbJgVa2PB3Y/s1280/IMG_7265%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0ZPKt69U9_vrsdVxKkex4b9NMvQvOmstbNSQVRt5fBPq_6zavJKrZcj8NXoJNeHRxslnsw_ZBup5uplqICn4yMeYMHqRaZ-MaFb4SOUU7V18tIj-FF3bF4ioV_omfxCJAR592ygrGwnbBkH-s4mnUy-wuHaX5dcfyfL1-0yntgfo81VnTlbJgVa2PB3Y/s320/IMG_7265%20Large.jpeg" width="240" /></a></div><p></p><p>So naturally the next step was to go through my box with old steel braided brake-lines and start converting the Goldwing from integral to conventional brakes. This would basically mean doing two things: Fit the front brakes with a double banjo bolt to handbrake pump. (Which would later be swapped out for a unit from a GSX600F with a 5/8" bore as the stock 14mm was leaking like a sieve.)</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF7Q2m1cwCrLS5CVoXlt9A8FpdQSYpKFvAX-ZB9Azl6hzrs2gMvQWQFtBlXbgTxn19BHOY0ixBNMmDAwR5VFEe5xAz71nr4vjY3TNlrZbKHL7Ce3W4bl5P_x_p1DUGT4Aszr12MYB1EHo9IvKf5y768vE6C8NyJEt_4Cc1JYWbDAaDyaNHnEVyyeKIWmI/s1280/IMG_7270%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF7Q2m1cwCrLS5CVoXlt9A8FpdQSYpKFvAX-ZB9Azl6hzrs2gMvQWQFtBlXbgTxn19BHOY0ixBNMmDAwR5VFEe5xAz71nr4vjY3TNlrZbKHL7Ce3W4bl5P_x_p1DUGT4Aszr12MYB1EHo9IvKf5y768vE6C8NyJEt_4Cc1JYWbDAaDyaNHnEVyyeKIWmI/s320/IMG_7270%20Large.jpeg" width="240" /></a></div><p></p><p>And the somewhat more elaborate part, of sealing up one port on the footbrake pump btw. the pump turned out to be somewhat of a show stopper as, just like its front counterpart, it was leaking and the old brake fluid had eaten away the paint on the frame. (Luckily repair kits are readily available and on the way.)<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXYodtdaVI-3-5yqClrptfcWj4sKrpRxztYJCSEsYanm93cSs6imXjtYe8HzKhs3LabXy7T7TK53qp-I0QR_MOHp41fV-jCEE33zgqkefVeKfdiRVCA6Nzx4seDO-AH5g7l7OyicQWAYk-p2LZXpouQ_tDUDxiC8LPev0Z0AaEGvak0rPjOdVVG-b6z4A/s1280/IMG_7616%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXYodtdaVI-3-5yqClrptfcWj4sKrpRxztYJCSEsYanm93cSs6imXjtYe8HzKhs3LabXy7T7TK53qp-I0QR_MOHp41fV-jCEE33zgqkefVeKfdiRVCA6Nzx4seDO-AH5g7l7OyicQWAYk-p2LZXpouQ_tDUDxiC8LPev0Z0AaEGvak0rPjOdVVG-b6z4A/s320/IMG_7616%20Large.jpeg" width="320" /></a></div><p>The actual conversion is pretty straightforward, as all I had to do was to cut the hardline with the fitting installed in the brake pump and then weld it up. Why the hardline? Because the flare on the bottom is what actually seals and whilst I am 99 percent sure that an M10x1.25 bolt and copper or ally washers would have done the job just as fine, this is kind of the more correct way to do it. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOB4bolNQdo4lWr0vG-bE5wFjzhUMx1XgbdB-HxWdJw5tV7QliRB5UD-aJ9sEFYh7PF3SztPkrQwVJvlllH00TvucfMEDP0fdYX2WApGVcSvcnZdKM4BXf4HeBs-j-UIZJWkDalpC9v-EDT0w5Ve40mlCkTLZXLUE9EHUmFVgiid9kH3jQzL4XZWd3Eh0/s1280/IMG_7617%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOB4bolNQdo4lWr0vG-bE5wFjzhUMx1XgbdB-HxWdJw5tV7QliRB5UD-aJ9sEFYh7PF3SztPkrQwVJvlllH00TvucfMEDP0fdYX2WApGVcSvcnZdKM4BXf4HeBs-j-UIZJWkDalpC9v-EDT0w5Ve40mlCkTLZXLUE9EHUmFVgiid9kH3jQzL4XZWd3Eh0/s320/IMG_7617%20Large.jpeg" width="240" /></a></div><p></p><p>The remaining port got a bit of cleanup with a brush and a file just to make sure it would seal well with a washer (it does, thanks for asking) and then really just route a brake line along the swingarm. Easy peasy really. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLZ3mCymAhMD3LKm1knGlFaQySoxZf4OG6a8z7tc4E2e5mxyyccVn19OQp6F3ZG5rIGdOMKEksmBVjXvhyphenhyphenCKZ-VNIbZei6lZQUiBnTDGTxGsmY7qcJgLZM8swmjOF358TNC3d68TxPRpVXS2kcHiJJWUdjNV8hJZH0VRLc-jACmUSWejMOb9QvGswaHC4/s1280/IMG_7618%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLZ3mCymAhMD3LKm1knGlFaQySoxZf4OG6a8z7tc4E2e5mxyyccVn19OQp6F3ZG5rIGdOMKEksmBVjXvhyphenhyphenCKZ-VNIbZei6lZQUiBnTDGTxGsmY7qcJgLZM8swmjOF358TNC3d68TxPRpVXS2kcHiJJWUdjNV8hJZH0VRLc-jACmUSWejMOb9QvGswaHC4/s320/IMG_7618%20Large.jpeg" width="240" /></a></div><p></p><p>Which basically only left one hydraulic circuit left to tackle and for this one, as the name implies I went to a local hydraulics supply shop and bought a totally-not-a-brake-line to replace the bloated mess that was stock on this bike. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdENe-i9LhpKusOA8VBynHeHAzKHewNKdzMnLj2Rr9KFWr-v1kZ2owPklLifBeI0VNl9B9VOl0sx_JwU2_NnCfqRR2UCWkZisaEKxcwDYo4i-TcgVm-r02H2reZqlcX2gmQJbkMjQWkbTRVbrRbHs3BcFV_rwG7JWI9Q2i2kF6bRIFqFeHYoLlUxsJqJE/s1280/IMG_7619%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdENe-i9LhpKusOA8VBynHeHAzKHewNKdzMnLj2Rr9KFWr-v1kZ2owPklLifBeI0VNl9B9VOl0sx_JwU2_NnCfqRR2UCWkZisaEKxcwDYo4i-TcgVm-r02H2reZqlcX2gmQJbkMjQWkbTRVbrRbHs3BcFV_rwG7JWI9Q2i2kF6bRIFqFeHYoLlUxsJqJE/s320/IMG_7619%20Large.jpeg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgG_epMuqQTmKBtH719pucqREk-St-i34YYC0nRebKHYkcU4nuyisrQqASJWZ3Mun7naSPsaz8xepYTY_oT4x70nVDPx4u8E21dNyaSi4w6bb3hDP31qZtnouWfga3M1KvFe7fdH6FymjHM5CTWXUCox8YRz43g1y75BNv_XoAUQKfRSfOmJ7HhhXBIS98/s1280/IMG_7625%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgG_epMuqQTmKBtH719pucqREk-St-i34YYC0nRebKHYkcU4nuyisrQqASJWZ3Mun7naSPsaz8xepYTY_oT4x70nVDPx4u8E21dNyaSi4w6bb3hDP31qZtnouWfga3M1KvFe7fdH6FymjHM5CTWXUCox8YRz43g1y75BNv_XoAUQKfRSfOmJ7HhhXBIS98/s320/IMG_7625%20Large.jpeg" width="240" /></a></div><p></p><p>Aside from a completely clogged up bleed nipple on the clutch slave cylinder things went about as smooth as one would expect things to go, when pretty much all the components are new or freshly overhauled. (Even though I overhauled that clutch slave four years ago.)</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPD225Zgrt8P5S4VpHbscZR2wmirfYQWAhVkOWnEp-DZFPK2ToQOdmeuTxNLFCjeIhsothLUNgvU-8TRV3CbKbFkeAJg7RKUq213Y6AkKgl6RkE4wYn5vx9aS5mYszuqZ7ajQyvYFYzN9R3SYaWG8CAPnZD1SvuhJvAcNbC-FnrjrAbLblwZSUWTM0nxg/s1280/IMG_7628%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPD225Zgrt8P5S4VpHbscZR2wmirfYQWAhVkOWnEp-DZFPK2ToQOdmeuTxNLFCjeIhsothLUNgvU-8TRV3CbKbFkeAJg7RKUq213Y6AkKgl6RkE4wYn5vx9aS5mYszuqZ7ajQyvYFYzN9R3SYaWG8CAPnZD1SvuhJvAcNbC-FnrjrAbLblwZSUWTM0nxg/s320/IMG_7628%20Large.jpeg" width="240" /></a></div><p></p><p>(Also in this picture - the new brake pump and slightly re-routed brake cables to make them fit a bit neater.)<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHQc9f_u2NbJORNVmWZn4FhM7UVHm9bVJEQY0ESrjhC30fR8tU1PRAZvenrmyYJwqrCtjG5bHmNCsoHUtjqxCYxE6mcEREWwFbMQK28BR3Df67uafNhyvVgG74qXM3v544tSy9_GcXAED9Z32GI8UKuQeXeYq9KuMAgzy9O7eSBGeMrqqkj3M9pgxdh14/s1280/IMG_7629%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHQc9f_u2NbJORNVmWZn4FhM7UVHm9bVJEQY0ESrjhC30fR8tU1PRAZvenrmyYJwqrCtjG5bHmNCsoHUtjqxCYxE6mcEREWwFbMQK28BR3Df67uafNhyvVgG74qXM3v544tSy9_GcXAED9Z32GI8UKuQeXeYq9KuMAgzy9O7eSBGeMrqqkj3M9pgxdh14/s320/IMG_7629%20Large.jpeg" width="240" /></a></div><p>Looks pretty good or stock if you ask me.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDkq5m7iiagnb44FT7dzmwyHSysSSoOEbv6WuKSXVhY9-WnLbG5PC8Yq39F6PCi5kTdF1QdqzsB2cnkLuFjHMSDqeeKngRAchpUt0nx0RptSgMx1sQML46lULViIGIIQmQRFsdqfAptriB9ONGFXGdjdzvYo1I1oFLkM73WjVuzT6xg7u_sl651DEm6WU/s1280/IMG_7630%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDkq5m7iiagnb44FT7dzmwyHSysSSoOEbv6WuKSXVhY9-WnLbG5PC8Yq39F6PCi5kTdF1QdqzsB2cnkLuFjHMSDqeeKngRAchpUt0nx0RptSgMx1sQML46lULViIGIIQmQRFsdqfAptriB9ONGFXGdjdzvYo1I1oFLkM73WjVuzT6xg7u_sl651DEm6WU/s320/IMG_7630%20Large.jpeg" width="240" /></a></div><br />Bleeding went... well enough to be honest, but as for now Project Pickle, my new (to me) Suzuki SJ410 has priority over the Goldwing and before fitting the exhaust, I really want to overhaul the rear brake system entirely as the pump is leaking and brake pistons are "a bit" sticky or in other words, once applied won't let you move the big girl an inch. As such, for now she's back in hibernation, but I promise it won't be another four years... <br />Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-90540603194352086962024-03-03T20:00:00.013+01:002024-03-04T12:56:24.586+01:00Project Pickle - making the engine run again (part 5.1)<p>Now I ended the last post along the lines of:</p><p><i>I somewhat doubt I messed up the timing</i></p><p><i></i></p><div class="separator" style="clear: both; text-align: center;"><i><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMeh9tSEgXM2q7-S7OBhX4hMPKZpzKVT7C5dC5dPHfct4OJaNjICkn9lPVlx2bxb2C4vdtkZ0E_Yu758sagmKQaYfOMwvUoYXaUqTqT5xf8LP7j7OEtppWSYZf9Sl84fb7_ab04WOr1pSubfdt6GJRSFL7y886ggFCyiyaK4fdWMugDZldxYvwLEuN-24/s1280/IMG_7941%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMeh9tSEgXM2q7-S7OBhX4hMPKZpzKVT7C5dC5dPHfct4OJaNjICkn9lPVlx2bxb2C4vdtkZ0E_Yu758sagmKQaYfOMwvUoYXaUqTqT5xf8LP7j7OEtppWSYZf9Sl84fb7_ab04WOr1pSubfdt6GJRSFL7y886ggFCyiyaK4fdWMugDZldxYvwLEuN-24/s320/IMG_7941%20Large.jpeg" width="240" /></a></i></div><p></p><p>Which, to be honest is exactly what I did. Luckily it was the kind of harmless, not breaking anything kind of "messed up the timing". At least I was right about the fanblades hitting the shroud. As I had a few lovely days in Palermo to think about all of this the most obvious answer was that I must have gotten the crank 180 out, when I rolled it forward to flush the block and accidentally knocked it in gear. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFgaOeiAU8XpLsrJrxcq83BE0Ot8YdfFQ46NYYTrUYd3DvwaiDba4lwi-K8qroisoj1KNyZ5v7Pn43ODv4Lb37p8Ppt35VKAiWDb0uTscrYwp9JMxvJhoazbSLT-lxS2YrSFgkF2_WVBjPVt7765hPhWo6GwQnYqLFhmOpD0Jp5xMCGAYOESMBgFBjWhQ/s1280/IMG_7942%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFgaOeiAU8XpLsrJrxcq83BE0Ot8YdfFQ46NYYTrUYd3DvwaiDba4lwi-K8qroisoj1KNyZ5v7Pn43ODv4Lb37p8Ppt35VKAiWDb0uTscrYwp9JMxvJhoazbSLT-lxS2YrSFgkF2_WVBjPVt7765hPhWo6GwQnYqLFhmOpD0Jp5xMCGAYOESMBgFBjWhQ/s320/IMG_7942%20Large.jpeg" width="240" /></a></div><p></p><p>Whilst my working hypothesis would turn out true, I was a bit relieved to see that the markings still lined up and nothing had gone terribly wrong on the inside for the timing case.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvY-HI_lJJsv-OPXQ-uJJSkpEwHOUzaQUCsmNheFZtM9LHDlB4Z0JCJqrurKWUX05ca5DXMu53lITtLC4gYJKHMxK8Hwfq2xLsh6HXhtESD5MCCnXgqrEewp_pKqmvJtTr9wIydrYQdApgCz7yvpU2PjLq_gwEgzTw5-fIK46c0KRUEay1d0KhE_CKLNA/s1280/IMG_7944%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvY-HI_lJJsv-OPXQ-uJJSkpEwHOUzaQUCsmNheFZtM9LHDlB4Z0JCJqrurKWUX05ca5DXMu53lITtLC4gYJKHMxK8Hwfq2xLsh6HXhtESD5MCCnXgqrEewp_pKqmvJtTr9wIydrYQdApgCz7yvpU2PjLq_gwEgzTw5-fIK46c0KRUEay1d0KhE_CKLNA/s320/IMG_7944%20Large.jpeg" width="240" /></a></div><p></p><p>The master-bodgineer in my concluded that if this was truly the case, the rotor would point in the completely wrong direction, as in the opposite of either of the cylinders 1 or 4 that would be at TDC. Easiest way to establish this was by taking the distributor cap off and having a look and guess what: #4 was at TDC and it was in the ballpark of #1.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc8gE205BMfWRyxK71jOFgjRKey7ya9FNSE5cM5qicjoBLXFIeIkWIKKMBfQuluHQQDVu6USH6O0ew0dhbZPp3bUip4zqRD3d_aITvjCf0fOJhXsRhVrIAKk_Oqa5z2Pr2rsgY4Bo44b2DkZ2IBQzNY6OCfQ9HohKJPcSbjG23ZWkWPLqOpRDhzQYFQS4/s1280/IMG_7945%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc8gE205BMfWRyxK71jOFgjRKey7ya9FNSE5cM5qicjoBLXFIeIkWIKKMBfQuluHQQDVu6USH6O0ew0dhbZPp3bUip4zqRD3d_aITvjCf0fOJhXsRhVrIAKk_Oqa5z2Pr2rsgY4Bo44b2DkZ2IBQzNY6OCfQ9HohKJPcSbjG23ZWkWPLqOpRDhzQYFQS4/s320/IMG_7945%20Large.jpeg" width="240" /></a></div><p></p><p>Now you can obviously fix this the right way, by adjusting the cam-timing, or you could test it by flipping the cap around 180 degrees, which some clever Nippon-Denso engineers prevented by making the distributor body sport a little nose on one side. Cheeky b*st*rds.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirIGq7Z8M3DR85vmf-FUss3AtUP3_0x3Bzl2g4kVLTqXvla-EzuCFJvitrp38gqzTBqlEaJimQW_hjp7a730pGs9aB9KDtCAacw0OVQ19zwPjBm7ueaiteIq31eKyBDNsp6TR7719E5wONZurXaFmt1xTZn4AQcpYFl53UkYguJefTFiPxVTDiZjMGTB4/s1280/IMG_7946%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEirIGq7Z8M3DR85vmf-FUss3AtUP3_0x3Bzl2g4kVLTqXvla-EzuCFJvitrp38gqzTBqlEaJimQW_hjp7a730pGs9aB9KDtCAacw0OVQ19zwPjBm7ueaiteIq31eKyBDNsp6TR7719E5wONZurXaFmt1xTZn4AQcpYFl53UkYguJefTFiPxVTDiZjMGTB4/s320/IMG_7946%20Large.jpeg" width="240" /></a></div><p></p><p>So I removed the timing belt tensioner and turned the crank a full revolution until the marks lined up again and then reinstalled the belt, making sure that it would be tight on the tension-side.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2ewMPBi10WFVMy8jLMF0yAHIX9mhick0rvLHNnHByRbzvXODz5IENGbtgO_zvE2akcWsAPTdZ3ewE2aFeM35p1pONyuxOzaRgL8KAQFWREZmOr4iN-Ywb2dH2MXunHjpiFoMKF9zLZjVxHbhV1eGr0K0PjvR2kpQy3egzOHDySzZBZ4UH01ExMCi2koU/s1280/IMG_7948%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2ewMPBi10WFVMy8jLMF0yAHIX9mhick0rvLHNnHByRbzvXODz5IENGbtgO_zvE2akcWsAPTdZ3ewE2aFeM35p1pONyuxOzaRgL8KAQFWREZmOr4iN-Ywb2dH2MXunHjpiFoMKF9zLZjVxHbhV1eGr0K0PjvR2kpQy3egzOHDySzZBZ4UH01ExMCi2koU/s320/IMG_7948%20Large.jpeg" width="240" /></a></div><p>As a sort of extra-curricular activity, I also marked TDC on the crankpulley. Even though there are no marks on the outside of the timing belt cover, it could at some point in the future come in handy for adjusting the valves or the like. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1rh1RGkkQJcwRsd5howmTPQ50oN19_G-s3xPs7zAy4ub1FebN9qByoOzq90PmkDhmQSAgP3bTO2Qrwu49rAlwxi9K-UrAAFW8XZu8Uie5X34lZspNE4dficR251Z_94ZU0IGqi_tLbNzWAQ27Lxfi3KFJ3H6WzbZLOoDw383Acerm17k980RdBv_iqEk/s1280/IMG_7951%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1rh1RGkkQJcwRsd5howmTPQ50oN19_G-s3xPs7zAy4ub1FebN9qByoOzq90PmkDhmQSAgP3bTO2Qrwu49rAlwxi9K-UrAAFW8XZu8Uie5X34lZspNE4dficR251Z_94ZU0IGqi_tLbNzWAQ27Lxfi3KFJ3H6WzbZLOoDw383Acerm17k980RdBv_iqEk/s320/IMG_7951%20Large.jpeg" width="240" /></a></div><p>Talking of stuff that might come in handy in the future: I also painted the timing marks on the flywheel so I will have a slightly easier time dialing in the ignition in the hopefully not too distant future.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4MxKf9HNsUZKmaMLm6puWg-evl6B8ZPDmguxD9yFc8WFow7rr3Evhe0MNCZYJesSnHDe1m7sGzWyrXIk9LmaQC_erZYdphcVnyhgeETGd-8jLpQbSg6H1IRiiEQp5a0ojcbLhKuByUsG5DMoPKy-7nvydEVzOXurQuL4jyVdXp_7SmMfK7r7yFqAGP3o/s1280/IMG_7962%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4MxKf9HNsUZKmaMLm6puWg-evl6B8ZPDmguxD9yFc8WFow7rr3Evhe0MNCZYJesSnHDe1m7sGzWyrXIk9LmaQC_erZYdphcVnyhgeETGd-8jLpQbSg6H1IRiiEQp5a0ojcbLhKuByUsG5DMoPKy-7nvydEVzOXurQuL4jyVdXp_7SmMfK7r7yFqAGP3o/s320/IMG_7962%20Large.jpeg" width="240" /></a></div><p></p><p>With the engine running again like it should, as a matter of fact with 4 tightened spark plugs it ran nicer than ever, the terrible noise of the fanblades hitting the shroud hadn't disappeared and left quite a mark...</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNvklngCYVk7qcsM5y6jqUTpQLaLEkmXsTy1_glVtjqq4TC8UZh172l515657HSHwvmQjJ0QXuYUedWdIrJo6Og1mkWMONkneP94SbevXuW8mGrBmBGQwcPG6-RtZqDEtvQRtdEICvpNvKA53u3S3rRsTww7eTVVBi_cMLG1ZoEugmWIHTWqpLwkUJJsA/s1280/IMG_7972%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNvklngCYVk7qcsM5y6jqUTpQLaLEkmXsTy1_glVtjqq4TC8UZh172l515657HSHwvmQjJ0QXuYUedWdIrJo6Og1mkWMONkneP94SbevXuW8mGrBmBGQwcPG6-RtZqDEtvQRtdEICvpNvKA53u3S3rRsTww7eTVVBi_cMLG1ZoEugmWIHTWqpLwkUJJsA/s320/IMG_7972%20Large.jpeg" width="240" /></a></div><p></p><p>... and for future reference: there's a quite prominent UP-mark on the right side of the fanshroud that's obviously not just there for stylistic purposes.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnHysyqoUXiGuy99va50iwzru_H3uJ4PFBL9eZW8md7uTbZv5QtcVAvXUi5DR1RxyZobDl1vBx24QkJG9f7bWi1zuiWOrhP7Qo4FSmiZMItzbDV7mQZ_xAkIxTWD8LYcSBkI1u15zKnsuV9Hl7g-8ChYgDdok9Tbg9WNKAzj1XLPhbWtKT7A8_8BFSae8/s1280/IMG_7973%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnHysyqoUXiGuy99va50iwzru_H3uJ4PFBL9eZW8md7uTbZv5QtcVAvXUi5DR1RxyZobDl1vBx24QkJG9f7bWi1zuiWOrhP7Qo4FSmiZMItzbDV7mQZ_xAkIxTWD8LYcSBkI1u15zKnsuV9Hl7g-8ChYgDdok9Tbg9WNKAzj1XLPhbWtKT7A8_8BFSae8/s320/IMG_7973%20Large.jpeg" width="240" /></a></div><p></p><p>I still have one more post in my quiver to bridge the current work of cutting out all the old rusty panels and until I am able to show some actual progress in that field. (Or in other words: currently tackling the floorpans and oh my, some good surprises there...) Regardless of that I hope someone will find this post useful in troubleshooting his or her timing mistakes.<br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-29578250665137519452024-02-21T20:00:00.001+01:002024-02-21T21:31:00.729+01:00Project Pickle - engine tidy up (part 5)<p>
Once back in my dad's workshop it was really the first time that I realised
just how much smaller the little Pickle is compared to Comrade Car (my
previous Lada Niva 1600).
</p>
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</div>
<p></p>
<p>
With the front grill removed, I have to admit, I have yet to find a car/truck
that is nicer to work on. Also, as hinted at before, I am sure there's bigger
Golf-carts than the lil' Pickle.
</p>
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</div>
<p></p>
<p>
With the radiator removed (4 bolts for the radiator, 4 for the fan shroud),
slightly loosen the alternator mounting bolts and the fan belt comes right
off.
</p>
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<p></p>
<p>Couple dugga-duggas and the crankpulley comes right off.</p>
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</div>
<p></p>
<p>
Timing belt was definitely due - it felt more like a rubber band than an
actual belt to be honest.<br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhEEKED2YA7jA8WKQ9yiNK9V3uWfejcRdSErL8KGYIz28e-vFQe9uSPLBwCZ99bfXenLtlNo6TOGVXwKzSoMhjGgifswrc02cJauWsjn1c8n3dzOjbjKCaMWzWgLkuhMFnqnijWItnc1eVZvPCfFxrbS_bf-BM7vrr1ybbNe7g-Z6xgYhzJd3Nc-1cMP0/s1280/IMG_7749%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhEEKED2YA7jA8WKQ9yiNK9V3uWfejcRdSErL8KGYIz28e-vFQe9uSPLBwCZ99bfXenLtlNo6TOGVXwKzSoMhjGgifswrc02cJauWsjn1c8n3dzOjbjKCaMWzWgLkuhMFnqnijWItnc1eVZvPCfFxrbS_bf-BM7vrr1ybbNe7g-Z6xgYhzJd3Nc-1cMP0/s320/IMG_7749%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
To make life easier (and be able to feel, if I got the timing wrong), I marked
all the plug caps and then proceeded to remove the plugs. Only to find out
that the two center ones weren't even remotely tightened.
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi337voI8eMWstUSF6p4vIxOf93Mi8XlBVHIn3MbiHuPwKpBpoLc0KMGBjgaoxO1sXb5IfL5plkVwGnJrfD8H5DZLAerBVlzg8a7k8X1EJy8hcjRtvUUrrLA9oF0ismx-QnOYZRkrfuE3la-zeVNa4xHCDnpUPbl2XnX6kaJTZpjt5pEN3Ze03MCjpHQ5s/s1280/IMG_7751%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi337voI8eMWstUSF6p4vIxOf93Mi8XlBVHIn3MbiHuPwKpBpoLc0KMGBjgaoxO1sXb5IfL5plkVwGnJrfD8H5DZLAerBVlzg8a7k8X1EJy8hcjRtvUUrrLA9oF0ismx-QnOYZRkrfuE3la-zeVNa4xHCDnpUPbl2XnX6kaJTZpjt5pEN3Ze03MCjpHQ5s/s320/IMG_7751%20Large.jpeg" width="240" /></a>
</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJ1sEJsH0sEnkJGMQFAlXzgvuaEE9qi-Q9AUPizsApcOXcgHlXU7vT2jLqdsiW1MwV8pGSpDq_tlYXPX_baf2o2UH1u7rpIe7qacjA3CIkR9Hk2Bu9sBebGBDko_JwGbN9SbkKXCQcQoqQS5KNjZ0IEgVZ4QOAOslAM0szmWwW7xjKEqyQN9LfVL-QS5w/s1280/IMG_7752%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJ1sEJsH0sEnkJGMQFAlXzgvuaEE9qi-Q9AUPizsApcOXcgHlXU7vT2jLqdsiW1MwV8pGSpDq_tlYXPX_baf2o2UH1u7rpIe7qacjA3CIkR9Hk2Bu9sBebGBDko_JwGbN9SbkKXCQcQoqQS5KNjZ0IEgVZ4QOAOslAM0szmWwW7xjKEqyQN9LfVL-QS5w/s320/IMG_7752%20Large.jpeg" width="320" /></a>
</div>
<p></p>
<p>
And a quick picture of how the timing was set up, when it was still running,
never hurt nobody. (Foreshadowing)
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAoEUYroBh4X5wKRx10tJpfv_rIshyIGtNsLUme9Og46EWehj4oowtYd9_KxYiUTDI_iybM-5bS1h41dEehnq7wqBi_k4Zhsn9xXbEDOax4crv04u-Onp218uD_7R5-bb5VvFdd_ukpJpC-dXGPQuL6tydqEaTk8g2SYnfJ2cihk9JUFnmOnW5Q0d1a9M/s1280/IMG_7753%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAoEUYroBh4X5wKRx10tJpfv_rIshyIGtNsLUme9Og46EWehj4oowtYd9_KxYiUTDI_iybM-5bS1h41dEehnq7wqBi_k4Zhsn9xXbEDOax4crv04u-Onp218uD_7R5-bb5VvFdd_ukpJpC-dXGPQuL6tydqEaTk8g2SYnfJ2cihk9JUFnmOnW5Q0d1a9M/s320/IMG_7753%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
The lower pulley has got some M8-threads and the pivot bolt of the tensioner
is perfect to press it off the crank.
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbjT-Hai0N4GrBLuZo2R_-W5nRVtt3HRMd0CCO6loddIIJLfrpHwX_PXMsnW9NfTPpyKKA-PFAW1jqMhMsM6XIngZE3annuiIiOImAXfFKCeIqWF023Yny_rECF3MH-QkSpbx1WRk90_Cwd0CzQS1K0NRXRe92ZfIOWpDz-6k1WP8TcwqU5yWEAttVKZ4/s1280/IMG_7754%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbjT-Hai0N4GrBLuZo2R_-W5nRVtt3HRMd0CCO6loddIIJLfrpHwX_PXMsnW9NfTPpyKKA-PFAW1jqMhMsM6XIngZE3annuiIiOImAXfFKCeIqWF023Yny_rECF3MH-QkSpbx1WRk90_Cwd0CzQS1K0NRXRe92ZfIOWpDz-6k1WP8TcwqU5yWEAttVKZ4/s320/IMG_7754%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Looking at the area around the crankshaft seal made me realise that I might
have found the very first of the oil-leaks of this engine.
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHudDUUJFuQy0b7f94f6hr8E1lVTE_KDMEQkI4GkBnQYDV3nihEVyupHpg_YcuhwicaPK0L8whnH6juxRK9dX6mCCCuYxQdSD98CECaQtgxAK8NOYJ4VSJBNPXVzBMrrgZ-2H08iUbsHTFXErmelPDNmnD5hlEdO-6Cl889GjBZ7nCLKmRMLx8eLjuWDk/s1280/IMG_7755%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHudDUUJFuQy0b7f94f6hr8E1lVTE_KDMEQkI4GkBnQYDV3nihEVyupHpg_YcuhwicaPK0L8whnH6juxRK9dX6mCCCuYxQdSD98CECaQtgxAK8NOYJ4VSJBNPXVzBMrrgZ-2H08iUbsHTFXErmelPDNmnD5hlEdO-6Cl889GjBZ7nCLKmRMLx8eLjuWDk/s320/IMG_7755%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
To be honest, when you're already in there, you might as well do the camshaft
seal as well.<br />
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEOrT66L6GwtLkNQwMKL_f4fkhajVtbVEnu1dKKYH9FHk7MRAjP4QH1kqhUxRfK3naUL0Ha7DjghRlQXdNL8pipkyptx7iDSQp9TQI54jXQhrfvff5pDwkDib0BE5QJCoKjrM_acZwPXe1IPAmCiatfSxMga2WEvFR044E-O3a1uleyzX86VkLxLGGNqs/s1280/IMG_7759%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEOrT66L6GwtLkNQwMKL_f4fkhajVtbVEnu1dKKYH9FHk7MRAjP4QH1kqhUxRfK3naUL0Ha7DjghRlQXdNL8pipkyptx7iDSQp9TQI54jXQhrfvff5pDwkDib0BE5QJCoKjrM_acZwPXe1IPAmCiatfSxMga2WEvFR044E-O3a1uleyzX86VkLxLGGNqs/s320/IMG_7759%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgr59HatzyRE916xssnTqhTMBWYwXPGVA_qEZiOor7Ob8qy9QvNQBuO8ioRgU1spuxrjwnMyPBmCMTP5URyNdQfv_j3M0E1AVY9FZUoowvgZW_8tbcbNdbEJOlzc7eresR_0af1H2HSGjR9V_1wrQSlRw7hQWO1fPltCOerkB9negFogCuU-MyHNmeZKf4/s1280/IMG_7760%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgr59HatzyRE916xssnTqhTMBWYwXPGVA_qEZiOor7Ob8qy9QvNQBuO8ioRgU1spuxrjwnMyPBmCMTP5URyNdQfv_j3M0E1AVY9FZUoowvgZW_8tbcbNdbEJOlzc7eresR_0af1H2HSGjR9V_1wrQSlRw7hQWO1fPltCOerkB9negFogCuU-MyHNmeZKf4/s320/IMG_7760%20Large.jpeg" width="240" /></a>
</div><p>
</p><p>Ironically despite its looks, the thermostat was still working.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiK4Pa4H9YomPbtDvBMxj79OlAUC8Yw7n5S85APtuDt0QrCJZUk4FMaWdcYPARN5cUvzL41UviAdyIfAy48j9gEt4TOdfKyB4Omkf7W7S3YA4w2D89_F1-fi-ue4ADdMImEg60spn_wS6tzpBsJAnLKPMLZvJNV36oStoeOofBVJrqIQt6D7MHH-YcQrbI/s1280/IMG_7761%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiK4Pa4H9YomPbtDvBMxj79OlAUC8Yw7n5S85APtuDt0QrCJZUk4FMaWdcYPARN5cUvzL41UviAdyIfAy48j9gEt4TOdfKyB4Omkf7W7S3YA4w2D89_F1-fi-ue4ADdMImEg60spn_wS6tzpBsJAnLKPMLZvJNV36oStoeOofBVJrqIQt6D7MHH-YcQrbI/s320/IMG_7761%20Large.jpeg" width="240" /></a></div><p></p><p>The waterpump put up a good fight and must have been leaking for a while already.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtYR6IqAJEe29vy980XO4kLZqtX4p-kfaP6TuaHLIQrUVLyfa_XYj16N0TPhet_Z855IFCIGOkOaPVn3ppmG6wp92ZIrFawvV0UAOATF4ooqH_QXqYUYgPfuemZXHIIFvpG_Ns9wVAqm6049uWAjO4KGcBy3hVR1mrqCOQnqHcojU2xAKodljQPXj67bw/s1280/IMG_7762%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtYR6IqAJEe29vy980XO4kLZqtX4p-kfaP6TuaHLIQrUVLyfa_XYj16N0TPhet_Z855IFCIGOkOaPVn3ppmG6wp92ZIrFawvV0UAOATF4ooqH_QXqYUYgPfuemZXHIIFvpG_Ns9wVAqm6049uWAjO4KGcBy3hVR1mrqCOQnqHcojU2xAKodljQPXj67bw/s320/IMG_7762%20Large.jpeg" width="240" /></a></div><p></p><p>As the cast iron of the mating surface was a bit pitted, a generous amount of liquid gasket was applied to the block in order to stop things from leaking again.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVvibhrcvPJMJhy29-FOyr_jyjGU5HR3zVWgru9V-zFxl8HwA0FXoYNY1Sxt7RrC9kU_jmIh3SRTcH2JvjHi8qxi1VNAoNPJPS0iRjJmWOdqrN7LQa8jkAtL827tsKUPWRrmGaQZEHw8mdZC0W05aeYl47Ai1_55D0cYABZj5066SAJIm74bruAJYyrDg/s1280/IMG_7763%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVvibhrcvPJMJhy29-FOyr_jyjGU5HR3zVWgru9V-zFxl8HwA0FXoYNY1Sxt7RrC9kU_jmIh3SRTcH2JvjHi8qxi1VNAoNPJPS0iRjJmWOdqrN7LQa8jkAtL827tsKUPWRrmGaQZEHw8mdZC0W05aeYl47Ai1_55D0cYABZj5066SAJIm74bruAJYyrDg/s320/IMG_7763%20Large.jpeg" width="240" /></a></div><p></p><p>As some previous owner had lost at least one of the spacers for the timing cover (10mm OD, 7mm ID, 7mm tall), I quickly turned a bit of stainless pipe into a handful of spacers. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLXm0XlDYayo6AXLHl-dabUAE81809-tkA8-OEuG0XAq5Nb2gDHddyJAhZpN7JmdOpWNoisCUnLdht7iMZjPQDvY3lCkyfL6EkYcaFtywVzNPKe1bpNId25EnOFiuIJZgWKFa6gfQFuXxZGSEmNCCkbaOlKBXj5VacXBJPpjIn2y93AYMvdcTBxAl3yTA/s1280/IMG_7764%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLXm0XlDYayo6AXLHl-dabUAE81809-tkA8-OEuG0XAq5Nb2gDHddyJAhZpN7JmdOpWNoisCUnLdht7iMZjPQDvY3lCkyfL6EkYcaFtywVzNPKe1bpNId25EnOFiuIJZgWKFa6gfQFuXxZGSEmNCCkbaOlKBXj5VacXBJPpjIn2y93AYMvdcTBxAl3yTA/s320/IMG_7764%20Large.jpeg" width="240" /></a></div><p></p><p>And then reinstalled everything to the same marks as before...</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUu4hpWP6i7FYgSklRaiyBksq4Rri-JUZHQUt0MCQLoQ2dBDIAzSFVLHti5YRTuRsr9eZc2L6tOrXa2nVFgGZP7GQ_-iehlUrWHEjJ4yAkQzvqJTEl_ltAVeOAbbwZaqapBce4hR0bWMwT0wOp0uou3-nC_zHX4XU9tMfhHv0iCcnovsgNcBHkEtMVkm0/s1280/IMG_7765%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUu4hpWP6i7FYgSklRaiyBksq4Rri-JUZHQUt0MCQLoQ2dBDIAzSFVLHti5YRTuRsr9eZc2L6tOrXa2nVFgGZP7GQ_-iehlUrWHEjJ4yAkQzvqJTEl_ltAVeOAbbwZaqapBce4hR0bWMwT0wOp0uou3-nC_zHX4XU9tMfhHv0iCcnovsgNcBHkEtMVkm0/s320/IMG_7765%20Large.jpeg" width="240" /></a></div><p></p><p>Double checked by turning the engine over two full revolutions without plugs.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1mcxUj-Bia_wmlJPFeqQcw_eQsbo_ruONCKR6EwTT7r-bT4-y5IG2bqyty3A11FYkgEeg_xPndrKlnAVmjh0xpyjIYPXQRkxF7WBKnFDw_axg9FccO7lx28YZheJIDcLNPbjXCZc69G1i7loOvcFOC432V72pWr8uZQmnO294DOG8fiVV3oMmOvHKWeU/s1280/IMG_7766%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1mcxUj-Bia_wmlJPFeqQcw_eQsbo_ruONCKR6EwTT7r-bT4-y5IG2bqyty3A11FYkgEeg_xPndrKlnAVmjh0xpyjIYPXQRkxF7WBKnFDw_axg9FccO7lx28YZheJIDcLNPbjXCZc69G1i7loOvcFOC432V72pWr8uZQmnO294DOG8fiVV3oMmOvHKWeU/s320/IMG_7766%20Large.jpeg" width="240" /></a></div><p></p><p>A few drops of loctite to make sure that the camshaft pulley retainer bolt stays put.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgE4M0iHHhbvpXc3TkIfh94EOay8a0CLNWotEWcEC7lJlv5z0AxCs_SBMIFXQVhVusoU0iy2j6eb7zASLuspjK_Quz0ZjcHZJ1P11muZVAwSdy4RvI1OOvl_45GWG_IYzwIX0hatsVa1wOYi0Kb8vah7QDVJ8Fuhx9NJDjGBhu5GLPV3J9IR2XX1XVz6dA/s1280/IMG_7767%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgE4M0iHHhbvpXc3TkIfh94EOay8a0CLNWotEWcEC7lJlv5z0AxCs_SBMIFXQVhVusoU0iy2j6eb7zASLuspjK_Quz0ZjcHZJ1P11muZVAwSdy4RvI1OOvl_45GWG_IYzwIX0hatsVa1wOYi0Kb8vah7QDVJ8Fuhx9NJDjGBhu5GLPV3J9IR2XX1XVz6dA/s320/IMG_7767%20Large.jpeg" width="240" /></a></div><p></p><p>Everything buttoned up.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2xMC_meSc0JGXwe7RMzQkB7FlM-7IGwNWpp76Gr6kYK33rXM3VEH4VzpEWJODKDVYTGFFpxRFCX4uNy0w3GkSsRifkvU3ur5kQUg1jcMW8htfV1NdN71ltW_eBfR8kh0C4x9YaU8zOcZQVjS32Tvn7Ns005w2CzBSR1dAeGbzeNXXlqnhNOGihYddZQA/s1280/IMG_7768%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2xMC_meSc0JGXwe7RMzQkB7FlM-7IGwNWpp76Gr6kYK33rXM3VEH4VzpEWJODKDVYTGFFpxRFCX4uNy0w3GkSsRifkvU3ur5kQUg1jcMW8htfV1NdN71ltW_eBfR8kh0C4x9YaU8zOcZQVjS32Tvn7Ns005w2CzBSR1dAeGbzeNXXlqnhNOGihYddZQA/s320/IMG_7768%20Large.jpeg" width="240" /></a></div><p></p><p>Flushed the radiator one more time<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAkihRRB9D2OZvxN7C-NGZ3gQTtz5jQdfnc1pLdN3Kjxz7eD5fNewZgfb78EE0P9fJ3UPcTln7hBmAkoxLT9sBEhR_A9AbdAsmTb_hUv13VgIAuD44UFYuzEEJ8sV-p3imV23S6-DKsyLPsgrF-F7wqCTvaNfv197b2rTfCGftp0fxYb2eLGQ_UZ118G8/s1280/IMG_7769%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAkihRRB9D2OZvxN7C-NGZ3gQTtz5jQdfnc1pLdN3Kjxz7eD5fNewZgfb78EE0P9fJ3UPcTln7hBmAkoxLT9sBEhR_A9AbdAsmTb_hUv13VgIAuD44UFYuzEEJ8sV-p3imV23S6-DKsyLPsgrF-F7wqCTvaNfv197b2rTfCGftp0fxYb2eLGQ_UZ118G8/s320/IMG_7769%20Large.jpeg" width="240" /></a></div><p></p><p>Installed the whole lot and filled the cooling system via the thermostat housing.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6n3XUdXS5fYiZ9okixaiBdTtuA7Ojw61jYCfXLs43XibwAgXGL_Hs5SUGmv0gPQMGL7AK6-UZtlx8oTdLjHlzyVDrqrMzpz7DT-kpx6ZDysJ7bE0Vn37WtwZOxjI1w14c0Uxvt37MJGXaHBxYEphxDhAmVNqMLansokJn2q88wllLCunPvqgn_xEnQ-w/s1280/IMG_7771%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj6n3XUdXS5fYiZ9okixaiBdTtuA7Ojw61jYCfXLs43XibwAgXGL_Hs5SUGmv0gPQMGL7AK6-UZtlx8oTdLjHlzyVDrqrMzpz7DT-kpx6ZDysJ7bE0Vn37WtwZOxjI1w14c0Uxvt37MJGXaHBxYEphxDhAmVNqMLansokJn2q88wllLCunPvqgn_xEnQ-w/s320/IMG_7771%20Large.jpeg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZnagXCZD8gm-WBTIw82KNG7gOmILtvUfRx-PCY-0Ur8aPPIJivxGBOR8ji0LzYABQdsJ0soyKaQc4QTvq4njccyet0ikkl5z1dzZnaFil6ib1nnq3uc5lA0uYyYNEdAS5i19iFggau3mi3e38vgaNEO6fmlpxamQF1wdAzsjtoGmyz3Lqv4Eljr_5WSg/s1280/IMG_7772%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZnagXCZD8gm-WBTIw82KNG7gOmILtvUfRx-PCY-0Ur8aPPIJivxGBOR8ji0LzYABQdsJ0soyKaQc4QTvq4njccyet0ikkl5z1dzZnaFil6ib1nnq3uc5lA0uYyYNEdAS5i19iFggau3mi3e38vgaNEO6fmlpxamQF1wdAzsjtoGmyz3Lqv4Eljr_5WSg/s320/IMG_7772%20Large.jpeg" width="240" /></a></div><p>
</p><p></p><p>Unfortunately there's no happy end to this story here, to me the timing looks correct (left-side as it was, right side when I was done):<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipE-EF1CJBoeWg3TuN54163TH2BB7v-JVC-JnTAFbvKnMH58JMrNbGglOCaNJoUGCMZ2Jk9aK8dc0FR3Zd9-RbqHeQnN321Fe0xTSIF6qMPFOeHrWLVb4k8mFQggZOHJ3fnZdW2mifkPbTF70t3X0gVDPvBjcko0zz8aYpy4p5Vv6BAlY7rbSebzcKPVQ/s1280/Suzuki%20timing%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="969" data-original-width="1280" height="242" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipE-EF1CJBoeWg3TuN54163TH2BB7v-JVC-JnTAFbvKnMH58JMrNbGglOCaNJoUGCMZ2Jk9aK8dc0FR3Zd9-RbqHeQnN321Fe0xTSIF6qMPFOeHrWLVb4k8mFQggZOHJ3fnZdW2mifkPbTF70t3X0gVDPvBjcko0zz8aYpy4p5Vv6BAlY7rbSebzcKPVQ/s320/Suzuki%20timing%20Large.jpeg" width="320" /></a></div><p> But alas, it makes the most horrible ticking sound imaginable and instantly wants to rev to the moon. Two theories on my side: </p><ol style="text-align: left;"><li>The fan-blades are hitting the shroud (had that on the Lada, because there the metal shroud got bent, when I removed it.</li><li>The spark plugs weren't tightened, because they are too long. (The engine is tuned with an LJ80 head to bump up compression.)</li></ol><p>I somewhat doubt I messed up the timing, so I hope it's the harmless bit with the fan blades and now that the two center plugs are done up correctly it's running like it should and the carb and ignition are completely off. If it's the plugs hitting the valves, well let's hope I haven't broken anything yet. <br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-49720078508421331432024-02-20T20:00:00.002+01:002024-02-20T21:18:57.879+01:00Project Pickle - Rust (part 4)<p>Now, I assume it's a pretty safe bet to say that nobody likes to find rust on his/her/their project car, but I have to admit it was kind of soothing to find it for me. Why? Becaus if it walks like a duck, quacks like a duck, it's most likely just a dog with flippers. Seriously though, it simply seemed too unreasonable to expect no rust, especially given how rust holes were fixed in the past. And dare I say: someone LOVED bondo.</p><p>First step was to remove the front bumper.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMArWCdL4jeVnG6Ls-d-PmKvfESF81MIkKI5e4hcLcKgysHfCEcInfFE9eaZ9PIGV5BK6tqbEJev-8b02JfOk4ad_mSlD8Sf-iRPcyAAuTbkBjsHZa0WX_mjYKY2M5nb8dFwG20CcG9hThFbJ2g0Twwh1ngpfkwCBA9U07l7ezmvssLZZOhD3R-EY9y8g/s1280/IMG_7711%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMArWCdL4jeVnG6Ls-d-PmKvfESF81MIkKI5e4hcLcKgysHfCEcInfFE9eaZ9PIGV5BK6tqbEJev-8b02JfOk4ad_mSlD8Sf-iRPcyAAuTbkBjsHZa0WX_mjYKY2M5nb8dFwG20CcG9hThFbJ2g0Twwh1ngpfkwCBA9U07l7ezmvssLZZOhD3R-EY9y8g/s320/IMG_7711%20Large.jpeg" width="320" /></a></div><p></p><p>And then get the angle grinder with a wire brush out and see why pickle sported completely flat sides atop of the wheel arches. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFollZr_NFwdjmfkbo3Ib3UR2yT_IVH_UKQxPszhXY6g4NPtFAlol3kdyvzsfp4vP29vYELIcD_lJnkyAJ0IHHQFE9E8pfk-7Puge9Bz_biQUlhVEHR6JsDskPS0Q1u3gY0ho8gKJB9iJ7uTIVTc0Rr2O4KH8oq4YbWiKGYsa8S_Vm44DZCpT9vUzGVKM/s1280/IMG_7712%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFollZr_NFwdjmfkbo3Ib3UR2yT_IVH_UKQxPszhXY6g4NPtFAlol3kdyvzsfp4vP29vYELIcD_lJnkyAJ0IHHQFE9E8pfk-7Puge9Bz_biQUlhVEHR6JsDskPS0Q1u3gY0ho8gKJB9iJ7uTIVTc0Rr2O4KH8oq4YbWiKGYsa8S_Vm44DZCpT9vUzGVKM/s320/IMG_7712%20Large.jpeg" width="320" /></a></div><p></p><p>Ah yes, that'll explain the bow in the sill. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7uFr1Vwe4dYwbKM8kQP-z_g22WMOxzmbIC4hNiRya7v9JIQJgvLVUzC2HvrTxCN2PmqaQ0KUinKj_w61iCR-9j1zVwcAixm34E7BKK-EY3rCTs2PEZN2Q69Esf_786JvLhm9HKVvCwpu-rGq2rKOk-u4NI5EPQW_ZTmLOWTOxZAy_H7IbpjmfPcfd8P0/s1280/IMG_7713%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7uFr1Vwe4dYwbKM8kQP-z_g22WMOxzmbIC4hNiRya7v9JIQJgvLVUzC2HvrTxCN2PmqaQ0KUinKj_w61iCR-9j1zVwcAixm34E7BKK-EY3rCTs2PEZN2Q69Esf_786JvLhm9HKVvCwpu-rGq2rKOk-u4NI5EPQW_ZTmLOWTOxZAy_H7IbpjmfPcfd8P0/s320/IMG_7713%20Large.jpeg" width="320" /></a></div><p></p><p>Bit more digging and it's clear - two new front fenders will save A LOT of work. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtFBR4mcF0-wbytfMsfKWkWGrzXnnbJLvW5tYgwjTPNdbZFB1ejmFsjG9NwfZiEJLgYZ9rKHXyhFV4B25zBX5Lswc32M8xG3Fc-SPQMOucVI3FNnYXKOSd_9Ob9pZk9yKRyYpMBGspZmF66bxjAF9C7_GXs9VV6DqCj9EWu8dSmtS4l7Fsamn-vqDjTzM/s1280/IMG_7715%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtFBR4mcF0-wbytfMsfKWkWGrzXnnbJLvW5tYgwjTPNdbZFB1ejmFsjG9NwfZiEJLgYZ9rKHXyhFV4B25zBX5Lswc32M8xG3Fc-SPQMOucVI3FNnYXKOSd_9Ob9pZk9yKRyYpMBGspZmF66bxjAF9C7_GXs9VV6DqCj9EWu8dSmtS4l7Fsamn-vqDjTzM/s320/IMG_7715%20Large.jpeg" width="320" /></a></div><p></p><p>Did I mention that someone that someone loved bondo? Seriously the section under the fuel filler cap is a healthy 13mm (1/2") thick and the bead has been completely plastered over.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBip2TKNzxE-HLQBXHWXuIYvf2g8rtcncIvaBuHArq59tnIkTvMOMYHGfsMKee7WApia6L61PV8Nk6eByItHE4pWotlSj60AKSOYr2G9jNokulha6c83mdb9kF5nIE2f0VvaMJJahO0PVyPv2e3qG3Brf-eA6nzcwa3LHcmmM4OQKH14sxwvIdiWaZFRM/s1280/IMG_7717%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhBip2TKNzxE-HLQBXHWXuIYvf2g8rtcncIvaBuHArq59tnIkTvMOMYHGfsMKee7WApia6L61PV8Nk6eByItHE4pWotlSj60AKSOYr2G9jNokulha6c83mdb9kF5nIE2f0VvaMJJahO0PVyPv2e3qG3Brf-eA6nzcwa3LHcmmM4OQKH14sxwvIdiWaZFRM/s320/IMG_7717%20Large.jpeg" width="240" /></a></div><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9yq1QBiHf3o6QZ4Lfd6kEvpGNR7Tg1-lYdUI4eEX_eWsVBbNmhj3Q-MrIfRvefkwR0re8m7cvCltLt8g64s0kg1M8mFAdYp3hD7k2fwMOWW0a9wy4m9pKBKJ9QcmhyfhtipVPqZHgfN2tJA-RYhRR3tlJw2JinscPZlV6xK7Gjarp7a-U8qPF9-_EsTM/s1280/IMG_7726%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9yq1QBiHf3o6QZ4Lfd6kEvpGNR7Tg1-lYdUI4eEX_eWsVBbNmhj3Q-MrIfRvefkwR0re8m7cvCltLt8g64s0kg1M8mFAdYp3hD7k2fwMOWW0a9wy4m9pKBKJ9QcmhyfhtipVPqZHgfN2tJA-RYhRR3tlJw2JinscPZlV6xK7Gjarp7a-U8qPF9-_EsTM/s320/IMG_7726%20Large.jpeg" width="240" /></a></div> <p></p><p>As I had already arrived at the back of the little car, it seemed rude not to take the rear bumper off - all 4 bolts holding it to the floorpan snapped and the center bolt had a stripped nut, so here's a bit of work for future me. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVqtOHp0Q9O7quzvmgZGxZEF4NmgBHhjT_W2P-DjqPBeA_xDGVUPHqU6W7jVMu1EtHI9bnKM8ID5dWw4pNsQbMUmcd0wIhU4tn7MWAgtULaIJi3mfLkTkGiyrqGKe4k4CHVA82klvLwlTdyuDSEAh2ARpuW702NS6N89Wz5Y5wrOl9MiBAIwRlSf4oTHc/s1280/IMG_7718%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVqtOHp0Q9O7quzvmgZGxZEF4NmgBHhjT_W2P-DjqPBeA_xDGVUPHqU6W7jVMu1EtHI9bnKM8ID5dWw4pNsQbMUmcd0wIhU4tn7MWAgtULaIJi3mfLkTkGiyrqGKe4k4CHVA82klvLwlTdyuDSEAh2ARpuW702NS6N89Wz5Y5wrOl9MiBAIwRlSf4oTHc/s320/IMG_7718%20Large.jpeg" width="320" /></a></div><p>As the rear body corners were both fine, I went ahead removed the grill, which unlike the fenders had next to no rust at all. (Which sort of makes me wonder, if this one might have been swapped at some point in time.) Admittedly I feel a bit of a Series Landy vibe going on and I am almost sure one could fabricate a front to match... Also as the next thing (even prior to doing the rust repairs) is to do a full service on the engine: timing belt, thermostat, swap the radiator, reseal the manifold, tackle some oil leaks, you get the idea, having no grill in the way makes it even easier to do those jobs. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrw_d-0CW_Mxdn6fI5XbYFdQGI6joM6y3D-EF7DaxtRdXKcAYj9fHK7oBCnfabrKClR3fag3nkMs4UHLUeVxiYosK3leLU5kU2l1C5OMRiuOoG_wNjrQeZrF073WozJH9QG_u7FNurSmMsRvb9NoJPY6b2hB1v2qPvtaMQZcqpVdYUr0COUGRCanlSLB0/s1280/IMG_7720%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrw_d-0CW_Mxdn6fI5XbYFdQGI6joM6y3D-EF7DaxtRdXKcAYj9fHK7oBCnfabrKClR3fag3nkMs4UHLUeVxiYosK3leLU5kU2l1C5OMRiuOoG_wNjrQeZrF073WozJH9QG_u7FNurSmMsRvb9NoJPY6b2hB1v2qPvtaMQZcqpVdYUr0COUGRCanlSLB0/s320/IMG_7720%20Large.jpeg" width="320" /></a></div><p></p><p>With the front tackled as far as I can take it at this point (as I want to drive the little truck over to the other workshop and not have to push it all the way), I turned my attention back to the rear. Usually the cover for the filler neck is bolted on, here it was welded to the floor plate with an ungodly ugly patch panel, which to put it mildly didn't inspire the level of confidence I was aiming for and guess what: mouse poop and rust. Especially seeing how the last person did the inner wheel arches made it very easy to come to the conclusion to do a slightly better job at this end myself. </p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhb9qUcdg0o0cK7oHLzl7o7A6PS-oZgxll91QSkPAczo75G15UqHLMKktz6NNkhMJsJIRlQ5U8WnNy5Tjq6DcJIyo21r6FoNtHnO9Ng2Tb-7TQL626tjvLx6t0dAZT_u9OaLz878ZdfMaARDPH08lVDH5YOxj4wvfnfX_D9cTc_9aUPWEn2SbW3zETrkfQ/s1280/IMG_7721%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhb9qUcdg0o0cK7oHLzl7o7A6PS-oZgxll91QSkPAczo75G15UqHLMKktz6NNkhMJsJIRlQ5U8WnNy5Tjq6DcJIyo21r6FoNtHnO9Ng2Tb-7TQL626tjvLx6t0dAZT_u9OaLz878ZdfMaARDPH08lVDH5YOxj4wvfnfX_D9cTc_9aUPWEn2SbW3zETrkfQ/s320/IMG_7721%20Large.jpeg" width="240" /></a></div><br /> This left the tailgate as a last piece to undergo a more thorough inspection and to no one's surprise, there's a few spots both inside and outside, where the skin had and thus leaked inside and outside. Or in other words, the rear window has to come out as well and a bit of reconstructive metal surgery needs to be done.<p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjimtMB8sEKw2O1aiM4fX31vrP4Bdfj3yhwrw8Q06hz-diDUTJcRUjy3LCo46cGfHLum5HUxd99xF6WBp3tcZ2uxaeQ8xV_xnYqPMxH31zGH_GQ4d379yY8gDGCp041bYIiukNQIc1n-W9lKx8A7S3g0hS4iuqPbnlH_umKnajekbqj6dfTX86EZSE2LRw/s1280/IMG_7723%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjimtMB8sEKw2O1aiM4fX31vrP4Bdfj3yhwrw8Q06hz-diDUTJcRUjy3LCo46cGfHLum5HUxd99xF6WBp3tcZ2uxaeQ8xV_xnYqPMxH31zGH_GQ4d379yY8gDGCp041bYIiukNQIc1n-W9lKx8A7S3g0hS4iuqPbnlH_umKnajekbqj6dfTX86EZSE2LRw/s320/IMG_7723%20Large.jpeg" width="320" /></a></div><p></p><p>And with that the little Suzuki was placed inside the other workshop and rust repairs should start very, very quickly. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7e1CjEAD08-JRG5vfoUv6P4H1dBaD8sprYWacJw6cQ7Nc6Bqosgas7AVYDhchyphenhyphen02U0_69qDNA8t6X-U55ya4q349vLSgl7d74e9ZNFq-SwLgL8IVV_Q30cUj94js73MI2-tJYJCEybAa6iCucpnyNuWrk7TE8nEvmAERGGuJf_U7de4Fidnfpy11q4Lg/s1280/IMG_7728%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7e1CjEAD08-JRG5vfoUv6P4H1dBaD8sprYWacJw6cQ7Nc6Bqosgas7AVYDhchyphenhyphen02U0_69qDNA8t6X-U55ya4q349vLSgl7d74e9ZNFq-SwLgL8IVV_Q30cUj94js73MI2-tJYJCEybAa6iCucpnyNuWrk7TE8nEvmAERGGuJf_U7de4Fidnfpy11q4Lg/s320/IMG_7728%20Large.jpeg" width="240" /></a></div><br /><p>One thing I plan to do differently than how I did it on the Lada is to break the work down into smaller subassemblies, for example I will fix the new bonnet in my workshop and then transfer it to the car, same goes for the tailgate. I am still a bit on the fence on how to do the sills as a lot of guys seem to swap them for thick-wall box section, which is very, very pragmatic, but I am not sure what my MOT guy would have to say about that. If I go down that route it's <b>*just*</b> the floorpans, inner and outer wheel arches and a repaint, before I can get back to reassembly. Sounds overly optimistic? Yep, totally. </p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-43584521514272148882024-02-19T20:00:00.002+01:002024-02-20T21:19:13.707+01:00Project Pickle - Get shafted (part 3)<p>Shaft drives are awesome until the universal joints need doing. Then its a bit of work and once fixed, they are awesome again. The very last UJ next to the rear diff was really, really f*cked.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEji7x7pMCMbbVoa-Cx2YR8J6J-IWBLxC-JQkxrZSlGi35zoFjduTWFJyAyQhFKzPdFCe2ojMViw_kvq5PHFP41NwYxwKI6Jsy3pJuLs21Tk5yJ2dQRLD3bYMXwn3PhG1m6QpZkTvuRA7fxktzKClGbBjTKn5yjJTWrPnnXVqUqSDde1XeQ4I2rs5_86NPc/s1280/IMG_7643%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEji7x7pMCMbbVoa-Cx2YR8J6J-IWBLxC-JQkxrZSlGi35zoFjduTWFJyAyQhFKzPdFCe2ojMViw_kvq5PHFP41NwYxwKI6Jsy3pJuLs21Tk5yJ2dQRLD3bYMXwn3PhG1m6QpZkTvuRA7fxktzKClGbBjTKn5yjJTWrPnnXVqUqSDde1XeQ4I2rs5_86NPc/s320/IMG_7643%20Large.jpeg" width="320" /></a></div><p></p><p>The stock M8 nuts are 12mm size, which means a deep-wall socket fits nicely over the UJ. It doesn't work when someone lost them or rounded them off and swapped them for 13mm (DIN standard size) nuts.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNAfokM9NFy-gsqmpASaQabAItCeWOSfaJOZ1axra-gBilrJ5kCClezReIJ7V006OqIOgX6ZB3S5fwJ_9jAxfC5McMYV3i_gJ_I6HUPtE7kL0pi7APGXjuQnGuDVgCmLzMrm5UwFqrUC98-7XLMitSoSQwTUF0sgK3bIZQXO-hVGqBPdW-3d1DIWWyoL0/s1280/IMG_7644%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNAfokM9NFy-gsqmpASaQabAItCeWOSfaJOZ1axra-gBilrJ5kCClezReIJ7V006OqIOgX6ZB3S5fwJ_9jAxfC5McMYV3i_gJ_I6HUPtE7kL0pi7APGXjuQnGuDVgCmLzMrm5UwFqrUC98-7XLMitSoSQwTUF0sgK3bIZQXO-hVGqBPdW-3d1DIWWyoL0/s320/IMG_7644%20Large.jpeg" width="240" /></a></div><p></p><p>Aside from that - easy peasy. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhulHxwYMQAa5s64jzbF0-ALIixP7OGhcCvkLWKN-71txLySpxQACDys8TRtifZNwBD3M4_vMcuh1kuZ1XAWHCbRlP-aErOsCOtezQ6OUWPp2ufJuFmUxT4U0Lu99R7BfVq6INdlj9q5pTURUq6L-x59Rkp0dZD3o7749ucDqfOqx3WZ2agok5n7uZ2nhk/s1280/IMG_7645%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhulHxwYMQAa5s64jzbF0-ALIixP7OGhcCvkLWKN-71txLySpxQACDys8TRtifZNwBD3M4_vMcuh1kuZ1XAWHCbRlP-aErOsCOtezQ6OUWPp2ufJuFmUxT4U0Lu99R7BfVq6INdlj9q5pTURUq6L-x59Rkp0dZD3o7749ucDqfOqx3WZ2agok5n7uZ2nhk/s320/IMG_7645%20Large.jpeg" width="240" /></a></div><p></p><p>Quick witness mark to make sure it goes back in the same orientation. (spoiler alert, you can't reassemble those 180 degrees out, so as long as the the UJs are in the same plane you've assembled the shaft correctly!)</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK_C3bL7EEOkPWxKpdtwTgQSRB74ADuaB-p9LTdZxH2lAB5TE9CKvLhbvaRYC5m4ROIeUJSbCgdPhx8yQLQ_dRLE1ibsu9qGJvhW7v23yBN6WWwCwSRsuvPjktMFteWs_vdqLSPngbwptAXyb68Vos8W4Edv6BpNlfEPALRaJqFkOSamY-MT7DbDMvRAQ/s1280/IMG_7647%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK_C3bL7EEOkPWxKpdtwTgQSRB74ADuaB-p9LTdZxH2lAB5TE9CKvLhbvaRYC5m4ROIeUJSbCgdPhx8yQLQ_dRLE1ibsu9qGJvhW7v23yBN6WWwCwSRsuvPjktMFteWs_vdqLSPngbwptAXyb68Vos8W4Edv6BpNlfEPALRaJqFkOSamY-MT7DbDMvRAQ/s320/IMG_7647%20Large.jpeg" width="240" /></a></div><p></p><p>Generally there's two types of UJs: the ones with clips on the outside and on the inside. The latter is normally found on LARGE trucks. (With UJ-sizes to match.) Disassembly works the same either way: There's a retaining clip that prevents the caps from falling out and keeps everything in place.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR-93r4mlnJm7c5bO-QV0q5qmaFHdxblPqd7VkyWUjjJEEK6vzqNJaieh1tPZUf3XY7Dof77UueEtilZfAhCzj7rcsnxGdaN5O0_ozQKn9-rrbdU4R_Zenc-dclK4BXthoxWiamEJM-XI41gjm_Fd3LjbPHuzh0QAED5cvEh56-8moM8ghoXa_OcWjPhY/s1280/IMG_7648%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR-93r4mlnJm7c5bO-QV0q5qmaFHdxblPqd7VkyWUjjJEEK6vzqNJaieh1tPZUf3XY7Dof77UueEtilZfAhCzj7rcsnxGdaN5O0_ozQKn9-rrbdU4R_Zenc-dclK4BXthoxWiamEJM-XI41gjm_Fd3LjbPHuzh0QAED5cvEh56-8moM8ghoXa_OcWjPhY/s320/IMG_7648%20Large.jpeg" width="240" /></a></div><p></p><p>To say that this UJ was completely dead is a bit of a mild understatement.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvPspG3rdNsEB5-oIJBiQznUJJATC8AxRogbTYuE2ZtNQ8X9a5JzhGat4vUZF7y7CRQSE-jKRUjRxnKCqcdOea3bzntSl-3AlBU3ie8EDZbCbnctSou3opIbUV09edeaLQRwokwsgIQ6zY3sBSErPSwRgEkqkKge8LvJl1ZXLUCTydIrvXPCq_oHm3Tp4/s1280/IMG_7649%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvPspG3rdNsEB5-oIJBiQznUJJATC8AxRogbTYuE2ZtNQ8X9a5JzhGat4vUZF7y7CRQSE-jKRUjRxnKCqcdOea3bzntSl-3AlBU3ie8EDZbCbnctSou3opIbUV09edeaLQRwokwsgIQ6zY3sBSErPSwRgEkqkKge8LvJl1ZXLUCTydIrvXPCq_oHm3Tp4/s320/IMG_7649%20Large.jpeg" width="320" /></a></div><p></p><p>And neither lube/grease nor a single needle inside those two worn bearing cups. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJqbhZ6R4Qs6r1UAlt7gDl7ZNTmLQJR4KRDLHLU62IKHMx7R5lhu4rZj5FRN-PoOyrXDttUpHVMjzzRWPrOMPUzmnDtKq71-ciS9EocYJ40Df2ZNlHLkpzrDPbEb95gdJHmqAV1P5KDrIlXXbopYL9oY5dNZIOaQvKtm2REz-bHKjsCV7tFA6wSWB-HlU/s1280/IMG_7650%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJqbhZ6R4Qs6r1UAlt7gDl7ZNTmLQJR4KRDLHLU62IKHMx7R5lhu4rZj5FRN-PoOyrXDttUpHVMjzzRWPrOMPUzmnDtKq71-ciS9EocYJ40Df2ZNlHLkpzrDPbEb95gdJHmqAV1P5KDrIlXXbopYL9oY5dNZIOaQvKtm2REz-bHKjsCV7tFA6wSWB-HlU/s320/IMG_7650%20Large.jpeg" width="320" /></a></div><p></p><p>Easiest way to install new cups is to press them in on the vice, install one of the clips and then preload everything either in a press or the vice<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_3AhSOWEi0FlsElZtUg2j5wn-x_XfFYpZB9mpWBe6fCjbkzwZTNIi7hJwuiDdkPPCeWGj6bB4b1yNzEY163zYMhoPcp5UwaCsndCcDJMBgq_gmYuL6v_dXMSvtuQYX-RkjkcXfYT0KAkVY1w301i8Od2zIgfVx8f8UTvvj52o4l4GBToH1hKMHDyfjMk/s1280/IMG_7651%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_3AhSOWEi0FlsElZtUg2j5wn-x_XfFYpZB9mpWBe6fCjbkzwZTNIi7hJwuiDdkPPCeWGj6bB4b1yNzEY163zYMhoPcp5UwaCsndCcDJMBgq_gmYuL6v_dXMSvtuQYX-RkjkcXfYT0KAkVY1w301i8Od2zIgfVx8f8UTvvj52o4l4GBToH1hKMHDyfjMk/s320/IMG_7651%20Large.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcy80mpcwr96dpzOunP05sSD5MMlPcWzlSIUrjxMcPJVVh8qKHZk2GPAlcVPLGrumCcohgc7ibibyewUsvYxFPYzOKSgEy5jkDQz2xlFUhyphenhyphenlfe2bQEEqDhzhv54gTFH1H4XVfNTqAuGhzcxLye96w97UcMVGCB98YvMwX5ndDkQwF4YACiSeVJxgyPujs/s1280/IMG_7656%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcy80mpcwr96dpzOunP05sSD5MMlPcWzlSIUrjxMcPJVVh8qKHZk2GPAlcVPLGrumCcohgc7ibibyewUsvYxFPYzOKSgEy5jkDQz2xlFUhyphenhyphenlfe2bQEEqDhzhv54gTFH1H4XVfNTqAuGhzcxLye96w97UcMVGCB98YvMwX5ndDkQwF4YACiSeVJxgyPujs/s320/IMG_7656%20Large.jpeg" width="240" /></a></div><p>Would have been rude not to get the version with the grease nipples, right?</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMdZN4i7MG7eo3JmDMGy1x8p37l2XiBXQfQyvxSNCDKN-hezHJ-uqlTLluiEqY7BtkhsrrdFXnPnrDUuspsUJsHqRRNa4_makRL2IWfjUQ1v5V7B_Aas8uhSq8scn8dyfI4_52iuu1I2gZbVIwtxqTnjauH9Z9fNsWUrWdMy0L15coUT0utio0yM0Izto/s1280/IMG_7657%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMdZN4i7MG7eo3JmDMGy1x8p37l2XiBXQfQyvxSNCDKN-hezHJ-uqlTLluiEqY7BtkhsrrdFXnPnrDUuspsUJsHqRRNa4_makRL2IWfjUQ1v5V7B_Aas8uhSq8scn8dyfI4_52iuu1I2gZbVIwtxqTnjauH9Z9fNsWUrWdMy0L15coUT0utio0yM0Izto/s320/IMG_7657%20Large.jpeg" width="320" /></a></div><p></p><p>... and even more rude, if one were not put them to good use.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkxw_wYAFAjdYjqSggHUhqy0VJ-gqWLMxqvF9asaEzvEPtqhdXvImyY76ylq4SpA3E56zfraMobfFDChhN7UScZM2OtpDtmT9omZGLZVay9hyphenhyphenZiI7xIjHP_yEyqKq60KetsfUB1sVQB-Y5g7awMb7xBKHX6H1JX1zXu7sPKCaUyvYbegv6xWYDaUTFYes/s1280/IMG_7658%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgkxw_wYAFAjdYjqSggHUhqy0VJ-gqWLMxqvF9asaEzvEPtqhdXvImyY76ylq4SpA3E56zfraMobfFDChhN7UScZM2OtpDtmT9omZGLZVay9hyphenhyphenZiI7xIjHP_yEyqKq60KetsfUB1sVQB-Y5g7awMb7xBKHX6H1JX1zXu7sPKCaUyvYbegv6xWYDaUTFYes/s320/IMG_7658%20Large.jpeg" width="320" /></a></div><p></p><p>Fun fact: the mounts of the transfer case are so worn out, that you can push it towards the front by greasing up the splined section of the shaft. 😅<br /></p><p><br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-60273300906525226432024-02-18T20:00:00.001+01:002024-02-18T20:00:00.125+01:00Dre-XT-Stück - sidestand<p>I have to admit, that lately it seemed as if the old girl had a bit more of a "sporty" lean to her and knowing fair well that those sidestands are known to bend (and eventually break) I thought a bit of bending it back and maybe bracing it was all it would take. But the sidestand's not the main culprit. </p><p> With the old girl leaned onto the little pickle...</p><p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyEl2ZY84c0UJRgV4UaPNjvajZ7mgig9HgSvAX51_2CN3YrVSE-kwo7YavsR_Q7OsjI7I4rhMrSj1XkWj8fpwXeDGbDuc67J93BcrUye_d6GzhQJZdovAfECmdQKG-_6i6XM5WZmVUG2fbsVVGte3MAgWJfyJdfHd7uQOHGplxJ_mWu3s9QQYPFfHdIHQ/s1280/IMG_7605%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyEl2ZY84c0UJRgV4UaPNjvajZ7mgig9HgSvAX51_2CN3YrVSE-kwo7YavsR_Q7OsjI7I4rhMrSj1XkWj8fpwXeDGbDuc67J93BcrUye_d6GzhQJZdovAfECmdQKG-_6i6XM5WZmVUG2fbsVVGte3MAgWJfyJdfHd7uQOHGplxJ_mWu3s9QQYPFfHdIHQ/s320/IMG_7605%20Large.jpeg" width="240" /></a></div><br /><p></p><p>I wanted to unbolt the sidestand, which was substantially easier than planned. </p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4r5tucbVmDXT6vkAuTe55cZ-uSWsYiatu9gOSYv5oAcJvOAri87NXme_ILpKUT3v7NeFWLzhPiKcgXfGMDrYmVt5DLBrewCJdkxxonSYvstIqMsjVmpHV8qQchyBlH-4ltfy-J6QeKc7CKq06CXy91J4xq68L3hReXKnvwaebydtAxk6d07NKoE_pbL4/s1280/IMG_7599%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4r5tucbVmDXT6vkAuTe55cZ-uSWsYiatu9gOSYv5oAcJvOAri87NXme_ILpKUT3v7NeFWLzhPiKcgXfGMDrYmVt5DLBrewCJdkxxonSYvstIqMsjVmpHV8qQchyBlH-4ltfy-J6QeKc7CKq06CXy91J4xq68L3hReXKnvwaebydtAxk6d07NKoE_pbL4/s320/IMG_7599%20Large.jpeg" width="240" /></a></div><p></p><p>So the assumption that something had given in, wasn't fundamentally wrong, it was just that it was the clevis that had bent because the pivot bolt snapped. The shank is 12mm and there was a sufficiently long M12-bolt in stock.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8p4wkkmuKpdmZgQwi2HMgPgJsq7Q-S9juafCXRPL9FYR-RVV_w3RoZkdL9Nlno74_J1CMCYDSQnuqbw2WwRvNT76X81IRFRz_6epQkSqtAuLzDFFbaAqbC-JWxRfUMiUC5cp5n95ulCU99PemLhgv5bVvj7bxkesfmYil6vdcXFzOC39ju5ooPMz46oI/s1280/IMG_7601%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8p4wkkmuKpdmZgQwi2HMgPgJsq7Q-S9juafCXRPL9FYR-RVV_w3RoZkdL9Nlno74_J1CMCYDSQnuqbw2WwRvNT76X81IRFRz_6epQkSqtAuLzDFFbaAqbC-JWxRfUMiUC5cp5n95ulCU99PemLhgv5bVvj7bxkesfmYil6vdcXFzOC39ju5ooPMz46oI/s320/IMG_7601%20Large.jpeg" width="240" /></a></div><p></p><p>These bolts are widely available (even new from Yamaha), but should you find yourself in a pickle and have to machine one yourself and maybe lost some of the fragments, these are measurements mine had.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1GCC8MAex_rjhKdelJzUDr1I5E0Oa-Yg-z_Q8d3h4uRZZ6GIzyoJviDklX_h3n7Nz_Bm8qLcL5yHLyeDXGHULMhzc30XhcPXQg1Lhg32IyxSf-la6i5xNSFg211S5xoDR26ftrP6i-8NLX9OEgIZYtJcCZet_jShdp3TuV_QuZD5UAx0So2WiQfx27No/s1280/IMG_7602%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1GCC8MAex_rjhKdelJzUDr1I5E0Oa-Yg-z_Q8d3h4uRZZ6GIzyoJviDklX_h3n7Nz_Bm8qLcL5yHLyeDXGHULMhzc30XhcPXQg1Lhg32IyxSf-la6i5xNSFg211S5xoDR26ftrP6i-8NLX9OEgIZYtJcCZet_jShdp3TuV_QuZD5UAx0So2WiQfx27No/s320/IMG_7602%20Large.jpeg" width="240" /></a></div><p></p><p>Depending on how worn the hole in your frame is, the 12.0mm might range from <b>T-I-G-H-T</b> to rather sloppy. I repaired that one, when painting the frame, so I had to take a bit off as things got very sticky.</p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-9562785684378905082024-02-17T20:00:00.005+01:002024-02-17T20:00:00.125+01:00SR500 - lights out<p>
Very sneakily the SR500 sidecar has made its way towards becoming a veritable
and reliable daily. Until about two weeks ago, when very suddenly the
headlight started to fail, which together with admittedly rather improved
weather conditions meant that the old Dre-XT-Stück was pressed back into
service.
</p>
<p>
After a bit of wiggling, especially on the blue cable coming down from the
right hand side switch cluster, the light worked again. <br />
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfmNLFflXaHpv_yuVEbrcJi9f5Jm9bMd12deTr9rg4ArNLLG47cmdJ-sZiSly7umbrIuUT4wQnuMc7QQ1NOfBgTAPWi9dU4BP_Ph63jXDyNY-0MqrPyTzO2vFN9ziFBjuSoJpRbqKKjAkp2F1QES654Ul-0FZYMplBRH5X-9bflJnMGNmu5xgoSoOKaE0/s1280/IMG_7673%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfmNLFflXaHpv_yuVEbrcJi9f5Jm9bMd12deTr9rg4ArNLLG47cmdJ-sZiSly7umbrIuUT4wQnuMc7QQ1NOfBgTAPWi9dU4BP_Ph63jXDyNY-0MqrPyTzO2vFN9ziFBjuSoJpRbqKKjAkp2F1QES654Ul-0FZYMplBRH5X-9bflJnMGNmu5xgoSoOKaE0/s320/IMG_7673%20Large.jpeg" width="240" /></a>
</div><p>
</p><p>A slight bit of
pulling then made everything fall apart permanently.
</p><div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEiMs49QjzmtODIUNnNVmRkGq7m627GGVPKtWT9YSy6kNMZ9aljJyAOLi97Jnh8gGMiJd9dkhdMoUhvSdQE-JraNmlqhYqdND9fhyphenhyphentX-HPYn5I_8p-E96GwE0JZ4Jlo9LkRXYWHBg_4TbbAUR4PgfygAqomGz8CUo6jucG_qwBa2LJEEeelqxmtrF21ao/s1280/IMG_7676%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEiMs49QjzmtODIUNnNVmRkGq7m627GGVPKtWT9YSy6kNMZ9aljJyAOLi97Jnh8gGMiJd9dkhdMoUhvSdQE-JraNmlqhYqdND9fhyphenhyphentX-HPYn5I_8p-E96GwE0JZ4Jlo9LkRXYWHBg_4TbbAUR4PgfygAqomGz8CUo6jucG_qwBa2LJEEeelqxmtrF21ao/s320/IMG_7676%20Large.jpeg" width="240" /></a>
</div><p>
</p><p>Luckily after some rummaging in my parts stash I found an even more knackered right handlebar switch from a XV750SE and borrowed a new plug. (Yes I know, you can buy those plugs from Kedo, they don't actually cost a fortune... but I wanted to fix it now.)</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwvnurIxJFQuI5nZwU6tioeSWAEUMdzpwvAx7np8RxXWBdKO1dHSgn2YSEubUUSFPLkTW8VOuytMKptraaLW0XNSeQe0MuXSM1bmRovxFUavgd8ciJwRjZGwR0R1RzgIk2GaXOOYqoC26yQCBlSbhJipgZIGs-rxR7_80DjDemFVCrwiinmUD-9wT_yBo/s1280/IMG_7677%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwvnurIxJFQuI5nZwU6tioeSWAEUMdzpwvAx7np8RxXWBdKO1dHSgn2YSEubUUSFPLkTW8VOuytMKptraaLW0XNSeQe0MuXSM1bmRovxFUavgd8ciJwRjZGwR0R1RzgIk2GaXOOYqoC26yQCBlSbhJipgZIGs-rxR7_80DjDemFVCrwiinmUD-9wT_yBo/s320/IMG_7677%20Large.jpeg" width="320" /></a></div><p></p>
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSWE_tpbgwor1HnW0ZPwAdmyJip9ur157wmIQFR5LPVv2baRct8Xtxdhobl2g54d2gL2TwynsFD6qwNb3naL4SB4s0QEI8WyOM_fY-OesLc-q7L3PJR6JACMP7x_NiVoQdfCNA3HDkP9iwMieP9igrK_da72ZZSof_pdEyTDHkR1VWeGNSWnkApHc9Bek/s1280/IMG_7678%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSWE_tpbgwor1HnW0ZPwAdmyJip9ur157wmIQFR5LPVv2baRct8Xtxdhobl2g54d2gL2TwynsFD6qwNb3naL4SB4s0QEI8WyOM_fY-OesLc-q7L3PJR6JACMP7x_NiVoQdfCNA3HDkP9iwMieP9igrK_da72ZZSof_pdEyTDHkR1VWeGNSWnkApHc9Bek/s320/IMG_7678%20Large.jpeg" width="240" /></a></div><p></p><p>Whilst I was at it, it was really about time to reposition the front right pin holding down the sidecar cover as over the last two years the cover had stretched quite a bit. As is indicated by the fact that this is now the third time to reposition the pin. (I should really patch up the old holes...)</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiYRh5XcyFo7qsMjjQj6vFT9w3tMRP4dFej_OGHK0rD2nGBVfCgJGyZ19Rvj7uHI9lhkQipQY4JIplYy9n2JZaYFM1IsAMWECLLO6lsK58p600zebweadO3Vq52yvwH_QA7uadRXoqzdCmE7YthTaQGHX4-AqXSXP5CjnZyoKzqFEYANpMILPTI7My6yQ/s1280/IMG_7680%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhiYRh5XcyFo7qsMjjQj6vFT9w3tMRP4dFej_OGHK0rD2nGBVfCgJGyZ19Rvj7uHI9lhkQipQY4JIplYy9n2JZaYFM1IsAMWECLLO6lsK58p600zebweadO3Vq52yvwH_QA7uadRXoqzdCmE7YthTaQGHX4-AqXSXP5CjnZyoKzqFEYANpMILPTI7My6yQ/s320/IMG_7680%20Large.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgy3IsPjGw8nTU7ve2_8TcXA97Oc51Z4jNSYzj4UHQ9zpxT8hkAZI53Z-mdPYDJ4Z6yObK6Y4fL2-kMGzC9s-0ykpk2zSa-RNpToesfuaDjzFvRHJXvublBuxrxjneYrAkxuEg6CgVhQIvm1m3c6UXAyq3js1TMYXKv5m54UH_eJEgRPktyHzoJoY2rRU0/s1280/IMG_7681%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgy3IsPjGw8nTU7ve2_8TcXA97Oc51Z4jNSYzj4UHQ9zpxT8hkAZI53Z-mdPYDJ4Z6yObK6Y4fL2-kMGzC9s-0ykpk2zSa-RNpToesfuaDjzFvRHJXvublBuxrxjneYrAkxuEg6CgVhQIvm1m3c6UXAyq3js1TMYXKv5m54UH_eJEgRPktyHzoJoY2rRU0/s320/IMG_7681%20Large.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5dWNACSAN4Gx_oq_5td7Vxv3yvadzuQA2c99sI3PIrTUxOiqn2jogb4ihW-2dZcFbk5WcznBEi_oiVPaIl5_u8f8HaJ-iC15uGWwfabT8g1RdL-gwC38CjdHNjzeChlwXL1VhyphenhyphenR-YV2-OHclSRLze4dvD-4jCc-kE9jV6jeeC_t_9-CjxZv_cleV8Ag8/s1280/IMG_7682%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg5dWNACSAN4Gx_oq_5td7Vxv3yvadzuQA2c99sI3PIrTUxOiqn2jogb4ihW-2dZcFbk5WcznBEi_oiVPaIl5_u8f8HaJ-iC15uGWwfabT8g1RdL-gwC38CjdHNjzeChlwXL1VhyphenhyphenR-YV2-OHclSRLze4dvD-4jCc-kE9jV6jeeC_t_9-CjxZv_cleV8Ag8/s320/IMG_7682%20Large.jpeg" width="320" /></a></div><p></p><p>And last but not least - the turn signal indicator - the bulb had simply burnt out. Now it works - doesn't work - works - doesn't work - works ... 😉</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUCDvv4YNjN8FvcnZ4zuNQ0FB-CEiOiNGsfCDSI9hyC0WtTK8qhyh1QKzkMOdQK5_k5oVX9rKF8bxgay6lq3tWKWqSe_gnOt1BWFYU8dch8xZ0CupzN_XmyfCvpwPWNFkNLcaZryF5-lLcauEqO1whQpoR1vWcSSlBkN4mgJsLhkg4ifQjt1KwLbwWFyY/s1280/IMG_7684%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUCDvv4YNjN8FvcnZ4zuNQ0FB-CEiOiNGsfCDSI9hyC0WtTK8qhyh1QKzkMOdQK5_k5oVX9rKF8bxgay6lq3tWKWqSe_gnOt1BWFYU8dch8xZ0CupzN_XmyfCvpwPWNFkNLcaZryF5-lLcauEqO1whQpoR1vWcSSlBkN4mgJsLhkg4ifQjt1KwLbwWFyY/s320/IMG_7684%20Large.jpeg" width="240" /></a></div><p>So next in the cards is a proper big 30k service with oil-change and adjusting the valves and then we're probably even ready for the upcoming MOT. <br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-59411895060465455392024-02-10T20:00:00.001+01:002024-02-10T23:04:25.323+01:00Project Pickle - brakes (part 2)<p>
So the little pickle runs and not too bad actually, but out of four brakes,
only one somewhat worked. And as at least two wheels were stuck, which meant
moving it around in the yard would be no fun at all this instantly increased
the priority to deal with the brakes.
</p>
<p>
As the little pickle is already a late 1983 model, it came standard with disks
at the front, which are absolutely no big deal at all, as the very same brakes
are installed at least up to the penultimate generation of the Jimny, so all I
had to do was get a pair of new calipers, pads, disks and rubber lines. The
drums on the rear are a bit of a different story.
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEFJ4pqQox2fX2G0b47Hr1Il_o1KQduuYMf0v7bO9nWPrtcTj8XsmCfSiee1zPIN6P3HODUBT_G9jkgFbSKe8mjzhLFG-BbO7f4Z8NB2Htm7QN65lhjE4IIDFE5En-XkvZm0EkixKUqNHl-0k-9mfmmH9daGuTgpSNscomavTikqA54-K0JPKMFmxl-vQ/s1280/IMG_7420%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiEFJ4pqQox2fX2G0b47Hr1Il_o1KQduuYMf0v7bO9nWPrtcTj8XsmCfSiee1zPIN6P3HODUBT_G9jkgFbSKe8mjzhLFG-BbO7f4Z8NB2Htm7QN65lhjE4IIDFE5En-XkvZm0EkixKUqNHl-0k-9mfmmH9daGuTgpSNscomavTikqA54-K0JPKMFmxl-vQ/s320/IMG_7420%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
As the two M8 nuts reveal, it is the very first version with manual adjustment
of the brake shoes and 56mm brake cylinders. Luckily this is the same version
as can still be found in the Indian Army Maruti Gypsy (not the Gypsy KING as
that's 1.3L or SJ413 based). Regardless of which, in order to get the drums
off, unlike on the Lada, a puller has to be fabricated, which pushes against
the axle. (And no the althread is not bent, but that was due to some weird
lens angle / lens distortion.)<br />
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXHx0ABlHOS8aVMmVx7DNX7o01sgVCYS4J1WXUyCAM2wInOdDueqh4jtUFk6vHD-jJSslF5JTRB02x0-tlP8wLq-vB3tdDMXM5Y4gac7MxXXEIHrhjUqYO1_djLOEfTUwvynZWL_925SNYAbuY4LvU0Hf_LRdqih0QUaq_vrBXMhkwN90bnSz5ZEGa9BI/s1280/IMG_7434%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiXHx0ABlHOS8aVMmVx7DNX7o01sgVCYS4J1WXUyCAM2wInOdDueqh4jtUFk6vHD-jJSslF5JTRB02x0-tlP8wLq-vB3tdDMXM5Y4gac7MxXXEIHrhjUqYO1_djLOEfTUwvynZWL_925SNYAbuY4LvU0Hf_LRdqih0QUaq_vrBXMhkwN90bnSz5ZEGa9BI/s320/IMG_7434%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Inside the drum, everything looked a bit crusty, but quite alright and nothing
obviously mangled. (The adjusters were obviously seized, but nothing a bit of
penetrating oil couldn't solve.)<br />
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieIfLjsTXSEsXf3o_bBPDtQbr2lP6V32AtMYJFNvlnBY7jHq7HzsBuijaiOknY7QBSDjKiM1cO6XPdN3YjEWLlkk69dZOQV3P8vqrvQ3oJUW637jEH7XJiINl-XmAxrEY9VfuxQO8ubmV2nauiftl2S32zS4ZotfQgq3UMAbfjS1ZU5Dv32xynkHnHAjk/s1280/IMG_7435%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieIfLjsTXSEsXf3o_bBPDtQbr2lP6V32AtMYJFNvlnBY7jHq7HzsBuijaiOknY7QBSDjKiM1cO6XPdN3YjEWLlkk69dZOQV3P8vqrvQ3oJUW637jEH7XJiINl-XmAxrEY9VfuxQO8ubmV2nauiftl2S32zS4ZotfQgq3UMAbfjS1ZU5Dv32xynkHnHAjk/s320/IMG_7435%20Large.jpeg" width="240" /></a>
</div>
<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4UOrPDvwNSUWY7LJns_rLVWCzbvch9-EcPioqkOUrS_glqRdllesEZGkzFHFzKQ6UmWODWdJWH2jXwu9oWClJM1DVdDEf1NDzvjc18UA8K6uCDEKrLcdb04EwWqJlCxujYTiokjRq74Cc91xGagJ2dmAmAsnslrX-jyLoh5zvZqGC_sH7zfRxVD25qCI/s1280/IMG_7437%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj4UOrPDvwNSUWY7LJns_rLVWCzbvch9-EcPioqkOUrS_glqRdllesEZGkzFHFzKQ6UmWODWdJWH2jXwu9oWClJM1DVdDEf1NDzvjc18UA8K6uCDEKrLcdb04EwWqJlCxujYTiokjRq74Cc91xGagJ2dmAmAsnslrX-jyLoh5zvZqGC_sH7zfRxVD25qCI/s320/IMG_7437%20Large.jpeg" width="240" /></a>
</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjnn8cky0EYump19Jwd1DUyYuZq-1Qa7d8Ge1RdTJfH3vWGHk7lx1XWLIMmhI6crumsj5rJ9GksUhE4PESmlWKh8RrRToo_Zqd8Ump5c-ZphsxVHVXEHfn4SvFmv6cvqcs_EJ6g_J6-OBRAH7lDszLoMEXotYAHel1QIvA2nT651aVbZFPKfZq_6MnCWA/s1280/IMG_7441%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjnn8cky0EYump19Jwd1DUyYuZq-1Qa7d8Ge1RdTJfH3vWGHk7lx1XWLIMmhI6crumsj5rJ9GksUhE4PESmlWKh8RrRToo_Zqd8Ump5c-ZphsxVHVXEHfn4SvFmv6cvqcs_EJ6g_J6-OBRAH7lDszLoMEXotYAHel1QIvA2nT651aVbZFPKfZq_6MnCWA/s320/IMG_7441%20Large.jpeg" width="320" /></a>
</div>
<p></p>
<p>
So on the left side it was quite literally just a new wheel cylidner, copious
amounts of anti-seize on the adjuster, new pads and hardware and call it good
enough.
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMIPkAln0AppuaCBykQ66lVxz7xTGcojwT1_FVZ0lwt4QVlPSMlmadP3v14rV_ghCKvOJvKSpdLn5zcg-b4UjGVKRSYtYrPpWOin2ZbBRV3UknrINeE3FjvmzA8k1C-RUCrY_oV86TJKq23Ys6pWnjMY4qCA5AUCB3_TsdiFKyTlr7bU0Ea2beIQbtoLY/s1280/IMG_7537%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMIPkAln0AppuaCBykQ66lVxz7xTGcojwT1_FVZ0lwt4QVlPSMlmadP3v14rV_ghCKvOJvKSpdLn5zcg-b4UjGVKRSYtYrPpWOin2ZbBRV3UknrINeE3FjvmzA8k1C-RUCrY_oV86TJKq23Ys6pWnjMY4qCA5AUCB3_TsdiFKyTlr7bU0Ea2beIQbtoLY/s320/IMG_7537%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
But then again, the left side was the easy side, because even though the wheel
didn't brake, it also didn't lock up. The right side on the other
hand...
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis-svxZ13HEQn2HjVVRtbAu464Bo6LZUIxuTelqOprMNjSl2kQhjP599KEyoFHlhU59WecZ0k2S87mS0S-KJIM9VuaPEEYrxhKl4erj4xBwsVtDxMpW5Y4hk6UTBjzjGu6Ii9oANo6WigdsFpqZoHduMASlHWFTag-eOhdhTe1FujvSxo5EJzyN3kZ74Y/s1280/IMG_7472%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis-svxZ13HEQn2HjVVRtbAu464Bo6LZUIxuTelqOprMNjSl2kQhjP599KEyoFHlhU59WecZ0k2S87mS0S-KJIM9VuaPEEYrxhKl4erj4xBwsVtDxMpW5Y4hk6UTBjzjGu6Ii9oANo6WigdsFpqZoHduMASlHWFTag-eOhdhTe1FujvSxo5EJzyN3kZ74Y/s320/IMG_7472%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Didn't quite look that bad after removing what was left of the pads. <br />
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOe9Xne9939FLNNXI0Qjmbm-A9CV0kWgBg3b4RG0zE9vLbCOCThlXgmLXyfjG0tsULIhexa5fozFBnLn_8QcK_Hn9M0aZK3iCzjFvgVg9-FCEr6Zkqu6PNR1nyZkAKNepmtT2MfqcSQCizbZch1W7TJkTY0fZw-YS5CfpRxsN0rn3Eo50KKDbJxSVw-PE/s1280/IMG_7473%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOe9Xne9939FLNNXI0Qjmbm-A9CV0kWgBg3b4RG0zE9vLbCOCThlXgmLXyfjG0tsULIhexa5fozFBnLn_8QcK_Hn9M0aZK3iCzjFvgVg9-FCEr6Zkqu6PNR1nyZkAKNepmtT2MfqcSQCizbZch1W7TJkTY0fZw-YS5CfpRxsN0rn3Eo50KKDbJxSVw-PE/s320/IMG_7473%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
In order to get the old wheel cylinder out the brake line had to be cut as on
the right both brake line nuts are staggered on top of each other with not
even remotely enough room to open them with proper tool without rounding them
off...
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisoRxCFphYQWI5NCQ3_cIAZqqiSEpe0d6Ke_KGCo2bZfi34C-ujBUgV7FwFcS1CkcMVCymkEt626w3m_1hkeDNZpGwuDPJjQ5DJri3PSAvy6YXAnTcDQ0IG8tG6kddFVQX2LeLw73hRmmH8ikpC0VCXr-cWNMdXvSRZ0wODdiDrl37ESX4EZc5Sd0-1m8/s1280/IMG_7474%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisoRxCFphYQWI5NCQ3_cIAZqqiSEpe0d6Ke_KGCo2bZfi34C-ujBUgV7FwFcS1CkcMVCymkEt626w3m_1hkeDNZpGwuDPJjQ5DJri3PSAvy6YXAnTcDQ0IG8tG6kddFVQX2LeLw73hRmmH8ikpC0VCXr-cWNMdXvSRZ0wODdiDrl37ESX4EZc5Sd0-1m8/s320/IMG_7474%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Just like on the left, after brushing the loose rust off, two coatings with
hammerite should keep rust at bay for a few more years and also hopefully
impress the mechanic, who will have to do the inspection. <br />
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIwxMigK9lXwUMHz3EfnVt96tmsM8LqgCNNAEb-uUh-weAJsY1bJz__ZKdqKb_PUTDBrflbLzTM6HAnMU0i9N4JmUpvfdrCdDHErkxodvIK7IFNejBRiSHn4D43VpVOR0u8G2tjgE5NXrx9lJ7g0aFKRO1l0boSNgtvnTRIFl9ctTzlBY4lqwWbOagYIU/s1280/IMG_7476%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiIwxMigK9lXwUMHz3EfnVt96tmsM8LqgCNNAEb-uUh-weAJsY1bJz__ZKdqKb_PUTDBrflbLzTM6HAnMU0i9N4JmUpvfdrCdDHErkxodvIK7IFNejBRiSHn4D43VpVOR0u8G2tjgE5NXrx9lJ7g0aFKRO1l0boSNgtvnTRIFl9ctTzlBY4lqwWbOagYIU/s320/IMG_7476%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Unfortunately the nut on the brake line wasn't the only one that put up a good
fight. One of the M8 bolts of the wear adjuster snapped when undoing the nut.
To me huge surprise, these are actually cast in, so the usual trick with
welding a nut on the stud didn't work at all. <br />
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJXkbL1YGS2qxzwUvdH4RGfu7KjV89HvdoXSS9OKodv7hzSH0PXxUJz_YqG2r6YRuHmZIywuPyYIXexoBnLBfclPqBs7HP8hws_TT52RP-AQZJQ4-dPnYZJ_tEGmLgYs1A_vpVHPvoJoemG90S2sq1InXuXPNopcZyQksIWD9GQxY5XsE6CUoM4tuvuQg/s1280/IMG_7505%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJXkbL1YGS2qxzwUvdH4RGfu7KjV89HvdoXSS9OKodv7hzSH0PXxUJz_YqG2r6YRuHmZIywuPyYIXexoBnLBfclPqBs7HP8hws_TT52RP-AQZJQ4-dPnYZJ_tEGmLgYs1A_vpVHPvoJoemG90S2sq1InXuXPNopcZyQksIWD9GQxY5XsE6CUoM4tuvuQg/s320/IMG_7505%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
So drilling it out and then attempting to remove the remnants with an EZ-out,
was my next step. Surprisingly without braking the tool as I found out a the
right time that it was cast in. <br />
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpdjEibCFx1p2pRSOinobn7UKYY4C4bR8L003eZwBSJPlDZ5Z88anHCcCbhkuFxShn96IuJDMPnsGO9_BOx6mBp80w4uoYu0lbyoyH2VB1jIPTUsBNqRRpBMcFRPgLCcBG-SSe_RjqIu39Q7msTEGqj1TI6CBYAyP32iorvF9rAhOzj8Baja1CIwME8ik/s1280/IMG_7506%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpdjEibCFx1p2pRSOinobn7UKYY4C4bR8L003eZwBSJPlDZ5Z88anHCcCbhkuFxShn96IuJDMPnsGO9_BOx6mBp80w4uoYu0lbyoyH2VB1jIPTUsBNqRRpBMcFRPgLCcBG-SSe_RjqIu39Q7msTEGqj1TI6CBYAyP32iorvF9rAhOzj8Baja1CIwME8ik/s320/IMG_7506%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Suited me just fine, drilled 6.5mm and tapped to M8 and with a bit of
M8-allthread it was just as good as stock. <br />
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuiV0TXbF7Op7ZBylte7NZOAZ_JI_T3pE2-lfOydRJQYY5BNcLvlDhxVEykwqO1t2zLeejV2fRDFgYwXHfjBB91NJHvp3l3-ltGN8wgpYbIiesxZsMBX53ERjHnyVtqti4PJTrNcnkZxBc-DmLfWZx694pWtmLUTIjeJNniN06UJviug7YJspHJYHsofw/s1280/IMG_7507%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuiV0TXbF7Op7ZBylte7NZOAZ_JI_T3pE2-lfOydRJQYY5BNcLvlDhxVEykwqO1t2zLeejV2fRDFgYwXHfjBB91NJHvp3l3-ltGN8wgpYbIiesxZsMBX53ERjHnyVtqti4PJTrNcnkZxBc-DmLfWZx694pWtmLUTIjeJNniN06UJviug7YJspHJYHsofw/s320/IMG_7507%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>... how much anti-seize is enough? Yes.<br /></p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaFQ5AEJaBTDfwe7nSuhyphenhyphenfXFhhdENCeVGOhfwwhDps-yx_XqG22J7ENnf9Jlj6dzE8pM9AoTiPLdBrlw8VBkGjF6Gww93f2a5uUQGBWFpRbyxeaJ6BjqyBFaLE_aKWirQA09KxsmiSM_rCsYk3I6oirob1oNLnTNvxClTq09zH4MsdQGtnrUrt3jPFmrw/s1280/IMG_7511%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaFQ5AEJaBTDfwe7nSuhyphenhyphenfXFhhdENCeVGOhfwwhDps-yx_XqG22J7ENnf9Jlj6dzE8pM9AoTiPLdBrlw8VBkGjF6Gww93f2a5uUQGBWFpRbyxeaJ6BjqyBFaLE_aKWirQA09KxsmiSM_rCsYk3I6oirob1oNLnTNvxClTq09zH4MsdQGtnrUrt3jPFmrw/s320/IMG_7511%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
This left me with making two new hard brake lines from scratch. New brake
lines are made from CuNiFeR, a copper nickel steel alloy, which is actually
TÜV approved. About twice as expensive as steel, but rust proof and much
easier to work with.
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4YKo0-7Kb2-XV-eyq76OveER7fo0Q82DrN_ycfzqY-0YQwJy2NdMHBLvxcMnf4Grm5IzZtA4a0nMROCBbrkJolHjKlW8kzP2KoYovKoB1peL97WGRvvqgaEJ9C4AYEZhyX42nlQso93f4vGiyf7ncFfHhI73YBPsBRWX3fCnVLJKJlFo20FfS7VacCnc/s1280/IMG_7522%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4YKo0-7Kb2-XV-eyq76OveER7fo0Q82DrN_ycfzqY-0YQwJy2NdMHBLvxcMnf4Grm5IzZtA4a0nMROCBbrkJolHjKlW8kzP2KoYovKoB1peL97WGRvvqgaEJ9C4AYEZhyX42nlQso93f4vGiyf7ncFfHhI73YBPsBRWX3fCnVLJKJlFo20FfS7VacCnc/s320/IMG_7522%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
As should be obvious: absolutely doable with even the cheapest brake line
flaring tool with absolutely no drama whatsoever.<br />
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiOsm9moYl_tFJCUsXeOvVMSh0cZAJftBEzepx3jafxsCmkhyphenhyphenaqMnb7Qrear7T4T1ZnmIyNcsWzlKmWbBj-O8uy5MPdwM8cnD5pfeKpygsIkhlTF-LM51u3Nj41EMQnGG2L2VXYWm315JhLAHwFQAL9iT4GqPaVnkfxlvLFEK8-PmcnllT4je_JCgF3cE/s1280/IMG_7523%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiOsm9moYl_tFJCUsXeOvVMSh0cZAJftBEzepx3jafxsCmkhyphenhyphenaqMnb7Qrear7T4T1ZnmIyNcsWzlKmWbBj-O8uy5MPdwM8cnD5pfeKpygsIkhlTF-LM51u3Nj41EMQnGG2L2VXYWm315JhLAHwFQAL9iT4GqPaVnkfxlvLFEK8-PmcnllT4je_JCgF3cE/s320/IMG_7523%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>Might be a bit hard to tell 😏, but the new line is on the right. <br /></p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4AtGhU1jZid57Oz8VitPSH24RQY-25jOWGOna6SQl8Qwb9fsrE5q1WsgL2hnI1Gm_RAq81mD2-03addgB53l9b2Hp74d8wNTcUwhmVLiwrqLh3zq1eQctyQKUja-I-1ziJ_JugtIGIrYv-mAZMjoF-T6KOrB_8024_fgDLztkhJ6VhmRor619NVDf5yo/s1280/IMG_7524%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4AtGhU1jZid57Oz8VitPSH24RQY-25jOWGOna6SQl8Qwb9fsrE5q1WsgL2hnI1Gm_RAq81mD2-03addgB53l9b2Hp74d8wNTcUwhmVLiwrqLh3zq1eQctyQKUja-I-1ziJ_JugtIGIrYv-mAZMjoF-T6KOrB_8024_fgDLztkhJ6VhmRor619NVDf5yo/s320/IMG_7524%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Even though the Maruti Gypsy is a very faithful continuation of the SJ410,
when it comes to brake lines, somewhere in the last 38 or 39 years, it went
from rubber lines with a locknut to a more modern clip style for retention. As
it turns out, these are exactly the same clips as can be found for example on
a Volkswagen Golf II (Rabbit for you Americans) and as such is a standard
25x13 clip. (In other words no need to buy the expensive clips from Suzuki
dealers.)
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBVpDio_kGUYRLXwa5lMv6Pmf0FOArhUSwmZcYcD6NkxgBPkZ0aC_fyouFmIk-5XYut-fwJZ0bNu9lzr9SglYN5-y2LXjfZX_Ds0kUB9oOt1L3fOxnEQC0ZhEy-39f0cOkaKdYKO731b-lDl9iscbea2CqO3bwv33Z2OiYHDnmLuDXJQbaOoRj2CGmp1g/s1280/IMG_7526%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBVpDio_kGUYRLXwa5lMv6Pmf0FOArhUSwmZcYcD6NkxgBPkZ0aC_fyouFmIk-5XYut-fwJZ0bNu9lzr9SglYN5-y2LXjfZX_Ds0kUB9oOt1L3fOxnEQC0ZhEy-39f0cOkaKdYKO731b-lDl9iscbea2CqO3bwv33Z2OiYHDnmLuDXJQbaOoRj2CGmp1g/s320/IMG_7526%20Large.jpeg" width="240" /></a>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAyMMhY2xOboqZ3QpDtek0yVLZL0RyT9YiqA7DcFk5kgGnSGwXJ-J_gdCFXlNP7r1A36MYogneDvj6YrypR3aKsYpcykraPUe4iotUjTbDYa46mp_xfllnEGCSJDeNMiA3nI33ZsKzqoi_ZxCrIjXdHCWgAfypezqYK7IoxmE6Sj9A62iR-ctIvHvU1rU/s1280/IMG_7527%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAyMMhY2xOboqZ3QpDtek0yVLZL0RyT9YiqA7DcFk5kgGnSGwXJ-J_gdCFXlNP7r1A36MYogneDvj6YrypR3aKsYpcykraPUe4iotUjTbDYa46mp_xfllnEGCSJDeNMiA3nI33ZsKzqoi_ZxCrIjXdHCWgAfypezqYK7IoxmE6Sj9A62iR-ctIvHvU1rU/s320/IMG_7527%20Large.jpeg" width="240" /></a>
</div>
<br />
<p>
Which at this point meant, I could run one brake line across the axle and the
other one to the flexible line coming down from the chassis and install the
new wheel cylinder.
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu5RxGuykzMorIi9xwcjYthW9DvvwaMOCO2NV0BrDp0nc3VptDAVEGromaJtRa1UWFHXQ8Fm5jvwrash1EVZglZLK6ghDM6jL6j8ofCaurFnWZA7w0ttiVmZB7wwwlsdCOD5RhDPMb_0OQhSvLCiATff-5bZpS0S_EnwwW_wgQwNoLnp0M8D1ME221iMA/s1280/IMG_7529%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu5RxGuykzMorIi9xwcjYthW9DvvwaMOCO2NV0BrDp0nc3VptDAVEGromaJtRa1UWFHXQ8Fm5jvwrash1EVZglZLK6ghDM6jL6j8ofCaurFnWZA7w0ttiVmZB7wwwlsdCOD5RhDPMb_0OQhSvLCiATff-5bZpS0S_EnwwW_wgQwNoLnp0M8D1ME221iMA/s320/IMG_7529%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>And then finally fill the other drum up with "goodness".<br /></p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpjSXWKxwAm3PySu4GtRXpNKqs9cXOylOzRsezY-Fex0CtJs0rf7WIc_M1ao4qdpml8U0i_TZXZbLvikTYoOiljtTJN7AhELJuxK9rvs96_b8gaud1i0-yFzsnPR9CH8KalgbVjh-pIefHE_ynb10eoIODwM-xmPYIn47zHChQ2jRkKTxqIWDf64CElfU/s1280/IMG_7536%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpjSXWKxwAm3PySu4GtRXpNKqs9cXOylOzRsezY-Fex0CtJs0rf7WIc_M1ao4qdpml8U0i_TZXZbLvikTYoOiljtTJN7AhELJuxK9rvs96_b8gaud1i0-yFzsnPR9CH8KalgbVjh-pIefHE_ynb10eoIODwM-xmPYIn47zHChQ2jRkKTxqIWDf64CElfU/s320/IMG_7536%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Only thing that was a bit of a let down (again - all of this was quite the
roller coaster): The right drum was well and truly scarred on the inside and
those new long-life pads? Well the long-life didn't refer to the compound, but
the fact that there was substantially more meat on them...
</p>
<p></p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9knqGNQ8qKiY1_nw1bT09kDODiyv90Kz8ZSH4E-SJTTXBJ_EoDQ9yri2ueMfbJ2hoQjj6v95TorxOKIa866B4ifMwb95MQ_YvmLB6h80IfOhRBM3Xz-2eglbwD_8ZnVlbkUSZeRBQW8J17oYRXgsK1NksSgr1t2VoCzG8O7d6WJhovnueIv4o_NBihYY/s1280/IMG_7541%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9knqGNQ8qKiY1_nw1bT09kDODiyv90Kz8ZSH4E-SJTTXBJ_EoDQ9yri2ueMfbJ2hoQjj6v95TorxOKIa866B4ifMwb95MQ_YvmLB6h80IfOhRBM3Xz-2eglbwD_8ZnVlbkUSZeRBQW8J17oYRXgsK1NksSgr1t2VoCzG8O7d6WJhovnueIv4o_NBihYY/s320/IMG_7541%20Large.jpeg" width="240" /></a>
</div>
<br /> Quick test-fit without wheel studs.<br />
<p></p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-uoG8yvkB9vglSsXGTsmvLMUru4WvhJpAvLa6bXFovTNq5jxLhWpNstTBUQxqZ0c4tOrHUCXx6Xt2m0QFETacnOY9ST4eyWCRyxzinuJvFQB40DzZNhsaDIdYD1fdzxjT0V-kdfl0dgeYibITi4FuHpWE_icGsF3IPVlb9fYPL76n7cbMJ-8SmvmK4_E/s1280/IMG_7543%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-uoG8yvkB9vglSsXGTsmvLMUru4WvhJpAvLa6bXFovTNq5jxLhWpNstTBUQxqZ0c4tOrHUCXx6Xt2m0QFETacnOY9ST4eyWCRyxzinuJvFQB40DzZNhsaDIdYD1fdzxjT0V-kdfl0dgeYibITi4FuHpWE_icGsF3IPVlb9fYPL76n7cbMJ-8SmvmK4_E/s320/IMG_7543%20Large.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Which are M12x1.25 and when they are out, it is sort of the best moment
possible run a die down that thread to make bolting on those wheels a lot
easier in the future.
</p>
<p><br /></p>
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</div>
<br />The studs are just a simple press fit, so nothing a hammer and a bit of dedication won't be able to fix.<br /><br />
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<p></p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXruA_IJ_X_hqYoXkTKczerbhA9Cyhcj4BVVQ8rDVjti9zOuQOz3jd7nMKXvmPFgp43Hdl1VGjK47IBRqEG1Bhz9U1UmKoCFyB_tFzvg8Lewnor3UEDWOVexBcRZLZ22gTAsWB9I7L6gVLnzb1OQCjiGbMdfNXb_9c4L0m1WF3k4OYvP6bLInA6E8JhV4/s1280/IMG_7548%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXruA_IJ_X_hqYoXkTKczerbhA9Cyhcj4BVVQ8rDVjti9zOuQOz3jd7nMKXvmPFgp43Hdl1VGjK47IBRqEG1Bhz9U1UmKoCFyB_tFzvg8Lewnor3UEDWOVexBcRZLZ22gTAsWB9I7L6gVLnzb1OQCjiGbMdfNXb_9c4L0m1WF3k4OYvP6bLInA6E8JhV4/s320/IMG_7548%20Large.jpeg" width="240" /></a>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2rN0pmC1oKMNqYElRS7DwskDSQrAkRmBYqteJt3h4W-uU5tJxtc0jgloDCZNMtaVzv8ZaCpBvj36vhVetGn-B1gHN7HTkGlLwzeiorqkutSs24BUTsm16pS5Tr2HzRIT3XH-PcH_uGHDGt6CVCoU2lgpyY8Ix6TVO1WVcXplaIZ86259ZUFwsGmjccFo/s1280/IMG_7547%20Large.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2rN0pmC1oKMNqYElRS7DwskDSQrAkRmBYqteJt3h4W-uU5tJxtc0jgloDCZNMtaVzv8ZaCpBvj36vhVetGn-B1gHN7HTkGlLwzeiorqkutSs24BUTsm16pS5Tr2HzRIT3XH-PcH_uGHDGt6CVCoU2lgpyY8Ix6TVO1WVcXplaIZ86259ZUFwsGmjccFo/s320/IMG_7547%20Large.jpeg" width="240" /></a>
</div>
</div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: left;">The front brakes? Considerably easier. </div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikrbXOYs41a38JrzUfxG6zF6PDQFXgYKUVMa_yvSggD1w_HivcrGHnrN6dS4dlr8pK7IqjM8C_n25J5R8XvGbEMCoQacnRxBD1Ya0SB1w0b7hB1RPihyHCOfPoussluJ9mNXTCdPQ2JBBNtB85_I7vw839tqlEcvdn7EV-vft9QnDj_zeMCBCJgGE-dpE/s1280/IMG_7564%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikrbXOYs41a38JrzUfxG6zF6PDQFXgYKUVMa_yvSggD1w_HivcrGHnrN6dS4dlr8pK7IqjM8C_n25J5R8XvGbEMCoQacnRxBD1Ya0SB1w0b7hB1RPihyHCOfPoussluJ9mNXTCdPQ2JBBNtB85_I7vw839tqlEcvdn7EV-vft9QnDj_zeMCBCJgGE-dpE/s320/IMG_7564%20Large.jpeg" width="240" /></a></div><p></p><p>Even though I have to admit, this level of brake pad destruction is new to me. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizVOF26x-MJurUw-KKJlcgdylr6lDOj9czVlIwIKWq_nBeRe_yPEJO1ltWreIVowR3uxp1XM2ruDJa0lm3LYELH7oWD2wfQauaF2SJjptla65zwnBxuqtcg6L5djl9Fqtkin9VuHj4LV6z0CZ8usqIawkPLDw0d49i0x46Y2ELG_5jNMb98Ac1oQ2vJuk/s1280/IMG_7565%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizVOF26x-MJurUw-KKJlcgdylr6lDOj9czVlIwIKWq_nBeRe_yPEJO1ltWreIVowR3uxp1XM2ruDJa0lm3LYELH7oWD2wfQauaF2SJjptla65zwnBxuqtcg6L5djl9Fqtkin9VuHj4LV6z0CZ8usqIawkPLDw0d49i0x46Y2ELG_5jNMb98Ac1oQ2vJuk/s320/IMG_7565%20Large.jpeg" width="240" /></a></div><p></p><p>Two very convenient M8 threads to push the disks off the hubs - even though they need a quick clean up.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_GCorM3sFFU8-RKP16JNAVH6YgRJnIkkvJazVhBeo-h7IJSBY-A37fVRnfX9tnHvfnGHswtHWJn8f-2kvAu5EFf4mXLdpJQYHGqc5Bcb8LTWHC3D9EpJ9IgT-tLFyCv80zCnCfym8zkiaYAcEzJKxNM4ehw2_dob2cRLez0ERsskfEV5-PgBKGzwJ6vE/s1280/IMG_7566%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_GCorM3sFFU8-RKP16JNAVH6YgRJnIkkvJazVhBeo-h7IJSBY-A37fVRnfX9tnHvfnGHswtHWJn8f-2kvAu5EFf4mXLdpJQYHGqc5Bcb8LTWHC3D9EpJ9IgT-tLFyCv80zCnCfym8zkiaYAcEzJKxNM4ehw2_dob2cRLez0ERsskfEV5-PgBKGzwJ6vE/s320/IMG_7566%20Large.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: left;">Again the dustshields and brake caliper mounts where cleaned and painted and then literally just slap everything together with a bit of strategically placed anti-seize between hub and rotor to make disassembly just that little bit easier next time. </div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4RI_n705ESYJsHxcY-mbjga6EiNGQi2aIj2rDh66OyWOrwGPI70UZxU00y6wCGOZDUfnm51bnx1LZD4CPOvx-L8S_QbrKx7vSXlMjzFDV_bZ_26lsVVxJMQWEG_AARqcELpouN78UWZj4gTo0OHqyUQysBRL9-wdf8FIfyx-2aZU3Wl0fuNi9uqM-2Qk/s1280/IMG_7570%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi4RI_n705ESYJsHxcY-mbjga6EiNGQi2aIj2rDh66OyWOrwGPI70UZxU00y6wCGOZDUfnm51bnx1LZD4CPOvx-L8S_QbrKx7vSXlMjzFDV_bZ_26lsVVxJMQWEG_AARqcELpouN78UWZj4gTo0OHqyUQysBRL9-wdf8FIfyx-2aZU3Wl0fuNi9uqM-2Qk/s320/IMG_7570%20Large.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQbes5G2sFZsOssZOjhUP9zLUrK7JtBO3xdvee65-zezuGrRqk9oEBMpSKOQas_gK5gPA3sU06-ne5ERqkpnRkLWdawbSFYeFkSostH6Q5SmZNLKsKhGIF6oU9LwvjZLCIjpsO55_8SI3oqOX1F_9ND7_i-JBiqZtkrGXUiz0N4Ut7JvXdGX_8l9vnSdQ/s1280/IMG_7571%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQbes5G2sFZsOssZOjhUP9zLUrK7JtBO3xdvee65-zezuGrRqk9oEBMpSKOQas_gK5gPA3sU06-ne5ERqkpnRkLWdawbSFYeFkSostH6Q5SmZNLKsKhGIF6oU9LwvjZLCIjpsO55_8SI3oqOX1F_9ND7_i-JBiqZtkrGXUiz0N4Ut7JvXdGX_8l9vnSdQ/s320/IMG_7571%20Large.jpeg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhA0o3NOvofQ_0byPSswvmJF9fEK-nZfJyY8tC-Q93fZScEEnLtE6IeHsMH0Dr77fTCpi0IAWGaXkgzqsG1jId6ZGPIxPQpQBe4GP4zdDKqUfPCDz77jYt-KWD8PJxL3PhAPkfnD3QhPb4lF7GRbMcDSp-kMx_0Tt2a-XDb_J2h86vwtljG0vqJJwB2_8A/s1280/IMG_7573%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhA0o3NOvofQ_0byPSswvmJF9fEK-nZfJyY8tC-Q93fZScEEnLtE6IeHsMH0Dr77fTCpi0IAWGaXkgzqsG1jId6ZGPIxPQpQBe4GP4zdDKqUfPCDz77jYt-KWD8PJxL3PhAPkfnD3QhPb4lF7GRbMcDSp-kMx_0Tt2a-XDb_J2h86vwtljG0vqJJwB2_8A/s320/IMG_7573%20Large.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: left;">And that was that whole thing with the brakes (aside from bleeding them). But there was one more thing: The ridiculous bull bar at the front: first of all, even though it was most likely a factory accessory I wouldn't be able to pass inspection with it installed and quite frankly I didn't like it all. </div><div class="separator" style="clear: both; text-align: left;"><br /></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjvh0IEQJowiB6k4yMIjolvlbcWozCpSdFDRYuRkmW8v7OgyoQ_Pv7sZqmF9MAHPuHQXA2d094VI5rQ3RQJaSx5igo17Z_nYzhNNSLrgDSnXVOdUWp-HKAi8hZVwOhE0FPey4tWAf0W-NFKolz6LGiXQjmkrWnFsXPWmiuWGrPsB2OdH_Wrxt_H1mb8fo/s1280/IMG_7574%20Large.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjvh0IEQJowiB6k4yMIjolvlbcWozCpSdFDRYuRkmW8v7OgyoQ_Pv7sZqmF9MAHPuHQXA2d094VI5rQ3RQJaSx5igo17Z_nYzhNNSLrgDSnXVOdUWp-HKAi8hZVwOhE0FPey4tWAf0W-NFKolz6LGiXQjmkrWnFsXPWmiuWGrPsB2OdH_Wrxt_H1mb8fo/s320/IMG_7574%20Large.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: left;">Ironically the hardest part of the whole endeavour was to reinstall the front bumper alone, as it just wouldn't want to stay in place.</div>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-28351096866147961072024-01-27T20:00:00.001+01:002024-01-27T22:42:54.135+01:00Rotary table gets a new 125mm chuck<p>
So, if you have a mill at some point you will want a rotary table,
because they are stupidly handy. The downside to a good rotary table is
usually the size and thus the weight. So if you have for example a 150mm (6")
rotary table and fit a 190mm chuck on it, you don't have to do any more weight
lifting for the day. This among the other fact that I only had external jaws
for it, drastically limited its usability for me. Add to that that I have been
a very good boy, so I treated myself to a new Chinese 125mm chuck.
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVdLzmY4sEJ__FYnA-qD6POUkuMIzo82S7oOBRxTBmeQDOpceKAYRffhzNHXMbWDUnpcm6to4h47ldbOQmeTwDjfCa23heqBBBFMYMkEUNlPBpuXlZCjLNuTr-zIs-Yk_QByuGNsctEmYMHZeKZ84RaSB7M_5BqKaK4Fyyn5F7QLSRPhWo-QEvePgVRhY/s1600/IMG_7257.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhVdLzmY4sEJ__FYnA-qD6POUkuMIzo82S7oOBRxTBmeQDOpceKAYRffhzNHXMbWDUnpcm6to4h47ldbOQmeTwDjfCa23heqBBBFMYMkEUNlPBpuXlZCjLNuTr-zIs-Yk_QByuGNsctEmYMHZeKZ84RaSB7M_5BqKaK4Fyyn5F7QLSRPhWo-QEvePgVRhY/s320/IMG_7257.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Originally I thought I'd make a completely new adapter for the chuck, but
after having a very long look at it, I decided that with some precision
lathe-work I could not only modify, but improve the base-plate and also have
an excuse to let the little engineer inside of me out.
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1xURZQlxZdA6LLc-4nGmwaqUqdNI5-YqbtZa6GEVXSzv9FQqrAggCDfsE6APbIcHvezo2712KqAi0aLyFFi-DJ7J7GYU2e6p75MOMRslJFqNTKkzFtTjNXwYrluyjcqvQQAlHVc_DO0ny_wevZF5Lpoje3wLFI1O-lyp_kW1nHqRTFTZuPC4og0_8JBY/s1600/IMG_7256.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1xURZQlxZdA6LLc-4nGmwaqUqdNI5-YqbtZa6GEVXSzv9FQqrAggCDfsE6APbIcHvezo2712KqAi0aLyFFi-DJ7J7GYU2e6p75MOMRslJFqNTKkzFtTjNXwYrluyjcqvQQAlHVc_DO0ny_wevZF5Lpoje3wLFI1O-lyp_kW1nHqRTFTZuPC4og0_8JBY/s320/IMG_7256.jpeg" width="240" /></a>
</div>
<p></p>
<p>
So how do you hold a 200mm plate in a 125mm chuck? The trick here was super
simple by using an 8mm allen head bolt and use that as a datum/reference for
all other work. Interestingly enough in the first picture the surface finish
looks absolutely terrible, which it isn't at all in real life. <br />
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt782yLdT2gkxEgKUywNS0Muznr0SfkfQvURNZK1ZIE8Lfgt8F3z02qABD9Z1r4XYVlYekAl36kxZArK2NHY4YaPA-hkOfhJZxsjUcXgp9AigigfdM7ahyphenhyphen5udcUVnw5Us1qwub8oRWUrqctaUPKfeqQUBY03zxro6zfAN72OKpfsC53SeQEcn5Y_KRYK8/s1600/IMG_7259.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjt782yLdT2gkxEgKUywNS0Muznr0SfkfQvURNZK1ZIE8Lfgt8F3z02qABD9Z1r4XYVlYekAl36kxZArK2NHY4YaPA-hkOfhJZxsjUcXgp9AigigfdM7ahyphenhyphen5udcUVnw5Us1qwub8oRWUrqctaUPKfeqQUBY03zxro6zfAN72OKpfsC53SeQEcn5Y_KRYK8/s320/IMG_7259.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Not only did I machine the chuck face, but also the back side and unlike in
the past, I now have two alignment edges, in the center it will locate into
the morse tape in the rotary table and also on the outer edge.<br />
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbfUTMjkdepvy6bAe67CTK75SF_lAefveYcTarMxmLLL9X_TPB5wtCh92VSt99MSH8nD2TPsrrPfhlElX9R9Yzz_0YIsdHKPE_jTuIKV99Qqynm1LEz0KTI7kUmew0GeBrx2PstNEzA40qw0TxTXRPmbURxFOgblBGgWq-wFFPDs4p2rtBCgdAOvXM4nc/s1600/IMG_7260.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbfUTMjkdepvy6bAe67CTK75SF_lAefveYcTarMxmLLL9X_TPB5wtCh92VSt99MSH8nD2TPsrrPfhlElX9R9Yzz_0YIsdHKPE_jTuIKV99Qqynm1LEz0KTI7kUmew0GeBrx2PstNEzA40qw0TxTXRPmbURxFOgblBGgWq-wFFPDs4p2rtBCgdAOvXM4nc/s320/IMG_7260.jpeg" width="240" /></a>
</div>
<p>Now I don't want to pat on my own back too hard, but that chuck registered on the hump in the middle like you wouldn't believe. Just downright perfect.<br /></p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-ahTRquYe4xBp7LEmV0LufUUrlx5LF6oy50uAw3GKOwdMnCnetfglAOsYYcteqe_aGQpH1oL0cFIvBuOMbBH1Kq0VU5Bqx_oe2yUrw8viPJX9N1A9AM_IqiE-7bR7hi9LswprRMQa-AU3C__ju6br_RAxInS16FfvAglWOVBrRbWXmTQiiOJLS4jWozE/s1600/IMG_7261.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-ahTRquYe4xBp7LEmV0LufUUrlx5LF6oy50uAw3GKOwdMnCnetfglAOsYYcteqe_aGQpH1oL0cFIvBuOMbBH1Kq0VU5Bqx_oe2yUrw8viPJX9N1A9AM_IqiE-7bR7hi9LswprRMQa-AU3C__ju6br_RAxInS16FfvAglWOVBrRbWXmTQiiOJLS4jWozE/s320/IMG_7261.jpeg" width="240" /></a>
</div>
<br />
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitXH-mPDhS4QhSHzbn1U6GHPLcR6msHlzHvYdYIBl1ktIx8ffiHNtqOFDC-pHKIPI3ER1xLCcSnrC9X3ZRWLVQvYv56ASMusC6oqSmZUa6S4D6scLv3guxNJk0qyRj0hBGNVWVxqMRcrUXr3V5OQ14xH539Tc-kljhsC_hlo7QDWJe9s-ZM05JegxmaMo/s1600/IMG_7262.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitXH-mPDhS4QhSHzbn1U6GHPLcR6msHlzHvYdYIBl1ktIx8ffiHNtqOFDC-pHKIPI3ER1xLCcSnrC9X3ZRWLVQvYv56ASMusC6oqSmZUa6S4D6scLv3guxNJk0qyRj0hBGNVWVxqMRcrUXr3V5OQ14xH539Tc-kljhsC_hlo7QDWJe9s-ZM05JegxmaMo/s320/IMG_7262.jpeg" width="240" /></a>
</div><p>
</p><p>Three M8x70 bolts, a bit of tapping and countersinking later and there you go. <br />
</p><div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBOBg8vDtonhswlsDwge5Pj9UZtdfzaRyPDwc3Eb6AWuTClRCbGzt-aSOFjreyEUowgSAUz6Oe8BQyGwesSiX8_cBuqx6NNFhSG1AmxhzEvZ_mUYLIci6yDtq8t0NF64CMQh1DeOHUUYke4VwJX-z_eN1CypUsfdoHiUoE6V4W0u_E5FWWpoasiI49q6Q/s1600/IMG_7457.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiBOBg8vDtonhswlsDwge5Pj9UZtdfzaRyPDwc3Eb6AWuTClRCbGzt-aSOFjreyEUowgSAUz6Oe8BQyGwesSiX8_cBuqx6NNFhSG1AmxhzEvZ_mUYLIci6yDtq8t0NF64CMQh1DeOHUUYke4VwJX-z_eN1CypUsfdoHiUoE6V4W0u_E5FWWpoasiI49q6Q/s320/IMG_7457.jpeg" width="240" /></a>
</div>
<br />So why the rush you ask? First of all I will need it make a few of the parts that I want to make for the Hotroad TR1, specifically cut some hexes onto shafts and more immediately, the little green pickle has got almost new front brake disks on it (seriously), but as it was parked for so long the pads rusted to the disks, so giving them a skim is the order of the day.<br />Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-37002306774933732972024-01-20T20:00:00.204+01:002024-02-10T22:00:22.589+01:00Project Pickle - Suzuki SJ410 resurrection (part 1)<p>What if you had some unfinished business with a certain 4x4 of suspiciously Soviet origin and wanted something that had a bit of that "let's do it even more simple" charm? It's sort of hard to imagine that someone would consider the Niva as too opulent, too luxurious, too much of anything really and then you meet it's biggest competitor of the same era. May I present "the pickle", a green-ish, overgrown with moss 1983-model Suzuki SJ410. (And don't you call it no "Samurai" - this is the grandma, the OG if you will.) 970cc, 45hp (at the flywheel when new), 860kg room for four (kind of) and I am pretty sure the designers had no compass at hand when designing it. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHA4NvGxFpbTcqwPuOUtuLQLzbPiAMXTOZCnXBf-aCvT8-CbXGGFUHqVo3QH_3BPW9RQOww5xm9S_4qmisQRpo5tZroktAf4Sz3xD3YNMRzTOzT0oAXJZvTA40Sygxg8fL8XZSrmE4SXq3S_-Ro_x7qwt4OsfMABgweRrbngALEPjcBjG1vI6kfOSVazQ/s1600/IMG_7317.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHA4NvGxFpbTcqwPuOUtuLQLzbPiAMXTOZCnXBf-aCvT8-CbXGGFUHqVo3QH_3BPW9RQOww5xm9S_4qmisQRpo5tZroktAf4Sz3xD3YNMRzTOzT0oAXJZvTA40Sygxg8fL8XZSrmE4SXq3S_-Ro_x7qwt4OsfMABgweRrbngALEPjcBjG1vI6kfOSVazQ/s320/IMG_7317.jpeg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzUl9lpuOdHbeKE1Ub39vstWIRR6bVakHBYJS1VKqiKQV7SHOzZYEJqTtvYsJ-GBTGsosVi7KJ8pmjjuW7V5AfoWNAfp-u_FTq3upX3hbeA05U-rWdyyUnMdHzO63zo77TfIMI4SR5oGYwYwbIB3h8Mmvtyd5tbheQWU3Q5QL15IarIY2BjSxUk2AwTr4/s1600/IMG_7316.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzUl9lpuOdHbeKE1Ub39vstWIRR6bVakHBYJS1VKqiKQV7SHOzZYEJqTtvYsJ-GBTGsosVi7KJ8pmjjuW7V5AfoWNAfp-u_FTq3upX3hbeA05U-rWdyyUnMdHzO63zo77TfIMI4SR5oGYwYwbIB3h8Mmvtyd5tbheQWU3Q5QL15IarIY2BjSxUk2AwTr4/s320/IMG_7316.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiW4IIcXawL4XBYtMuuyKLxhLl0iO1tenZdJhWK1y7DZfYBCpwKMDOck9Li3JYFPiYi2aM1VDp92JS8qr6XHI5iGsQHG69BrPxXs0rwqJVgVBJilr-v72koqnT2mTszGKKD08CKa_kTp6BxEfc4ax8GMy8xkmB0uJivg_TIIBCiVmDPiKr5vg6sUur2yo0/s1600/IMG_7318.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiW4IIcXawL4XBYtMuuyKLxhLl0iO1tenZdJhWK1y7DZfYBCpwKMDOck9Li3JYFPiYi2aM1VDp92JS8qr6XHI5iGsQHG69BrPxXs0rwqJVgVBJilr-v72koqnT2mTszGKKD08CKa_kTp6BxEfc4ax8GMy8xkmB0uJivg_TIIBCiVmDPiKr5vg6sUur2yo0/s320/IMG_7318.jpeg" width="320" /></a></div><br /><p></p><p>I'll be honest, I was on the hunt for one of these for a while, but it was incredibly difficult to find one I liked. Most of them were stupidly priced for what they are and to keep things interesting rotten as all hell. So earlier this week, I passed by one of those rather dodgy car salesmen that are next to some of the bigger roads leading out of town and there it was. Hood dented as all f*ck, enough moldy leaves on it that you couldn't tell were the bumper ended and the front grill started, rusted brake disks, the distinct scent of wet dog, when opening the door and as I was informed, it doesn't start. In other words an almost perfect candidate. After a bit of back and forth a price was agreed, money changed hands and I had become the proud owner of "the pickle".</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUSP1DbyNNgxZ5SjDXXx4dEAWQSnXN4brK_GUgZ917gMjtyHKm5TaVsaF-c570wvssbye5HWAg6gvToNBJHauSPjNjkWyXP-TKAqIEsH01JhjevwHM6oKaHbm5gH1hc8-_pFZiqV8WAtebZxIGT5kInuzWyyRI6gAjHzJ0ciV6RmO2OHggUlxXvzttB6U/s1600/IMG_7319.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUSP1DbyNNgxZ5SjDXXx4dEAWQSnXN4brK_GUgZ917gMjtyHKm5TaVsaF-c570wvssbye5HWAg6gvToNBJHauSPjNjkWyXP-TKAqIEsH01JhjevwHM6oKaHbm5gH1hc8-_pFZiqV8WAtebZxIGT5kInuzWyyRI6gAjHzJ0ciV6RmO2OHggUlxXvzttB6U/s320/IMG_7319.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ2beQJZxSJvfDXHXaBJEcs9v6WGImk6jfSkMIpGwWn1MOszjX14jxTazBEa4W-VaLIepOweGtgPfsDS7zkfX2mB4CdVrsutiOnVa8jC6RiIliGU5oaHEbjvFbRmqjUThjGu4SlAg4VmUIxj-3IvMuwb3FFITnG6SuKf6vaGNITG11jp883t8n88fmlPw/s1600/IMG_7324.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJ2beQJZxSJvfDXHXaBJEcs9v6WGImk6jfSkMIpGwWn1MOszjX14jxTazBEa4W-VaLIepOweGtgPfsDS7zkfX2mB4CdVrsutiOnVa8jC6RiIliGU5oaHEbjvFbRmqjUThjGu4SlAg4VmUIxj-3IvMuwb3FFITnG6SuKf6vaGNITG11jp883t8n88fmlPw/s320/IMG_7324.jpeg" width="240" /></a></div><p></p><p>What instantly caught me was this dash, where later models have a tach and a clock, here as this is the absolute base model: a fuel gauge, a temperature gauge, some idiot lights and that's it. No fluff, nothing playful or extra-vagant and this drives home a message with a mighty big hammer: what if you took a vehicle and then pulled out your red sharpie and crossed everything off that wasn't necessary until the essence of a vehicle was left over?<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsD5CyoByNqu-M27VXEiNHAVtBKwE3xRkCvVZgUinIVQFLJZewajogFR2bNRpILPVtSR3hGp_eDFDK44PfdRnY3oeqkXvzbfonI0NtNLGvlTj4w7u4OOezPgySda0uPLc7OLQQ4VxZ3wN1Q8ie_6DDlOw-TDbUvOQtrZvF6KzyXg0U_nr3o5xUGLeAl1Q/s1600/IMG_7326.HEIC" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsD5CyoByNqu-M27VXEiNHAVtBKwE3xRkCvVZgUinIVQFLJZewajogFR2bNRpILPVtSR3hGp_eDFDK44PfdRnY3oeqkXvzbfonI0NtNLGvlTj4w7u4OOezPgySda0uPLc7OLQQ4VxZ3wN1Q8ie_6DDlOw-TDbUvOQtrZvF6KzyXg0U_nr3o5xUGLeAl1Q/s320/IMG_7326.HEIC" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIFoujkzIHEbQjCnroAGTGT5aV2H53_JFpN1fU6M42fQSu2uYXN1z7gzTXoTGugn8oCEtZmieSl5F-jPsGOxlclNd5lgD2ADhJ5QZT8JZISIpU5UodfhUPjseVehkKH1KJCLImir1RXe0mP83LJj5uOwTSiP2W1cFKrnEK-RGVX-MePkwBUWydxrabpgc/s1600/IMG_7327.HEIC" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjIFoujkzIHEbQjCnroAGTGT5aV2H53_JFpN1fU6M42fQSu2uYXN1z7gzTXoTGugn8oCEtZmieSl5F-jPsGOxlclNd5lgD2ADhJ5QZT8JZISIpU5UodfhUPjseVehkKH1KJCLImir1RXe0mP83LJj5uOwTSiP2W1cFKrnEK-RGVX-MePkwBUWydxrabpgc/s320/IMG_7327.HEIC" width="240" /></a></div><br /><p>... and the essence lies in its off-road capabilities: There's a proper transfer case, with a crawling gear ratio and a manuel rear diff brake (even though that one is really only there, because the handbrake acts directly on the drive shaft and with an open diff it could still roll out of its parking position. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRgnIls_8d8549WnBtdCnqUIO76IdKQUJa0LSAc0YFS7M8r-nyelWJKn4wGMrrkgSnMhGtsxK-GZdNhl3S21WEOC2MtUEVaRyKAczUX1oi2gKRS4XXjq3m2hKUzn_jqSbk5mDEo9eLXfYioDZ-3YQYSPA7ZZtgWKddAJESI6sjuwnao8W-oehO72UZ78E/s1600/IMG_7321.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRgnIls_8d8549WnBtdCnqUIO76IdKQUJa0LSAc0YFS7M8r-nyelWJKn4wGMrrkgSnMhGtsxK-GZdNhl3S21WEOC2MtUEVaRyKAczUX1oi2gKRS4XXjq3m2hKUzn_jqSbk5mDEo9eLXfYioDZ-3YQYSPA7ZZtgWKddAJESI6sjuwnao8W-oehO72UZ78E/s320/IMG_7321.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7fy7mHPfcqv7F6DeJa-m2u6ItSnPcjB010UmOfFuntseWu9NGXXu7a1tToJ0MPfkbNL6hb1sejhX0ejrdLwpY9wE88uFQ4QKdwRuo0wGRityIZ9qE4FqMqSL2s19OzwUu3YC6zuTxr9CjY73wHwmQgk7gFJf-pwQ_uGR_CRbqCdvMSpeaiKaU-EKRTbY/s1600/IMG_7322.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7fy7mHPfcqv7F6DeJa-m2u6ItSnPcjB010UmOfFuntseWu9NGXXu7a1tToJ0MPfkbNL6hb1sejhX0ejrdLwpY9wE88uFQ4QKdwRuo0wGRityIZ9qE4FqMqSL2s19OzwUu3YC6zuTxr9CjY73wHwmQgk7gFJf-pwQ_uGR_CRbqCdvMSpeaiKaU-EKRTbY/s320/IMG_7322.jpeg" width="240" /></a></div><br /><p></p><p>As the engine turned over nicely and made rather healthy sounds, I admittedly had only very few qualms buying a car that was a non-runner. Unlike later models, it still has points ignition and no brake booster at all. Whilst the lack of brake booster is rather irrelevant for now, the points ignition really only needed a bit of love with a piece of emery cloth to be back in sparking order. </p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEie0frudLX2WrnZrf6o9G2_KTteo0iR2ge4MJx45Rdi2Bv12L6-QBN9IxZKKhUfhETwmWo0klwMADJ4ARX3VohDLicdyYm0NeZx9K8CQtu1EnyOLttSSdPGbpYgoPu99ilrG2NIXJLLS3xhm3HzVcWZVrvwAW3XeLj3FAUhLS7OR44FoW3BY5EXdJev1oQ/s1600/carb.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="900" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEie0frudLX2WrnZrf6o9G2_KTteo0iR2ge4MJx45Rdi2Bv12L6-QBN9IxZKKhUfhETwmWo0klwMADJ4ARX3VohDLicdyYm0NeZx9K8CQtu1EnyOLttSSdPGbpYgoPu99ilrG2NIXJLLS3xhm3HzVcWZVrvwAW3XeLj3FAUhLS7OR44FoW3BY5EXdJev1oQ/s320/carb.JPG" width="180" /></a></div><p style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOO4Yz7j28TUEAqrX2fx7jsRaHWgjiF1AXcz-Vmgvw3wzboFkWtq-Lr4mR8s4bJ5cbaB7GzzsGzQo9A5TxnWykv6ZFOHLL1fowInajpW8uCoPjOX7lj8XLLVcYoUOYRrTVINZiwH8f8yASUqxfdqajemxPlNmYIKiUZnQq4vi1OXmeVXeZdb7zgt83Z5A/s1600/IMG_7355.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOO4Yz7j28TUEAqrX2fx7jsRaHWgjiF1AXcz-Vmgvw3wzboFkWtq-Lr4mR8s4bJ5cbaB7GzzsGzQo9A5TxnWykv6ZFOHLL1fowInajpW8uCoPjOX7lj8XLLVcYoUOYRrTVINZiwH8f8yASUqxfdqajemxPlNmYIKiUZnQq4vi1OXmeVXeZdb7zgt83Z5A/s320/IMG_7355.jpeg" width="240" /></a></p> <div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhreWC6skng1YXBhbqVhBytNohM5l7ICr1EatOk5auQOSbBXRpr6DiNcEfY7pTRf5Lv0U3ac3zrWEW_B9cJ76yuEMBlqMmXIUkXjEmpRK_8bQrFtDH4_TMVT5LZ7DwFUWxC_GRZFRv6e9Uq5-vrzRRR2GTzkm5y0Man3DCN5Hr6KhYPJ1uYT5tlh5Q1rdQ/s1600/IMG_7357.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhreWC6skng1YXBhbqVhBytNohM5l7ICr1EatOk5auQOSbBXRpr6DiNcEfY7pTRf5Lv0U3ac3zrWEW_B9cJ76yuEMBlqMmXIUkXjEmpRK_8bQrFtDH4_TMVT5LZ7DwFUWxC_GRZFRv6e9Uq5-vrzRRR2GTzkm5y0Man3DCN5Hr6KhYPJ1uYT5tlh5Q1rdQ/s320/IMG_7357.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYguCPWwQW7s6oyrEwdbAUcE9fsRmqwOf_ZTvg8UaaKZJ-44YkhiydsRyg4mzBHve6oMCmB0v0ebPENN3OFZNAbOX6kWKajLhZcmwQaFRx4VE-l8bgzL9y2a1lRHagRGV2MsY96I5aKEQfoEhOzfUAux0pO9TMIu-4kb772QDrg7I52S7ir-VTfIMJzc8/s1600/IMG_7356.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYguCPWwQW7s6oyrEwdbAUcE9fsRmqwOf_ZTvg8UaaKZJ-44YkhiydsRyg4mzBHve6oMCmB0v0ebPENN3OFZNAbOX6kWKajLhZcmwQaFRx4VE-l8bgzL9y2a1lRHagRGV2MsY96I5aKEQfoEhOzfUAux0pO9TMIu-4kb772QDrg7I52S7ir-VTfIMJzc8/s320/IMG_7356.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhG7PYAptYrlUwhByulBtQJuf2fCfmWwiNUsPpbwaDKYLWjM85TDpKm01LG6WxeHbxKV4PhrwI3LwIHkRTPkbk6petUOPppWlsY5GEsGV6NIykFX7iG3TAXZN238ZG3omCMxnUdZdLlMwiEOO9AYGGIXAnnDQo-W_VIygpEbER7lebYGYx0E2LlNLg7AVI/s1600/IMG_7354.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhG7PYAptYrlUwhByulBtQJuf2fCfmWwiNUsPpbwaDKYLWjM85TDpKm01LG6WxeHbxKV4PhrwI3LwIHkRTPkbk6petUOPppWlsY5GEsGV6NIykFX7iG3TAXZN238ZG3omCMxnUdZdLlMwiEOO9AYGGIXAnnDQo-W_VIygpEbER7lebYGYx0E2LlNLg7AVI/s320/IMG_7354.jpeg" width="240" /></a></div><br /><p></p><p>Almost equally simple is the whole carb situation, everything is accessible from the top and if you (like me) soak it for 12hrs in carb cleaner, then clean out the float bowl, blow some compressed air (and brake cleaner) through various ports and jets and guess what:<br /></p><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen="" class="BLOG_video_class" height="266" src="https://www.youtube.com/embed/Jy5rrIxeNKs" width="320" youtube-src-id="Jy5rrIxeNKs"></iframe></div><p>What you saw there was the first attempts after cleaning the points and then after some good old fashioned carb cleaning the tiny pickle runs, as a matter of fact, it fired up and almost instantly fell into a solid idle.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZxhsOsSOOJ8d2CVGtQJglms3Kf7M_s4zYYi54at65nw8iTEcoi5eNyOts1iwh303WIIS02JT4yZcaFovTAz5yqutVF6qgz152KryJ801XEy4LRafzJ8g2TDCrlqhmQfMqPhqZ8ttTlj3KmznkYnwAyN02xJLthRVFSAjIC5G5wF07pbqvoI3sulOpm-A/s1600/IMG_7360.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZxhsOsSOOJ8d2CVGtQJglms3Kf7M_s4zYYi54at65nw8iTEcoi5eNyOts1iwh303WIIS02JT4yZcaFovTAz5yqutVF6qgz152KryJ801XEy4LRafzJ8g2TDCrlqhmQfMqPhqZ8ttTlj3KmznkYnwAyN02xJLthRVFSAjIC5G5wF07pbqvoI3sulOpm-A/s320/IMG_7360.jpeg" width="240" /></a></div><p></p><p>Which in turn meant some treats like cleaning out the airbox again and then fitting a new airfilter.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaeUttVGHvsjgSbmFTpeRRztvfz4Rr-poAHKipvL3LRyjvtDBvhQsi-lud_gsAdlWHcbbn6-WlhZxDYCKHVOEZPLiyMsH4lg121_lDslx1taP0hfSHTKT6Ke8QjpThfjChdABfWc3ntWRopAmtGrpmaXW7EUIz_dYSiYJTp8ATwRU8fK9gliXnocmryVQ/s1600/IMG_7352.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaeUttVGHvsjgSbmFTpeRRztvfz4Rr-poAHKipvL3LRyjvtDBvhQsi-lud_gsAdlWHcbbn6-WlhZxDYCKHVOEZPLiyMsH4lg121_lDslx1taP0hfSHTKT6Ke8QjpThfjChdABfWc3ntWRopAmtGrpmaXW7EUIz_dYSiYJTp8ATwRU8fK9gliXnocmryVQ/s320/IMG_7352.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLrxY8-d6XH9JsP5sLAldlKV9N5O9_OX4ovp5gTiMOR3uG1GhAqdsqQ3b5H1bysPlTPK6An0peSfM5r2vL05AHQ17ndL3rZf4_Ewu1Dhb_14I-S77SJMcfFmqdn1psAfzgg2HVs5Bb_-k-rQkL-4P-cy52RjVTuCGHa-bVfaSLBgSOR-d6mmQuah9NtdM/s1600/IMG_7353.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLrxY8-d6XH9JsP5sLAldlKV9N5O9_OX4ovp5gTiMOR3uG1GhAqdsqQ3b5H1bysPlTPK6An0peSfM5r2vL05AHQ17ndL3rZf4_Ewu1Dhb_14I-S77SJMcfFmqdn1psAfzgg2HVs5Bb_-k-rQkL-4P-cy52RjVTuCGHa-bVfaSLBgSOR-d6mmQuah9NtdM/s320/IMG_7353.jpeg" width="240" /></a></div><br /><p>Fix the coolant temp sensor where someone had snapped off the post, most likely when attempting to open the drain plug on the carb. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikfqvLNlGqwN6qqObTAnQo4HHOJmZJPhOOZ3A1cUzwRYa0s0bWAyuWLGvAO53Q30Rw1Lm21grAXSMfYTnjXAOWrSdWRrlEd0QcJtnTXgQPOHH00Wzkp4F9edxeSl7VWr2wgPyx1ot5ZX18f4pjC11SA9XeFKhqy-EYWXL6Y5Hd6mYb3OAxPD8HH66LoMk/s1600/IMG_7363.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikfqvLNlGqwN6qqObTAnQo4HHOJmZJPhOOZ3A1cUzwRYa0s0bWAyuWLGvAO53Q30Rw1Lm21grAXSMfYTnjXAOWrSdWRrlEd0QcJtnTXgQPOHH00Wzkp4F9edxeSl7VWr2wgPyx1ot5ZX18f4pjC11SA9XeFKhqy-EYWXL6Y5Hd6mYb3OAxPD8HH66LoMk/s320/IMG_7363.jpeg" width="240" /></a></div><br /><p>And ultimately top off the radiator with some anti-freeze as the overflow bottle was frozen solid. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggsPYbUqrKihKioVdvFpy8IoQxVlATLIlthHjQ4qsBjAs1AS4k3oww8JxgLAhCn_5Fnw6MzohUMx9S8S3qNonlsuRvuIb28-qNOeHiIrdOttsnZDfTIFJI2NtUBrt9-aHWpqlAzx-HiwxcgiZo4rGEhFPZYqvCa0GvZrD723ofzhzWBm-HQcInvkDatUI/s1600/IMG_7364.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEggsPYbUqrKihKioVdvFpy8IoQxVlATLIlthHjQ4qsBjAs1AS4k3oww8JxgLAhCn_5Fnw6MzohUMx9S8S3qNonlsuRvuIb28-qNOeHiIrdOttsnZDfTIFJI2NtUBrt9-aHWpqlAzx-HiwxcgiZo4rGEhFPZYqvCa0GvZrD723ofzhzWBm-HQcInvkDatUI/s320/IMG_7364.jpeg" width="320" /></a></div><br /><p>... just to prove it: I actually drove it over to my dad's house, to see if I could make it there and back. </p><p></p><p>So what's next: Basically when this post comes out, I will have spent an afternoon mostly on the floor underneath the car to look for rust spots, rotten gearbox mounting dampers (I already know about that one), leaking axles and kind of most important for me: find out which brakes are installed on this one and exactly which version this is as there's some very subtle differences between a type 1 (no 4wd warning light on the transfer case) and a type 2 (4wd warning light, thicker shafts) and then also check which timing belt I need as this probably hasn't been done in ages and the waterpump (and various other bits on the cooling system) appear to be leaking. So if my next post starts with a famous quote from Joseph Conrad's heart of darkness, well then you know I found stuff. <br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-55619964185325682082024-01-13T20:00:00.002+01:002024-02-10T23:16:03.166+01:00Dre-XT-Stück - brakepump upgrade<p>Let's agree that even when new XT600s weren't exactly known to be the absolute wonder-weapons when it comes to braking and admittedly the addition of a later model (still single piston though) brake caliper, steel braided brakehose and a freshly rebuilt brake master only got it to a level, where I am willing to call it a very early version of ABS. Or in other words: that front brake sucks. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpkPI1e1rlxR_pZUtZ0smqkv2iKd0JdKFNHNWeimRJIqOA9tBz3DUpwwykCzqsmgAJ6QD7MysukTsNruUKeW4SrpSZgqC9VrQ7uYLLTeXfHUbMlXuib_OT4fL4jVl8z11XRp1NfYY7sH1sah4Fcir6_cWpxavkfxg09e04z4LCXBR4kKkCkTrlSlBb9Ww/s1600/IMG_7275.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgpkPI1e1rlxR_pZUtZ0smqkv2iKd0JdKFNHNWeimRJIqOA9tBz3DUpwwykCzqsmgAJ6QD7MysukTsNruUKeW4SrpSZgqC9VrQ7uYLLTeXfHUbMlXuib_OT4fL4jVl8z11XRp1NfYY7sH1sah4Fcir6_cWpxavkfxg09e04z4LCXBR4kKkCkTrlSlBb9Ww/s320/IMG_7275.jpeg" width="240" /></a></div><p></p><p>And here it is, the answer to the question: what else can you do? What we have here is a 1980ies vintage XT350, 55V brake pump. Looks pretty similar to the one fitted at the moment, except for this little "11" marking. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhlw-nO1-9Fprcv-xz5H78PHU8hGuoVnZSZZPCCssjU5S4l7cHRn9wU4l4WHC3GSiegMhnuzLjOqLlB88VxpuZaQ_V1bAoffjZ0ls6tUP-Ht7Ea2Au-Bc6vhxXjWyKsgaKQvGWn-oiynXWOTlMusYc0oBwjlaBVkR55f7ZofUTIB-kVDD_cIDKk4ACUnk/s1600/IMG_7276.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhlw-nO1-9Fprcv-xz5H78PHU8hGuoVnZSZZPCCssjU5S4l7cHRn9wU4l4WHC3GSiegMhnuzLjOqLlB88VxpuZaQ_V1bAoffjZ0ls6tUP-Ht7Ea2Au-Bc6vhxXjWyKsgaKQvGWn-oiynXWOTlMusYc0oBwjlaBVkR55f7ZofUTIB-kVDD_cIDKk4ACUnk/s320/IMG_7276.jpeg" width="240" /></a></div><p></p><p>Which stands for 11mm brake piston diameter instead of 1/2" (12.5mm) and those 12 percent less diameter result in 12 percent more travel on the lever, but also 12 percent more clamping force on those brake pads. </p><p>Unfortunately this isn't a genuinely new idea or in other words, these pumps are pricey. So much so that at the current rates, four pumps would cost the same as the bike. Which in turn means, I went for a rather affordable example. It wasn't affordable without a reason, the lid has got some road rash, the bolts holding on the lid are hopelessly rusted and obviously the original brake lever pivot bolt was replaced with the "box-o-random-nuts'n'bolts" finest. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9RTaR1n93cwu3lquQElD2bP8scemI1ZUKc4ljT7bL1ev5M3s2MWd4riFnttDfyUiicrE7kcKAAuiyFBQNnsbkstkWBeYFya4GyZWT6wVzg3HIKGDl-9ATnWbZ6_B1ZwjZeY6_y0EjAjCFj30X0R9RS_fTM-KPt2flJz0Oy250MRWW_fFCZWBqTsvfz-I/s1600/IMG_7287.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9RTaR1n93cwu3lquQElD2bP8scemI1ZUKc4ljT7bL1ev5M3s2MWd4riFnttDfyUiicrE7kcKAAuiyFBQNnsbkstkWBeYFya4GyZWT6wVzg3HIKGDl-9ATnWbZ6_B1ZwjZeY6_y0EjAjCFj30X0R9RS_fTM-KPt2flJz0Oy250MRWW_fFCZWBqTsvfz-I/s320/IMG_7287.jpeg" width="240" /></a></div><p></p><p>Not that this ever stopped me from anything really. A bit of heat and a bit of penetrant got both the old mirror mount and the bolts off the lid open. The latter admittedly with the help of a bit of Newtonian persuasion.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrj0npvmEN8Vy1hlIrczqmeMMdQg1_HNh7g_OxxPjDOl0TliznZutPyy5bRjXIIC6_A4a9i2hoxse-mq605jNsFF4TWhZGZ1E31e-bw1UknV4qJpDPQ1kx-YJ8CZTw9B3uWNzmY9zBKBVvtnGvcHvpHKV2t4lJnbqg8Di91n_tSeKEOQWgdUZxPr9xT2M/s1600/IMG_7290%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrj0npvmEN8Vy1hlIrczqmeMMdQg1_HNh7g_OxxPjDOl0TliznZutPyy5bRjXIIC6_A4a9i2hoxse-mq605jNsFF4TWhZGZ1E31e-bw1UknV4qJpDPQ1kx-YJ8CZTw9B3uWNzmY9zBKBVvtnGvcHvpHKV2t4lJnbqg8Di91n_tSeKEOQWgdUZxPr9xT2M/s320/IMG_7290%20copy.jpg" width="240" /></a></div><p></p><p>The brakefluid in the reservoir had turned into something rather nasty.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGrKOHA67qT8EkH7F8RvbZad_TUsag_v70xNKl0poqKoioD5vtkNAkBf6vznJv74pRilPnwAfpBCY44IgdCVbAzW6PKAHhDwl_3_waZcacBLMKxHIhx3ocEmB0xZ7tM8tSiJQBchaIIcJ9a2olNDzZ5szH84xst_FU4pnxAv1cKky54bQxmQe4xu8y3G8/s1600/IMG_7293%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGrKOHA67qT8EkH7F8RvbZad_TUsag_v70xNKl0poqKoioD5vtkNAkBf6vznJv74pRilPnwAfpBCY44IgdCVbAzW6PKAHhDwl_3_waZcacBLMKxHIhx3ocEmB0xZ7tM8tSiJQBchaIIcJ9a2olNDzZ5szH84xst_FU4pnxAv1cKky54bQxmQe4xu8y3G8/s320/IMG_7293%20copy.jpg" width="240" /></a></div><p></p><p>Some decent bolts and a new(-ish) brakeline later, brake performance was at bluing the disk levels and that was still with a set of glazed pads. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijr3uEzXdcnuBxxcRHK6n6mAQV9FA5PddMzUZgCaoXlfXPDzxwELxwhBBFJW5eXWaFM9pR1Jpou65fB8JIpJ8Moj8j83nUNb1JN1ygDJALQURZ3zlEax7atiCccdelj0wBCBmObe5GWf28ppwCp08zFrzAhTANN_kLjnH6e2FIUwofnvTY1TI3AcAkAck/s1600/IMG_7294%20copy.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijr3uEzXdcnuBxxcRHK6n6mAQV9FA5PddMzUZgCaoXlfXPDzxwELxwhBBFJW5eXWaFM9pR1Jpou65fB8JIpJ8Moj8j83nUNb1JN1ygDJALQURZ3zlEax7atiCccdelj0wBCBmObe5GWf28ppwCp08zFrzAhTANN_kLjnH6e2FIUwofnvTY1TI3AcAkAck/s320/IMG_7294%20copy.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjndeipkuk28hpcdIAHKwFCnkD825csZ0jB4U3buwNvI6FlnhHaClIyH2bAoCRUT3OmpMe6qNu00DyUoSWCTice886ov_Uc_TSegSJ_PFIkaOjnnnT94RmGNl9dKCWkBKhV495NQq8kDUbsPbg8gCa7cgTHLLXPp6IGwZB5X2bt4hCO6QBgOs6M12C_axA/s1600/IMG_7295%20copy.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjndeipkuk28hpcdIAHKwFCnkD825csZ0jB4U3buwNvI6FlnhHaClIyH2bAoCRUT3OmpMe6qNu00DyUoSWCTice886ov_Uc_TSegSJ_PFIkaOjnnnT94RmGNl9dKCWkBKhV495NQq8kDUbsPbg8gCa7cgTHLLXPp6IGwZB5X2bt4hCO6QBgOs6M12C_axA/s320/IMG_7295%20copy.jpeg" width="240" /></a></div><p></p><p>As is already somewhat custom, the sightglass wasn't just a bit dull, but completely blind. So I drilled an 8mm hole into the plastic, well I tried as the "glass" crumbled away and then levered out the backside metal shield and knocked the remnants of the glass out with a drift. This also meant that the outer metal ring was pretty much unsupported and I could easily pry it out with a flat blade screwdriver.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ5la9WxdvVityt4zHm3JCUXmZg3nXM23xN7Sg9jw4mF4OjJK8c9cbAG3tLz27gxMmMxpJZwJbrYMfyANkSYR9oPdsLDBQ8mRg2Uiik-rfrjRXzFy4687T8URN0WuC2qm-tnKHpsJEGCLHe2_nosgnyJhehmBWBkUK6QWFgX6dTVYptYcMrg7tmt20bgw/s1600/IMG_7296%20copy.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJ5la9WxdvVityt4zHm3JCUXmZg3nXM23xN7Sg9jw4mF4OjJK8c9cbAG3tLz27gxMmMxpJZwJbrYMfyANkSYR9oPdsLDBQ8mRg2Uiik-rfrjRXzFy4687T8URN0WuC2qm-tnKHpsJEGCLHe2_nosgnyJhehmBWBkUK6QWFgX6dTVYptYcMrg7tmt20bgw/s320/IMG_7296%20copy.jpeg" width="240" /></a></div><p></p><p>As there's a very convenient hump on the inside, the new glass was pressed in with a set of parallel-jaw pliers in absolutely no time.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjaU6dNdtYb5Csye6LTAg_c8o8rtUEKsMnLXmh8trg03B5VyYIT5CMZGC4xVlHLCv8NaKAXPZglcr_Wu3QjJWx9TfmIjvkTV5iTLek54MwIfUHyDQZCqA8jUYlu5doasuUva3k469jjo1s7uMplVDgqAuC-Pb9Zbe28KAHUEgfLMB72nv3EeTD3wlvmrw/s1600/IMG_7297%20copy.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjaU6dNdtYb5Csye6LTAg_c8o8rtUEKsMnLXmh8trg03B5VyYIT5CMZGC4xVlHLCv8NaKAXPZglcr_Wu3QjJWx9TfmIjvkTV5iTLek54MwIfUHyDQZCqA8jUYlu5doasuUva3k469jjo1s7uMplVDgqAuC-Pb9Zbe28KAHUEgfLMB72nv3EeTD3wlvmrw/s320/IMG_7297%20copy.jpeg" width="240" /></a></div><p></p><p>And with the mirror and the handguard reinstalled it looks pretty much as it did before. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUiyfr-pFaSIC2SJhkS7UaMW2DCrGJvF-SvNzPkSjOc33DxyPew9vUflDdJvf-Spi2G2GMDo3d_9HkP9XcFcQYp3Bcrp_V_l7xB3Gq0vYy5T9ykV4vP3r1bM8SQoZX8YU2IjKzgVgSlr0I3oYEdA-CGoY-khj3RWYZstN8_u0uS5C36NNcnv9QtUFqmhw/s1600/IMG_7298%20copy.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUiyfr-pFaSIC2SJhkS7UaMW2DCrGJvF-SvNzPkSjOc33DxyPew9vUflDdJvf-Spi2G2GMDo3d_9HkP9XcFcQYp3Bcrp_V_l7xB3Gq0vYy5T9ykV4vP3r1bM8SQoZX8YU2IjKzgVgSlr0I3oYEdA-CGoY-khj3RWYZstN8_u0uS5C36NNcnv9QtUFqmhw/s320/IMG_7298%20copy.jpeg" width="320" /></a></div><p>Verdict: can't recommend enough to do this mod. In fact 1984 and 85 models would have come with a variant of exactly this brake master cylinder, so strictly speaking on the very first Teneré model (34L) and perhaps the very first XT600 (43F) models, it would actually be the right tool for the job. Unfortunately it was too cold and icy to really test out what the new setup can do, but with a set of half decent (i.e. not glazed) pads I bet it can work wonders. </p><p>ADDENDUM: With the temperature being in the double digits above zero in the last few days, I had a go on the Dre-XT-Stück, really just running some otherwise rather bland errands, but boy oh boy does the old girl brake now. She even did her first (little) stoppie at a traffic light today. <br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-74215200206829145442024-01-07T20:00:00.028+01:002024-02-10T23:20:13.639+01:00Project Volksrad - Goldwing reloaded<p>Of all motorcycles from the 1980ies the one I chose to bring back was a Goldwing 1200. A 700 pound amalgamation of steel, plastic and decadence. In a sense a vehicle that most likely represents the 1980ies like hardly any other. It is a testament to a time when striving for perfection in a (touring-)motorcycle meant installing each and every gizmo possible, creating a mountain of a motorcycle that is most likely best described as either a car with no roof or a couch with two wheels.</p><p>What we have here is a 1984 Goldwing GL1200 Interstate base model. In contrast to the higher spec Aspencade it comes with an analogue gauge cluster, no cruise control and no on-board air-compressor. It should have come with conventional brakes, but instead has the non-Euro spec integral brake system of the US-models. </p><p>So we left the old girl sitting in the shed <a href="https://greasygreg.blogspot.com/2020/03/project-volksrad-watercooled-beetle.html" target="_blank">almost four years ago</a> getting assembled from various boxes of parts into a rolling chassis, basically only needing to be wired up completely or at least to see if the engine turns over and find out a bit more about its condition. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyUx2CaPOvUly1fonn0iLs9EPKIDEZebuQf9xMohIiD1QUD_l3nkFgrCxtklnQHKFRGM-0mOFNBTwY8RypIPNtDMs5KkU_59xbBY9WqQFrImtnlslosHz9Kg73eSPwY_Ja5ZG-fqFQ8ImRtPjiZ70Lm-R2-6EOWfcrNjOZSKtDKgMgsZG9u449E9eTCHE/s1600/IMG_7124.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyUx2CaPOvUly1fonn0iLs9EPKIDEZebuQf9xMohIiD1QUD_l3nkFgrCxtklnQHKFRGM-0mOFNBTwY8RypIPNtDMs5KkU_59xbBY9WqQFrImtnlslosHz9Kg73eSPwY_Ja5ZG-fqFQ8ImRtPjiZ70Lm-R2-6EOWfcrNjOZSKtDKgMgsZG9u449E9eTCHE/s320/IMG_7124.jpeg" width="240" /></a></div><p>At first glance the wiring looks very daunting and to be honest it gets kind of worse when you realise that there should be a lid on top of it all and there's actually most of the components missing.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisDOl9iPflQayjL2c2BxmnUv9EueJs7c3GJEehJ60sKLKPsm7oFJq86d6DrICz4jY4-C5v8-eFNg_PgH2uwo3DqRFzto8SH9hIT8mI_oVmlj76AFKXg1rtjIeKmc-CBKObHLUR3fuTlXkHt8Glpb-w3XqlBNW5NG1VyOJFHxn7gjvFJ3brTw1jRQCmoxA/s1600/IMG_7125.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEisDOl9iPflQayjL2c2BxmnUv9EueJs7c3GJEehJ60sKLKPsm7oFJq86d6DrICz4jY4-C5v8-eFNg_PgH2uwo3DqRFzto8SH9hIT8mI_oVmlj76AFKXg1rtjIeKmc-CBKObHLUR3fuTlXkHt8Glpb-w3XqlBNW5NG1VyOJFHxn7gjvFJ3brTw1jRQCmoxA/s320/IMG_7125.jpeg" width="240" /></a></div><p></p><p>There has to be given credit, where credit is due, whilst the whole setup is overly complex not only by 1980ies standards, it is broken down into individual modules, which can be removed (I am not going to say easily) and worked on separate from the bike, which does make the whole madness under the tank cover a lot more manageable.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrEuTCDGf1p2fSC6VuPyn51pWTtACEu6p8qtoznsoxAR1H7rrOs51xrh7q33wN8wz47Ke67ukJP9uQgvevGMcP0ggOaeIUY2HqG-jOt4XG7W5JRZagI5FbGXSwmoBfoaLdqYiTyrq7pwNAvoRvvR5FsNxjTYggrihSJBNXVBr9iRpEyc7AIoSbIKJTnbo/s1600/IMG_7139.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrEuTCDGf1p2fSC6VuPyn51pWTtACEu6p8qtoznsoxAR1H7rrOs51xrh7q33wN8wz47Ke67ukJP9uQgvevGMcP0ggOaeIUY2HqG-jOt4XG7W5JRZagI5FbGXSwmoBfoaLdqYiTyrq7pwNAvoRvvR5FsNxjTYggrihSJBNXVBr9iRpEyc7AIoSbIKJTnbo/s320/IMG_7139.jpeg" width="240" /></a></div><p></p><p>Now if the routing of the spark plug cables makes you wonder a bit, it did make me wonder too at the time, but the manual clearly stated that it had to be done in this way. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWWLbeCA14-i5gvusTaJjWiMSdsuThd3nWfgHtPZaucopSCyO0ff6_gInfD5J0GmHXe2mw1C5V0G_LMBcwQgPELtvYkyHzput3U2lncHNw4MSq5QBjxPvUFBUuc4OuZKd7l2o8y-JdZdy0JGxEyOcn8E4_APSlJf0IKDomXWjLkGG9JBViZnhWe2c6tlY/s1600/IMG_7140.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWWLbeCA14-i5gvusTaJjWiMSdsuThd3nWfgHtPZaucopSCyO0ff6_gInfD5J0GmHXe2mw1C5V0G_LMBcwQgPELtvYkyHzput3U2lncHNw4MSq5QBjxPvUFBUuc4OuZKd7l2o8y-JdZdy0JGxEyOcn8E4_APSlJf0IKDomXWjLkGG9JBViZnhWe2c6tlY/s320/IMG_7140.jpeg" width="320" /></a></div><p>Another nice thing is the cable management on the whole bike - if there's a plug, there's also a holder nearby. If not, the cables are routed incorrectly. Not so much an issue under the left side cover with only two plugs present, but a proper game changer under the "tank".</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSaOiMWOrAciJy6bKZ_kB1rT4KMLJwaAO5408hysLqcU7OIBw0iTDZTSrL4L7w9oLToEI44uZxEHLP2I6jaqnSaihtybR62paKOPRAbwaWssaUoVlxL17hEEOE9TCJSRABjWPR6NYkClwGYtWj8K4WJOjZEY7CkHCoDLztA6djKFbSk61SuOLLwA3-N6Q/s1600/IMG_7150.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSaOiMWOrAciJy6bKZ_kB1rT4KMLJwaAO5408hysLqcU7OIBw0iTDZTSrL4L7w9oLToEI44uZxEHLP2I6jaqnSaihtybR62paKOPRAbwaWssaUoVlxL17hEEOE9TCJSRABjWPR6NYkClwGYtWj8K4WJOjZEY7CkHCoDLztA6djKFbSk61SuOLLwA3-N6Q/s320/IMG_7150.jpeg" width="240" /></a></div><br /><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibZAzlILllHXo1jKk11HWA7NBgu-sljUsQmecZ4mrtJ-5LuHmJ_Q8OxvXyaegw5gF5KkGP0RnVZ0fzp5cRGRuIntr49LHNBV6CBG_Gh9ZEUzNbUxnpNnNRsOOk574SsobmPs2gAVPxMRAKiKb8giT4esdR7dgAqXyqnbzM9WdYp5H2wLsDI2kZDNfPWPg/s1600/IMG_7142.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibZAzlILllHXo1jKk11HWA7NBgu-sljUsQmecZ4mrtJ-5LuHmJ_Q8OxvXyaegw5gF5KkGP0RnVZ0fzp5cRGRuIntr49LHNBV6CBG_Gh9ZEUzNbUxnpNnNRsOOk574SsobmPs2gAVPxMRAKiKb8giT4esdR7dgAqXyqnbzM9WdYp5H2wLsDI2kZDNfPWPg/s320/IMG_7142.jpeg" width="240" /></a></div><p></p><p>There are certain moment, when I would love to ask the Goldwing engineers what their reasoning was behind certain solutions: See this dipstick? Very nice, now look slightly to the left and a bit further up that's the filler port. My only assumption is that there were sidepanels available to essentially hide all of the engine, which would have made the filler plug inaccessible. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLFAo-uxHikY-9FMSfwzRJHk4A6uuc8GjXGrifbkSsyCEHoc6DoP-u5pYaUbqb1cYKDzwA6UmQgshU8vQE4FeHh2ZFCb9LRhHs3pkSb99jb4nenWvErp4lG0KN6vTXffTtDm334Nktiu6hwLAaArsnyqHKPHz_6RbdW6lIqanWR8d2oU77ikvH5kKZ0Bk/s1600/IMG_7144.heic" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLFAo-uxHikY-9FMSfwzRJHk4A6uuc8GjXGrifbkSsyCEHoc6DoP-u5pYaUbqb1cYKDzwA6UmQgshU8vQE4FeHh2ZFCb9LRhHs3pkSb99jb4nenWvErp4lG0KN6vTXffTtDm334Nktiu6hwLAaArsnyqHKPHz_6RbdW6lIqanWR8d2oU77ikvH5kKZ0Bk/s320/IMG_7144.heic" width="240" /></a></div><p></p><p>Using quite a few photos from the internet to find out where each component is supposed to go the space under the tank cover is now well populated and there's still quite a few spots left in those cable organizers, which is fair enough as none of the radio-equipment and the like is installed yet. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7dKxS1QJJZzdi4-SWGmKsEC6xvbR9C4OQCEm1sWNw21xFr5h1RjFfKepHbf1os-Dwym62S456f1L7gKkKRUx8vwgyzuB6QQDpes7wSxFoz10bQi6vkcig0HNl2jCK7xdFLVeevqtHtvl52iDiBi2BVyMg87WPe22SfF8DooRF7QwLJ-nZxijJxsFl5rU/s1600/IMG_7151.heic" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh7dKxS1QJJZzdi4-SWGmKsEC6xvbR9C4OQCEm1sWNw21xFr5h1RjFfKepHbf1os-Dwym62S456f1L7gKkKRUx8vwgyzuB6QQDpes7wSxFoz10bQi6vkcig0HNl2jCK7xdFLVeevqtHtvl52iDiBi2BVyMg87WPe22SfF8DooRF7QwLJ-nZxijJxsFl5rU/s320/IMG_7151.heic" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqKESgkgj3V49OYotrm9qXnHf6DMaPbfr4BYOgkl3VAzpUTqcz0-StI5q66_qvQnvfV-cf6insr-XeX2F4fURSUXUdXr93Rvb5hheKKOQpLjZSG1Boi0vHWuegLV-cYQ79XQ7wlsA7c_S9ZTJZDOfJpCxT3B44mC20zhpa9Skz_M63RWlnhapoojcfKSk/s1600/IMG_7241.heic" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqKESgkgj3V49OYotrm9qXnHf6DMaPbfr4BYOgkl3VAzpUTqcz0-StI5q66_qvQnvfV-cf6insr-XeX2F4fURSUXUdXr93Rvb5hheKKOQpLjZSG1Boi0vHWuegLV-cYQ79XQ7wlsA7c_S9ZTJZDOfJpCxT3B44mC20zhpa9Skz_M63RWlnhapoojcfKSk/s320/IMG_7241.heic" width="320" /></a></div><p></p><p>No smoke and quite a few lights doing ... something ... on the dash, but not even remotely willing to do anything at the press of a button. To cut a rather long story short, the first issue was the retrofitted sidestand switch, which had broken internally and would NOT cut the ignition in only one position and with that I mean literally only a few degrees out and it would do nothing or only very erratic things. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3hzbzZYtrB1Gmw9m-0XAjmgMdp0TUwfjc1xz6M-T8386Xe3f-kSWBoBzRKvu7nde-BqBbJOehoOVkgy1Id4cDDmquUFCFnXwz0Hlk2RCJjmLQC7LILwJhc4V4Y17VtxeYZz6VysRFpqeWTAe5gvVWT6usdGsmMvUvEfW5t0BRe8DZXYtqYIHOuVUWLzI/s1600/IMG_7243.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3hzbzZYtrB1Gmw9m-0XAjmgMdp0TUwfjc1xz6M-T8386Xe3f-kSWBoBzRKvu7nde-BqBbJOehoOVkgy1Id4cDDmquUFCFnXwz0Hlk2RCJjmLQC7LILwJhc4V4Y17VtxeYZz6VysRFpqeWTAe5gvVWT6usdGsmMvUvEfW5t0BRe8DZXYtqYIHOuVUWLzI/s320/IMG_7243.jpeg" width="240" /></a></div><p></p><p>Then there was one plug going to the dash that was plugged in into the incorrect counterpart, but the biggest one was, the official Honda factory manual was wrong. Scroll back up, if you like, where I wrote that it looked a bit weird and not quite how I would have run the spark plug cables myself.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiId3WdqZZba12e1Sy-eOPCdT7vsEdbn-e4t8oY3MqXuU065D1b4TLOovsuqnnctDCvHwBmRSSt_VCh33lmRtWdEifzWBOAQMX6dR6Q7jjGCDaE_c-yEbsgaDcsBtsHVvQuzFis5gd8731e9-hleYVVgb7u_EGrW-t0D2aPKm5kq3b9BSmxGn_uZcxeuFg/s1600/IMG_7138.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiId3WdqZZba12e1Sy-eOPCdT7vsEdbn-e4t8oY3MqXuU065D1b4TLOovsuqnnctDCvHwBmRSSt_VCh33lmRtWdEifzWBOAQMX6dR6Q7jjGCDaE_c-yEbsgaDcsBtsHVvQuzFis5gd8731e9-hleYVVgb7u_EGrW-t0D2aPKm5kq3b9BSmxGn_uZcxeuFg/s320/IMG_7138.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen="" class="BLOG_video_class" height="266" src="https://www.youtube.com/embed/Bc6TsoXcets" width="320" youtube-src-id="Bc6TsoXcets"></iframe></div><br /><p>A quick check revealed that my suspicion wasn't all that unfounded and turns out in later editions of the same manual this schematic can be found:</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsbz2czhlDwumAriNDoYwklFv7hquH57TNfhfReCKWejL4H0LXH9nUNmm72-79PR7VnAu4Wuzwxk2nYBzvq2W2OVfcI46k5uTgWk6tZ5mH97BkUSzlPKnOiGa_obWSG-G0Objpw44nrFTNx0BYynKyNGvInGJjb54uEc8tJ4aM24n6oWr6Il9f-1VHpCU/s1986/IMG_7244-cropped.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1986" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhsbz2czhlDwumAriNDoYwklFv7hquH57TNfhfReCKWejL4H0LXH9nUNmm72-79PR7VnAu4Wuzwxk2nYBzvq2W2OVfcI46k5uTgWk6tZ5mH97BkUSzlPKnOiGa_obWSG-G0Objpw44nrFTNx0BYynKyNGvInGJjb54uEc8tJ4aM24n6oWr6Il9f-1VHpCU/s320/IMG_7244-cropped.jpeg" width="193" /></a></div><p></p><p>Aside from the fact that one of the spark plug cables was so worn out (and too short to be trimmed any more), it was then just a case of add fuel and fire the old girl up. </p><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen="" class="BLOG_video_class" height="266" src="https://www.youtube.com/embed/QBkWUTLAp0w" width="320" youtube-src-id="QBkWUTLAp0w"></iframe></div><p>It was a this point that thanks to a tip from Lars I attempted to take the back cover off from the fuel pump body and instantly found the reason, why the pump would do absolutely nothing. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_W8k0yXvbJByNjw8_-LGS1USVZCogmUeoJd3zUkYVE7OsR_1wd7aUcgZ6msouhtNIaEKmkHMu1xO24McmvEv3LdJ0KwajBSA_xzBXER-67CcY8LLtN1pg7Ww27OHvf5lG82OE5OKRTrP-aVQClTzVIq3AnFf4-rEBeBsur5KxrA8k_yxLlI44A1M8TM4/s1600/IMG_7249.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_W8k0yXvbJByNjw8_-LGS1USVZCogmUeoJd3zUkYVE7OsR_1wd7aUcgZ6msouhtNIaEKmkHMu1xO24McmvEv3LdJ0KwajBSA_xzBXER-67CcY8LLtN1pg7Ww27OHvf5lG82OE5OKRTrP-aVQClTzVIq3AnFf4-rEBeBsur5KxrA8k_yxLlI44A1M8TM4/s320/IMG_7249.jpeg" width="240" /></a></div><p></p><p>What's next: Swap those spark plug cables for new ones, install the radiator and whatever is missing there. Then the integral brake system has to go in favor of a conventional setup with steel braided brake hose and whilst I am at it, the hydraulic clutch also needs a new (braided) line. The exhaust is quite a mess and so far at best half of the electrics is done, but it runs (on three legs) and it charges, so I guess the rest will work out eventually.</p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-78442465272195653192023-12-23T20:00:00.010+01:002023-12-23T20:00:00.150+01:00The pretty one - fixing stripped head bolt threads<p>
The pretty one is my dad's XT500T 4 valve. What it is, is essentially a
XT600 2KF, but with a smaller bore (87mm) and the cylinder head off a JDM
XT400. This means it has got smaller valves and a smaller combustion
chamber than a stock XT600. Whilst in a sense it is good that Yamaha put
the effort in to make the engine work decently with the smaller bore, it also
created its own set of problems. Whilst engine parts for the 600 are
comparatively cheap and definitely plentiful this is definitely not the case
for the 500 version as it was pretty much only sold in Austria. This should
answer the question why we didn't simply get another cylinder and be done with
it. Also yes, you can convert it to 600cc, but that would still mean you'd
have to bore out the engine case and quite simply my dad didn't want this.
(Remember when I did a frame swap, i.e. registered a new bike, because that
was easier than converting Dre-XT-Stück to 600cc? There might be an
explanation hidden in there somewhere...)
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEint1xLrNnsCdF-ESTHRsuLPND8eCl0pDMcArkzjI_gAqO2Xr55VeIEqD-X0FECmryRVK6qt1NSo0VvF8COF4FoUJMUSD-w8EWtH4JgYfhTBS8SAKbbkVSe0FP-QY8qYZT0FpZgQ4FL9WVvyEHJsUnbonjBqnjNf8_XgNgj9vYAklpbHA0xZTU9f0PKdbk/s1600/IMG_7109.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEint1xLrNnsCdF-ESTHRsuLPND8eCl0pDMcArkzjI_gAqO2Xr55VeIEqD-X0FECmryRVK6qt1NSo0VvF8COF4FoUJMUSD-w8EWtH4JgYfhTBS8SAKbbkVSe0FP-QY8qYZT0FpZgQ4FL9WVvyEHJsUnbonjBqnjNf8_XgNgj9vYAklpbHA0xZTU9f0PKdbk/s320/IMG_7109.jpeg" width="320" /></a>
</div>
<p></p>
<p>
So the story with the headbolt threads follows a very classic recipe: The
headbolts are M8, they are torqued to 30NM and they go straight into the
aluminium of the cylinder. The cylinder in question has already been
helicoiled three times, but there were two installation failure as I found out
during the repair. A more permanent solution was needed and it came in the
form of a handful of homemade threaded inserts. They are M12 on the outside
and M8 on the inside and the ones I ended up using where 20 and 30mm long.
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJepbEE5xZYY5ceERTuP8WN9AQVbtof3Ay4BCPDDX8DDd52KIgzO1o_wXEgvegZ_PghqnSBFSBCAlXNMOasvb46xusdh8UhL58VvWs4qVx4TARGvOGNYU0guyVYbbui9ugfwri4TlkwJRBQ_M3TEmhx5p0qtV5OVcYx5AwfZcpz75wUtzF1UIH4rv2a1k/s1600/IMG_6837.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJepbEE5xZYY5ceERTuP8WN9AQVbtof3Ay4BCPDDX8DDd52KIgzO1o_wXEgvegZ_PghqnSBFSBCAlXNMOasvb46xusdh8UhL58VvWs4qVx4TARGvOGNYU0guyVYbbui9ugfwri4TlkwJRBQ_M3TEmhx5p0qtV5OVcYx5AwfZcpz75wUtzF1UIH4rv2a1k/s320/IMG_6837.jpeg" width="240" /></a>
</div>
<p></p>
<p>
After taking the head off, it was pretty obvious where the headgasket leak
was.<br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmMKbNFUXm3HP5WhrAnQ_nko9_L83LO5pZB8N7Kbo7suNAvmYgkPIiDyn-I4YHLRimnSexzBVpEDglbpsYMurtNQxSRw7NjpYKr5EQIa55RR3uU5FruXWZxlje7mYkYaEPtyBpdreqwNOH0a5hyphenhyphenIwzgxuULC8m_ov_74YxEhqGezlU8AQj9XieaxSqFr0/s1600/IMG_7026.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjmMKbNFUXm3HP5WhrAnQ_nko9_L83LO5pZB8N7Kbo7suNAvmYgkPIiDyn-I4YHLRimnSexzBVpEDglbpsYMurtNQxSRw7NjpYKr5EQIa55RR3uU5FruXWZxlje7mYkYaEPtyBpdreqwNOH0a5hyphenhyphenIwzgxuULC8m_ov_74YxEhqGezlU8AQj9XieaxSqFr0/s320/IMG_7026.jpeg" width="240" /></a>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj31M1BXPXNlVy8K8KNugcegobuddNVonmweBp8vgc9rtM-5FETeuR8iH69p4v84yFfUMz5JWX2bmYOocv0PfJeoeg6-3RNpr2IsYAyfSxq-GEkoWm81k_yzpHc7moRMb8rXCNki9PKJfrTlE6vsnJTj8mYcxyyWnG3GaEo-tp-fGm5Ql4Txno9sRf-3Yc/s1600/IMG_7027.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj31M1BXPXNlVy8K8KNugcegobuddNVonmweBp8vgc9rtM-5FETeuR8iH69p4v84yFfUMz5JWX2bmYOocv0PfJeoeg6-3RNpr2IsYAyfSxq-GEkoWm81k_yzpHc7moRMb8rXCNki9PKJfrTlE6vsnJTj8mYcxyyWnG3GaEo-tp-fGm5Ql4Txno9sRf-3Yc/s320/IMG_7027.jpeg" width="240" /></a>
</div>
<p>
I (wrongly) assumed that the biggest challenge with this repair would be to
install the recessed threaded inserts... as the first one had spat out its
helicoils this was a very straight forward job. Nerve wrecking, but simple
enough.<br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1ajO8XgijssOH8XX-wlBygjT86qsgAH079AiO9FPybh12_eqgTm1uMdb0xfyctkLIhWHjPM3nAb9aWmaVLkpu72beT3uaFsMQXG__-iCFgb44JJEKaZ7kgU7wJHCLySgbgPhrQ5EjDKM-FMQ6fZ47n8Sui-0klCurAwIiIlWSHWR54DV4-EWBn3hkXwA/s1600/IMG_7048.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1ajO8XgijssOH8XX-wlBygjT86qsgAH079AiO9FPybh12_eqgTm1uMdb0xfyctkLIhWHjPM3nAb9aWmaVLkpu72beT3uaFsMQXG__-iCFgb44JJEKaZ7kgU7wJHCLySgbgPhrQ5EjDKM-FMQ6fZ47n8Sui-0klCurAwIiIlWSHWR54DV4-EWBn3hkXwA/s320/IMG_7048.jpeg" width="240" /></a>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgONZS_0cpr1qaGoUskdcbbZkXpDdBZDkYFYeg6D2Qziqkc77bXrKjWJhgugY4ygZlusbKDGOlPuuAd48qKpcFGoezYc8jhOH230dMU8Wg37mIBvHx7H4aSQgo_a2kUrJF8-Y1xURSTrlrcIw4TpVLeq9jgFV9pYdBWwbQCGQDmJOw6wO_wQgGAyn5bJig/s1600/IMG_7049.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgONZS_0cpr1qaGoUskdcbbZkXpDdBZDkYFYeg6D2Qziqkc77bXrKjWJhgugY4ygZlusbKDGOlPuuAd48qKpcFGoezYc8jhOH230dMU8Wg37mIBvHx7H4aSQgo_a2kUrJF8-Y1xURSTrlrcIw4TpVLeq9jgFV9pYdBWwbQCGQDmJOw6wO_wQgGAyn5bJig/s320/IMG_7049.jpeg" width="240" /></a>
</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaTu93AOxcr54sI8CJvoudWPOKgRYe4Zljg2fOKR9V1C7gIFmXm-Wj49_uXOz5HKVDnUx5DCGaJ5_JIdbL_lPonL6xleGGXhxCCsfWlHDRvgrl5XdGPIWcckKjYkY-vQf7DKNyTaKlIbguChA7C_Km2iSIw4Pdj8RywegHfSdmlpQkWgCt5KNkPz4-0Vc/s1600/IMG_7050.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaTu93AOxcr54sI8CJvoudWPOKgRYe4Zljg2fOKR9V1C7gIFmXm-Wj49_uXOz5HKVDnUx5DCGaJ5_JIdbL_lPonL6xleGGXhxCCsfWlHDRvgrl5XdGPIWcckKjYkY-vQf7DKNyTaKlIbguChA7C_Km2iSIw4Pdj8RywegHfSdmlpQkWgCt5KNkPz4-0Vc/s320/IMG_7050.jpeg" width="240" /></a>
</div>
<p>
On the second one, the helicoil was still in there, but as I found out, the
locking tab hadn't grabbed correctly and I just pulled it out.
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR-RjdLfKu8SnoNXzDE7VlYQSEbhHj0KDFzgOodK3h4cE5_Ubj2_jvSChYfqW5SCDh5v_M_yL0bwpI6NoleSfpWX7Ag9CxgWNe4XmtP51eCpC9Hm5D_8MzEyT0HNqaF0EdFLtAl8CUTu2By7LaLOeMpZ1LGKHbvNyHY6xOf5OrK_LqnHiPHmBdl9FHWsU/s1600/IMG_7052.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiR-RjdLfKu8SnoNXzDE7VlYQSEbhHj0KDFzgOodK3h4cE5_Ubj2_jvSChYfqW5SCDh5v_M_yL0bwpI6NoleSfpWX7Ag9CxgWNe4XmtP51eCpC9Hm5D_8MzEyT0HNqaF0EdFLtAl8CUTu2By7LaLOeMpZ1LGKHbvNyHY6xOf5OrK_LqnHiPHmBdl9FHWsU/s320/IMG_7052.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Installation was simple enough: an M8 bolt, a nut, a spacer and the insert.
(Yes the spacer is also made from a bit of turned down M12 threaded rod.
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyag-7NLiAyWnXK5WpH1FfbY9njCFgFGnHkzZqv_boSKQ7uYuQPwhOKX3X8uPbwo-jePTBT4mLAzU-iukULRn7zEhyphenhypheniUhdIUIGB5Yv8O5yVvHN7DKgFoujfPoY96vxM3QTkmGVl8cWlDmrsHPS3gL3HQSHq56jnTS_FfygXR5YbuiWTP3-2TSdC29Pj-E/s1600/IMG_7056.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyag-7NLiAyWnXK5WpH1FfbY9njCFgFGnHkzZqv_boSKQ7uYuQPwhOKX3X8uPbwo-jePTBT4mLAzU-iukULRn7zEhyphenhypheniUhdIUIGB5Yv8O5yVvHN7DKgFoujfPoY96vxM3QTkmGVl8cWlDmrsHPS3gL3HQSHq56jnTS_FfygXR5YbuiWTP3-2TSdC29Pj-E/s320/IMG_7056.jpeg" width="240" /></a>
</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvZClAcqG4AWAvRCVgqyC1w2YdZySgHnBHBOhRIgYdg61OMAOsuIdNP3E-a0J1w2VUmbaZ97BGVqrCV4_CLYD5dEiWb5NJ3xexJzz9BQJPZCHVq5-5AZk3qGcngMVUiyUX1OuXnqTQBhLYCKqaki9axDTKueRPoLTloZV5X2TR5d8kV8DRH0EsVR92cok/s1600/IMG_7059.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvZClAcqG4AWAvRCVgqyC1w2YdZySgHnBHBOhRIgYdg61OMAOsuIdNP3E-a0J1w2VUmbaZ97BGVqrCV4_CLYD5dEiWb5NJ3xexJzz9BQJPZCHVq5-5AZk3qGcngMVUiyUX1OuXnqTQBhLYCKqaki9axDTKueRPoLTloZV5X2TR5d8kV8DRH0EsVR92cok/s320/IMG_7059.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Just to be really sure the inserts were glued in with some high strength
locking adhesive.
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbyJExvwajdX1W3nV_394joa8x0dYn2tXY4Q1i2jb0AyAMo_AU9dC3zjtboXcMsOgxTGMUIa3TIUzzIQohXlyZqTtE9aVuIO5N6HHWPtFkywca4gROdzMdgbICSs5UcZa5OdRvXbs3ZRGn85VdcOsEYak53_bh9WdGCL0GsnGMS_MgmzLLawRASJZi_yE/s1600/IMG_7060.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbyJExvwajdX1W3nV_394joa8x0dYn2tXY4Q1i2jb0AyAMo_AU9dC3zjtboXcMsOgxTGMUIa3TIUzzIQohXlyZqTtE9aVuIO5N6HHWPtFkywca4gROdzMdgbICSs5UcZa5OdRvXbs3ZRGn85VdcOsEYak53_bh9WdGCL0GsnGMS_MgmzLLawRASJZi_yE/s320/IMG_7060.jpeg" width="240" /></a>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqvyh_JJ5vxsS1J_v-tMI-qJDHHQB4HVw_8mTGrZmYXc7KNUQM7LxcsgeZ-RXOx5gt2XT3kThqnzwaCsxz5yFRCAwmU16EzvAdmzycEC5O81xVjIG3_-oazQg_j5Mq1hapPg_hTFctPwAtXoah2J4prEdRky1Kl77jZvQbLgKTrqOrlCHQAAFvMpRtAu0/s1600/IMG_7061.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqvyh_JJ5vxsS1J_v-tMI-qJDHHQB4HVw_8mTGrZmYXc7KNUQM7LxcsgeZ-RXOx5gt2XT3kThqnzwaCsxz5yFRCAwmU16EzvAdmzycEC5O81xVjIG3_-oazQg_j5Mq1hapPg_hTFctPwAtXoah2J4prEdRky1Kl77jZvQbLgKTrqOrlCHQAAFvMpRtAu0/s320/IMG_7061.jpeg" width="240" /></a>
</div>
<p></p>
<p>Test fit with the locating dowels in place worked a treat.<br /></p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZ-rJ1IMkBE7Ry86wOusBBNUlm8opiQ0cb-bAKL72zGoVMDwEKA3JA2OxRplzTP32u6NLqbg-RwL_iEMBSmo9-EsgwNR75RVaxPd0DAw9i9gmTkknX5mNFUiABNzYfGFtpmxgD0yGTFlq9UD0BIpW0MHu1_gk4UHyRXd70RKxPN5r_l-7viTgvMD43aYo/s1600/IMG_7062.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZ-rJ1IMkBE7Ry86wOusBBNUlm8opiQ0cb-bAKL72zGoVMDwEKA3JA2OxRplzTP32u6NLqbg-RwL_iEMBSmo9-EsgwNR75RVaxPd0DAw9i9gmTkknX5mNFUiABNzYfGFtpmxgD0yGTFlq9UD0BIpW0MHu1_gk4UHyRXd70RKxPN5r_l-7viTgvMD43aYo/s320/IMG_7062.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Somewhat inspired by all of this, the next day I decided to upgrade all
remaining headbolt threads as well, including the one with the only working
helicoil of the previous repair attempt. It did not go well.
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGxWn_HpFwCDaCOXzN4tX3MM1oBGjXCowVwCtHCBXw5cBVysH7qjl6614fhbLi-FMY3jlHeA-Cuo10blgaLhxEOFsnhXEvFGW2loIhp7HDHY3RS3e-ov1CiyNk71MCOA4oxa_GZQ1_BAkVt-FqiR4ouY_R0NhSDNVJ5jgPGjA0t5Y6r-JKlrCF57iSKbo/s1600/IMG_7081.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGxWn_HpFwCDaCOXzN4tX3MM1oBGjXCowVwCtHCBXw5cBVysH7qjl6614fhbLi-FMY3jlHeA-Cuo10blgaLhxEOFsnhXEvFGW2loIhp7HDHY3RS3e-ov1CiyNk71MCOA4oxa_GZQ1_BAkVt-FqiR4ouY_R0NhSDNVJ5jgPGjA0t5Y6r-JKlrCF57iSKbo/s320/IMG_7081.jpeg" width="240" /></a>
</div>
<p></p>
<p>
As the previous attempt of getting a helicoil out worked rather well, I didn't
think much of it and snapped my drill about 10mm below the surface when it
locked up. Those were two no very funny hours. <br />
</p>
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</div>
<p></p>
<p>
... the final one was a case of "more of the same" was every bit as pleasantly
straight forward as one could have hoped for. (And yes, I had made a new
spacer in the meantime.)<br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEfeh7019yNxy68LnWuCiaJ6TpJ0sDJdhME11cju0-IXfRgxyFjPZy8-AM1Aeaiolf4WxlpoPXvAQvgEN4tEoiWBlbUB2__fsX5w49cSI5XqVHBEF12d10l8Ysl9vJPSwSOPK1-fdxD6OBNNxnvUA2FVzF8yhkqxPaCydsdFbUM9hVejgaWh4soIrD_Gk/s1600/IMG_7085.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEfeh7019yNxy68LnWuCiaJ6TpJ0sDJdhME11cju0-IXfRgxyFjPZy8-AM1Aeaiolf4WxlpoPXvAQvgEN4tEoiWBlbUB2__fsX5w49cSI5XqVHBEF12d10l8Ysl9vJPSwSOPK1-fdxD6OBNNxnvUA2FVzF8yhkqxPaCydsdFbUM9hVejgaWh4soIrD_Gk/s320/IMG_7085.jpeg" width="240" /></a>
</div>
<p>The finished product.<br /></p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfoCv8ycidPY-dIbsQRbXYmfp5UwaMrnXwjiVpn4QcqO0paY2dkjDotIgh-B4sT-K3NVgZVXyP0PgWFbjAN7eJ_3zROf8Z2atGYUVw4PSGS8dGCQGw-QzSKyvmfwMo5UijBTzpWThnQ-fMDGXihkrr-Wp8CE3kYU6Cz1hYgrXrLMJx5q_yixfShDKBgW8/s1600/IMG_7088.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfoCv8ycidPY-dIbsQRbXYmfp5UwaMrnXwjiVpn4QcqO0paY2dkjDotIgh-B4sT-K3NVgZVXyP0PgWFbjAN7eJ_3zROf8Z2atGYUVw4PSGS8dGCQGw-QzSKyvmfwMo5UijBTzpWThnQ-fMDGXihkrr-Wp8CE3kYU6Cz1hYgrXrLMJx5q_yixfShDKBgW8/s320/IMG_7088.jpeg" width="240" /></a>
</div>
<p></p>
<p>
What followed next is the "usual" assembly of an XT engine, though I have to
admit that there's a distinct difference between a completely sh*gged example
and a well-cared for two-owner bike.
</p>
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</div><p></p><p>Apparently last time I swapped the headgasket I made the same mistake as on the Dre-XT-Stück with choosing the wrong time mark (talk about consistency), so that was rectified in the same go. <br />
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</p><p>... and that one bit where I decided it was time to ruin the purity and replace some mangled JIS screws with some stainless M4x25 allen heads.<br />
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</p><p>The first startup was pleasantly unexciting. Let's hope it stays this way. </p><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen="" class="BLOG_video_class" height="266" src="https://www.youtube.com/embed/rbfMNounJLM" width="320" youtube-src-id="rbfMNounJLM"></iframe></div><p>Merry Christmas dad. 😌<br />
</p><p>(Yes there's plenty more work that needs to be done to make it usable, but at least for now it seems as if the head's going to stay where it is supposed to be.)<br /></p>
Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-50168956917044647022023-12-15T20:00:00.016+01:002023-12-15T20:00:00.233+01:00The SR500 sidecar - repairing the sprocket carrier and converting it to a more conventional style<p>First of all let me point out that the initial idea for all of this isn't from me, but I gave it my personal touch. The original idea can be found at <a href="https://motorang.com/bucheli-projekt/hinterradnabe.htm#6006" rel="nofollow" target="_blank">Motorang's Buchelli Projekt - Kettenblatttraeger</a> </p><p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKlrMmx97UdsVH6xxf6BgE4cON_I6gCHb3XxGCwPiXt07FJ2vCic4IU79RDgNgc6rJCcXx0Z2ch5_MrYWYmCJdT2ipU_oJ0refWrDpmHhVaSwqzDCXLzN3_EUcfuNw1BgzF3cAie_lh0nxB4NPPr8omjNp2aZ0OOO0dFuOLzY0O9hvT1RoqImCVxPftX0/s1600/IMG_6959.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKlrMmx97UdsVH6xxf6BgE4cON_I6gCHb3XxGCwPiXt07FJ2vCic4IU79RDgNgc6rJCcXx0Z2ch5_MrYWYmCJdT2ipU_oJ0refWrDpmHhVaSwqzDCXLzN3_EUcfuNw1BgzF3cAie_lh0nxB4NPPr8omjNp2aZ0OOO0dFuOLzY0O9hvT1RoqImCVxPftX0/s320/IMG_6959.jpeg" width="240" /></a></div><br /><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjz31QdH7om8Umq_Ik7dK-M22Sc19f5AS29mJH1jOzXY-kv_MN8aJvK9po07MRMjqMmD9u_bDf0QJb60FINK-Q3oRMCZmpsizlnK61xhsMlKL_acDz_7hyphenhyphenFCGsqstFlR_h4JrIAJ-n9_tzuEiJmbqLXB_sLMVJnVdH5oq0E5MWNSZnSNWmiMCVHgrWWMvU/s1600/IMG_6714.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjz31QdH7om8Umq_Ik7dK-M22Sc19f5AS29mJH1jOzXY-kv_MN8aJvK9po07MRMjqMmD9u_bDf0QJb60FINK-Q3oRMCZmpsizlnK61xhsMlKL_acDz_7hyphenhyphenFCGsqstFlR_h4JrIAJ-n9_tzuEiJmbqLXB_sLMVJnVdH5oq0E5MWNSZnSNWmiMCVHgrWWMvU/s320/IMG_6714.jpeg" width="240" /></a></div><p><br /> As you can see in this picture, the whole setup on XT500 and SR500 models is a bit on the weird side. In an attempt to save a bearing in the sprocket carrier a very elaborate clamping solution has been employed. This worked so well that on the XT600 models the almost identical rear wheel hub was modified to have a bearing and a spacer be independent from the rear wheel. </p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDiB1lh9v6aNMXR7Ad3DMopWi-pEO8Rmc4TwXHGp9tp4WWArm5AfPQmvP7Ns7UXIZsemanwIB0btqC_7N8UHJLvBfLWffJt1rxn-V5Qpf8QD3mDbC1kYtRvDz2dZM9aBZ_dEogJ0cn8W2lUIdV4_vsKM_aHh4I7uuPozqACbN24wvdcfObddoUbf3zSoM/s1600/IMG_6895.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDiB1lh9v6aNMXR7Ad3DMopWi-pEO8Rmc4TwXHGp9tp4WWArm5AfPQmvP7Ns7UXIZsemanwIB0btqC_7N8UHJLvBfLWffJt1rxn-V5Qpf8QD3mDbC1kYtRvDz2dZM9aBZ_dEogJ0cn8W2lUIdV4_vsKM_aHh4I7uuPozqACbN24wvdcfObddoUbf3zSoM/s320/IMG_6895.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEv8NmwmgcNshuy37W8sTLpuAfm5r1S_XMa2LRms0aGTnVgWAHNncfzbYCbFYxtsaxiHHsOFSZA5r8pDYgEwHpfIXDHXiDCk43kfHjCuJbeMHDj2DVFfeiKsB5_IpfDlMVGCGULqlpMBhL8Z2Cw9UN61rqmihkg8dExj_LIbzzLjAnVAnK00UjiJEGcLE/s1600/IMG_6896.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEv8NmwmgcNshuy37W8sTLpuAfm5r1S_XMa2LRms0aGTnVgWAHNncfzbYCbFYxtsaxiHHsOFSZA5r8pDYgEwHpfIXDHXiDCk43kfHjCuJbeMHDj2DVFfeiKsB5_IpfDlMVGCGULqlpMBhL8Z2Cw9UN61rqmihkg8dExj_LIbzzLjAnVAnK00UjiJEGcLE/s320/IMG_6896.jpeg" width="240" /></a></div> <p></p><p>Luckily there's enough meat in the sprocket carrier to modify it to accept a 6006-2RS ball bearing instead, as it <b>just </b>has<b> </b>to be bored out to 55mm and 13mm deep. The just part is that you don't really have a clean reference surface, so clocking and tapping it in is the bigger part of the job. </p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBwqF2dQIK-InyaIh_Bj42644OOBjFOev6JPjd4CUWUINEgUs2uYWlad6mjll0cZnw7e7ikJ2sKpjmtBa-_nMNKyrQ48LyAV8a5zdrlSEvXqFwmW7UF7Nx1aezA7WPfSDNYMKS5_JpWQMvp1Yq_UhsQSYohdXE_bWYwrJ63AOaGaN2aYdZE5efnCdDLUA/s1600/IMG_6898.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBwqF2dQIK-InyaIh_Bj42644OOBjFOev6JPjd4CUWUINEgUs2uYWlad6mjll0cZnw7e7ikJ2sKpjmtBa-_nMNKyrQ48LyAV8a5zdrlSEvXqFwmW7UF7Nx1aezA7WPfSDNYMKS5_JpWQMvp1Yq_UhsQSYohdXE_bWYwrJ63AOaGaN2aYdZE5efnCdDLUA/s320/IMG_6898.jpeg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZDJutofaPQzuOjRt-ODrcH-lODvf8cVzvp_S5lln8L_hRZA9l-UKN59A-gmZhlLwGD2LX5EHjULstjsYF4AsZXGHYhHZ85P1ZDyDopgjd7TzRi61rqq5F2d2rhNsLEWGKYY4_Jc0fxIfhezuyrx5ulstKa3_JLQ-Ujc2FGl0t89XOm7axqYBM-bUBCqA/s1600/IMG_6899.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZDJutofaPQzuOjRt-ODrcH-lODvf8cVzvp_S5lln8L_hRZA9l-UKN59A-gmZhlLwGD2LX5EHjULstjsYF4AsZXGHYhHZ85P1ZDyDopgjd7TzRi61rqq5F2d2rhNsLEWGKYY4_Jc0fxIfhezuyrx5ulstKa3_JLQ-Ujc2FGl0t89XOm7axqYBM-bUBCqA/s320/IMG_6899.jpeg" width="240" /></a></div><p></p><p>Aiming for a decent press-fit of 54.95mm, I beautifully overshot the mark and made the almost perfect sliding fit on my very first sprocket carrier. Nothing a bit of bearing glue can't fix though.<br /> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWoq0bQPihoBIjV8v_Ge67Rc7W4zVWd0TIn9dILBAKJZfuw1I_y4NV7-JagomZJKyeU41vwfU_zOqMGesomPa9bZLqhkTYuz1ee4lBoGQz7fUyxOSD2OzZjnhspdiwoyDtChHs0Fy35ueHSH6Gx-atFIVQXJAAJLQdoc4115elJokQhHxEJG9YUsbFfyo/s1600/IMG_6900.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWoq0bQPihoBIjV8v_Ge67Rc7W4zVWd0TIn9dILBAKJZfuw1I_y4NV7-JagomZJKyeU41vwfU_zOqMGesomPa9bZLqhkTYuz1ee4lBoGQz7fUyxOSD2OzZjnhspdiwoyDtChHs0Fy35ueHSH6Gx-atFIVQXJAAJLQdoc4115elJokQhHxEJG9YUsbFfyo/s320/IMG_6900.jpeg" width="240" /></a></div><p></p><p>A few days later there was "a bit" of snow outside the workshop. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWbI6NoAJNn5SpOqEudi6RUe9gJw9WiZFuDCTumxeO7o53h90ASxsl_sb2jLk_IX7soJltBPXoLNfCtx_3KZPNiXjOTqRcfklqFsWEgu9-c5D3PAOLVZlfoQzO76OwL-RdX8nVJK-s-hIHbOmNBNr1ipyuHqJqzyAlcvphsV82C1s2x7psG6HB29FzOEQ/s1600/IMG_6947.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWbI6NoAJNn5SpOqEudi6RUe9gJw9WiZFuDCTumxeO7o53h90ASxsl_sb2jLk_IX7soJltBPXoLNfCtx_3KZPNiXjOTqRcfklqFsWEgu9-c5D3PAOLVZlfoQzO76OwL-RdX8nVJK-s-hIHbOmNBNr1ipyuHqJqzyAlcvphsV82C1s2x7psG6HB29FzOEQ/s320/IMG_6947.jpeg" width="240" /></a></div><p></p><p>The drawing calls for a 30mm tall spacer, which over a length of 14mm is turned down to 30.00mm and an internal bore for a 17mm axle (i.e. 0.1mm oversized). As my stainless barstock was 55mm that dimension was set as well. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEheYxBEfxQ2epY6pwkHrLaM8_rFJb0MU1gXfQyep736u-rVdFX8IfMWcA4BTJcOICh-yPyIpx67GQVp5AaVZ5sBDyFzwmSdYJ-0FEEHSzF5yPaYWqYyIx1JehUqhy7qV4Xi6Y1oyrHKutf8vdnrg9E_WTc0wg7UGkUKO4yB15OglnTGzZPNokDzCMkfrdE/s1600/IMG_6950.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEheYxBEfxQ2epY6pwkHrLaM8_rFJb0MU1gXfQyep736u-rVdFX8IfMWcA4BTJcOICh-yPyIpx67GQVp5AaVZ5sBDyFzwmSdYJ-0FEEHSzF5yPaYWqYyIx1JehUqhy7qV4Xi6Y1oyrHKutf8vdnrg9E_WTc0wg7UGkUKO4yB15OglnTGzZPNokDzCMkfrdE/s320/IMG_6950.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2_MLjTJNCPtIgsSM0LV5g64HmldHRehYNbi7d8Q3_zSyEMWDFGNDSthB4FYBC2guyq65SEmjWT5TwoFLNq_bA7NndewLPaE_EgSudNWWO6lSE7gJ48XsBSyas7gM_y_S3M9cI6rRXI-_X_y8vm_fCqOoa0MsDgU9yidTizzNTyvh5eflhuTs-QkXn2Uc/s1600/IMG_6951.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2_MLjTJNCPtIgsSM0LV5g64HmldHRehYNbi7d8Q3_zSyEMWDFGNDSthB4FYBC2guyq65SEmjWT5TwoFLNq_bA7NndewLPaE_EgSudNWWO6lSE7gJ48XsBSyas7gM_y_S3M9cI6rRXI-_X_y8vm_fCqOoa0MsDgU9yidTizzNTyvh5eflhuTs-QkXn2Uc/s320/IMG_6951.jpeg" width="240" /></a></div><p></p><p>... and when you nail your dimensions like that, the sprocket carrier is a straight fit. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3IPCPcZ44l72UR7M3KfQ5dMJz9OKFIQONujsnqJLm3ySyTU-kY9dpbWNnz3ymG7kGhNgV20HcyyulFkbSUAAp7COORPq5qK9-IktILynMoFcYkYCY0ppf83leFkSbjNndAY5M9xp2yIwBJmYMdkvZRXKeHqlVMQYS1usB4hYJjdJAnenqCi2gJyKb4oQ/s1600/IMG_6952.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3IPCPcZ44l72UR7M3KfQ5dMJz9OKFIQONujsnqJLm3ySyTU-kY9dpbWNnz3ymG7kGhNgV20HcyyulFkbSUAAp7COORPq5qK9-IktILynMoFcYkYCY0ppf83leFkSbjNndAY5M9xp2yIwBJmYMdkvZRXKeHqlVMQYS1usB4hYJjdJAnenqCi2gJyKb4oQ/s320/IMG_6952.jpeg" width="240" /></a></div><p></p><p>The big trick here is that the actual spacer protrudes from the bearing by about 1mm. <br /></p><p> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKT1TUeMXx1DjTKGRKi68-gapEpnm0EHCCHLQ8wBIU5bptzmbjZVOWaGPhB6fpSZSMMSOig0ALC7lqdgoSK-hOR8R01-ntDpYsUiLrnQCHGfSiIJVipe4nTn0fKdGeivD0QhWooHgwl61cPvR1B2zI15wDYZR73PAtHfpa9zvB-ZU2J5G5lf7ckSVA9-4/s1600/IMG_6954.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKT1TUeMXx1DjTKGRKi68-gapEpnm0EHCCHLQ8wBIU5bptzmbjZVOWaGPhB6fpSZSMMSOig0ALC7lqdgoSK-hOR8R01-ntDpYsUiLrnQCHGfSiIJVipe4nTn0fKdGeivD0QhWooHgwl61cPvR1B2zI15wDYZR73PAtHfpa9zvB-ZU2J5G5lf7ckSVA9-4/s320/IMG_6954.jpeg" width="240" /></a></div><br /><p></p><p>Now whilst the modification of the sprocket carrier was (sort of) normal lathe work and engineering, the modification of the actual rear wheel was a bit more medieval. But let's have the pictures tell their story.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZAwEktjma1CiSYyZEzBoJaPDb1mWnulBudFjlQuVJH5CPLvItQNzNS9Qo8Oomkph_NtBtKsCi2jOiW-zmS5uzXOjtpPGEkVb76xmx0gUQ8WRrVMSEecsqr8r2uextDVUbeE41Y_Z7B1JVWa6YRykakuc5_v5q3cOkFZpMQovKMIWLzEp5m3KQc46LcTk/s1600/IMG_6961.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZAwEktjma1CiSYyZEzBoJaPDb1mWnulBudFjlQuVJH5CPLvItQNzNS9Qo8Oomkph_NtBtKsCi2jOiW-zmS5uzXOjtpPGEkVb76xmx0gUQ8WRrVMSEecsqr8r2uextDVUbeE41Y_Z7B1JVWa6YRykakuc5_v5q3cOkFZpMQovKMIWLzEp5m3KQc46LcTk/s320/IMG_6961.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcuTxNNfcs8xqB7jYzJbRVilwpkPs4XXDSNArzBWUNva6fZ0TesShw-CECykH2nhm96h4BBsRM7b1_AxaNSDzYe19BFoq-l45sqTTKlXJykNuvExMVKFLLvz-J1kIoRMFyo5yJr0I-daKqvo1OKzjqxJfO8rNR5tgk41tEL229BGoOpeN8CWrhrV_K4FY/s1600/IMG_6962.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcuTxNNfcs8xqB7jYzJbRVilwpkPs4XXDSNArzBWUNva6fZ0TesShw-CECykH2nhm96h4BBsRM7b1_AxaNSDzYe19BFoq-l45sqTTKlXJykNuvExMVKFLLvz-J1kIoRMFyo5yJr0I-daKqvo1OKzjqxJfO8rNR5tgk41tEL229BGoOpeN8CWrhrV_K4FY/s320/IMG_6962.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiZ_eEJlZbz6EfpytqXJ0594Nivs6fmcrpiXhuQNGHktj9NU06fJJf45wax3m1tGrLmTRlFGlM8GvsrnPIb5yVS_5cRFHwTWAPQR1rHYQbgYyZY7Q61WPCcDdPc1Bvj1SONNYKyS-x8a-S4KdCuuD3GqzrihVALHZJKyclwkerZafNi57jnYUU48tiLRY/s1600/IMG_6963.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiZ_eEJlZbz6EfpytqXJ0594Nivs6fmcrpiXhuQNGHktj9NU06fJJf45wax3m1tGrLmTRlFGlM8GvsrnPIb5yVS_5cRFHwTWAPQR1rHYQbgYyZY7Q61WPCcDdPc1Bvj1SONNYKyS-x8a-S4KdCuuD3GqzrihVALHZJKyclwkerZafNi57jnYUU48tiLRY/s320/IMG_6963.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjerDizLFz59VNXtoSGGIe-DvYOGo6UMOAhBFbtfumHhI5WUdbWKEW6Yla-HTVek24bYMzoLW1PqMvgoA-hbmAm0J1ObC2QX0PIc4yan4GJ_zqyK3bMyaU6rslfdSEhdIInJlbHYYOsLvV4bZiIP4-bG31zyyN9DEpzscrVTsjxybYYOBZwQOaA32_RPkg/s1600/IMG_6964.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjerDizLFz59VNXtoSGGIe-DvYOGo6UMOAhBFbtfumHhI5WUdbWKEW6Yla-HTVek24bYMzoLW1PqMvgoA-hbmAm0J1ObC2QX0PIc4yan4GJ_zqyK3bMyaU6rslfdSEhdIInJlbHYYOsLvV4bZiIP4-bG31zyyN9DEpzscrVTsjxybYYOBZwQOaA32_RPkg/s320/IMG_6964.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuKZGCAAWyhgZK3B2u6oYOELJ62kG-l33zQGARBa8RlzW3_68bNyGKznZD9UHl6MeztvF3oJrm7mZLEtn5XYx-OzB8KFz_pfdTxBEVsQmLfYkNhPr-IHmzanp5KKKK0QfBf2Fr4QfMDfKUZ2VvJJ_sMQU4oWkOAHmx1_BPQVBhDjlINp4Z3yeqbHddvP0/s1600/IMG_6965.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjuKZGCAAWyhgZK3B2u6oYOELJ62kG-l33zQGARBa8RlzW3_68bNyGKznZD9UHl6MeztvF3oJrm7mZLEtn5XYx-OzB8KFz_pfdTxBEVsQmLfYkNhPr-IHmzanp5KKKK0QfBf2Fr4QfMDfKUZ2VvJJ_sMQU4oWkOAHmx1_BPQVBhDjlINp4Z3yeqbHddvP0/s320/IMG_6965.jpeg" width="240" /></a></div><p></p><p>Up to this point this is where I followed the instructions from someone else. Whilst I cursed the 55mm round stock initially, when I had to turn it down to 30mm, it also meant there's an off the shelf seal available in 55x75x10mm and with a recess in the sprocket carrier that's 14mm deep, well it's a match made in heaven or by an engineer. 😎<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgB2UD60L0mS9kWBkc5xkDMlD3j2288fg7307jaHwR_daetiRPUtQIpZ49pC8bKrjT3vAShon3uBna-gwGTo7DSDntsQHMtHrLQr6GDrfeFOtPRIFEkz1FhTWZfPwG19gLEzY16AR0tY0hWOykg3XBmaNNh53NAArvP9smn5KtIGhaNHC_a9PTSL64UdHM/s1600/IMG_7019.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgB2UD60L0mS9kWBkc5xkDMlD3j2288fg7307jaHwR_daetiRPUtQIpZ49pC8bKrjT3vAShon3uBna-gwGTo7DSDntsQHMtHrLQr6GDrfeFOtPRIFEkz1FhTWZfPwG19gLEzY16AR0tY0hWOykg3XBmaNNh53NAArvP9smn5KtIGhaNHC_a9PTSL64UdHM/s320/IMG_7019.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbgyrCzeVBV3Lpd2BbfMiVQ8OGj9aGF-8OEruVp7nY6sywT9fnr9svTvgyeoRt-aetOafLsjwwNqIYraeApe_nQUp7gaeal1kzP0ARsWDAle__GiUwlCLONAASTZ14iOA1kSUHaH1qcwC2PKurJW8CrlWFlqJA8XqLWgz7lH-cDXThN0E2MU3ivLVcd9A/s1600/IMG_7020.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbgyrCzeVBV3Lpd2BbfMiVQ8OGj9aGF-8OEruVp7nY6sywT9fnr9svTvgyeoRt-aetOafLsjwwNqIYraeApe_nQUp7gaeal1kzP0ARsWDAle__GiUwlCLONAASTZ14iOA1kSUHaH1qcwC2PKurJW8CrlWFlqJA8XqLWgz7lH-cDXThN0E2MU3ivLVcd9A/s320/IMG_7020.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihUETaW3tHbdDDPUko4keP83BvzAiYHb9U9_jateUxow86NxueBhYU7rQqc8j5qZ3xMG7ARq_3QBhpw6PNnNb8XnLL-GRR1Revb7i5K0gi31z02kWI-UZ4bcSoBULLH3ChvKdvO4lNpHX-e2GdMGYTcdMcObHzm3wBvUGDtrwOC8m5oeIgwpdb4K7S7Xk/s1600/IMG_7021.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihUETaW3tHbdDDPUko4keP83BvzAiYHb9U9_jateUxow86NxueBhYU7rQqc8j5qZ3xMG7ARq_3QBhpw6PNnNb8XnLL-GRR1Revb7i5K0gi31z02kWI-UZ4bcSoBULLH3ChvKdvO4lNpHX-e2GdMGYTcdMcObHzm3wBvUGDtrwOC8m5oeIgwpdb4K7S7Xk/s320/IMG_7021.jpeg" width="240" /></a></div><p></p><p></p><p>At this point, swapping the tyre and then fitting the rear wheel should have been a more or less straightforward job... <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdTXSQQGY7J5CVodbApKYfShYz1awxR3BJWNTTxEaEVntSBvH-Hep8fw9HBR8WS2rhZPItUF7Gwx2BtRzY78JKt-HcRarG5O4xKujysczJJNzDbyMqMP72gzjGoUO34_tGvr1pyhOouT8ah4J172k2FTlCoX9tpNlA2SpNpsFLtkpluthCp2ExWSoBtRA/s1600/IMG_6999.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdTXSQQGY7J5CVodbApKYfShYz1awxR3BJWNTTxEaEVntSBvH-Hep8fw9HBR8WS2rhZPItUF7Gwx2BtRzY78JKt-HcRarG5O4xKujysczJJNzDbyMqMP72gzjGoUO34_tGvr1pyhOouT8ah4J172k2FTlCoX9tpNlA2SpNpsFLtkpluthCp2ExWSoBtRA/s320/IMG_6999.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEdJVAmnMQplJYoF8seuMVEPjIots6mDf9m7z-uLWtiaTHphIjLpic5F71dEJyeopEGSyeUCCrW0DKYicj1rZVPNG10_4TVv_2FUqgSfp6e5k6YqRyMa2XHwTh6F0YW5ADbfASrSNtE0aBKyCMa3oZdTfO7OJ4aFvt5oRe8SguUkCtqA8dDod9I-0WwJM/s1600/IMG_7003.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEdJVAmnMQplJYoF8seuMVEPjIots6mDf9m7z-uLWtiaTHphIjLpic5F71dEJyeopEGSyeUCCrW0DKYicj1rZVPNG10_4TVv_2FUqgSfp6e5k6YqRyMa2XHwTh6F0YW5ADbfASrSNtE0aBKyCMa3oZdTfO7OJ4aFvt5oRe8SguUkCtqA8dDod9I-0WwJM/s320/IMG_7003.jpeg" width="240" /></a></div><p></p><p>Let's just say that the Avon Sidecar tyre lasts a lot longer than is good for the lubrication of the rear wheel axle.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWGb5PPBVhgIED6H9jcHjtinRMM9hG32cnkeWePP4GbsHNL_8pOSjQpOHg6oWj7_tPyZ_oNAVXJJBEYMKdx-mbuN-T2z4KraJScRf11z1XJK5HRTB_gBkeTCv40b9NKVXTVnD2vbrJtj3IYw-t7SfZtIs1darcSUerqrGghBl3Io102Vc4rcUF7kVRDmc/s1600/IMG_7005.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWGb5PPBVhgIED6H9jcHjtinRMM9hG32cnkeWePP4GbsHNL_8pOSjQpOHg6oWj7_tPyZ_oNAVXJJBEYMKdx-mbuN-T2z4KraJScRf11z1XJK5HRTB_gBkeTCv40b9NKVXTVnD2vbrJtj3IYw-t7SfZtIs1darcSUerqrGghBl3Io102Vc4rcUF7kVRDmc/s320/IMG_7005.jpeg" width="240" /></a></div><p></p><p>And absolutely no one upset the thread on both the rear wheel axle or nut. Which is also why absolutely no one would know that it is a M16x1.5 thread. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgO6u7XCFedAm0tnjs0k1-kOJEEAZKKGTDm8UHvE0Db14HbSR_BmmUBz5ngmWudayipB7g99eX7O-K8l1l1w-JDWZLVwAeZqzeeOSl57QzRVp1REHwCPcelUrJrANQpzpAemDN0m9JHRo96En8VZCnkm9jIAlSdiil_Tbi_J_gb_whFrTqsUVb8VbSFYYE/s1600/IMG_7007.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgO6u7XCFedAm0tnjs0k1-kOJEEAZKKGTDm8UHvE0Db14HbSR_BmmUBz5ngmWudayipB7g99eX7O-K8l1l1w-JDWZLVwAeZqzeeOSl57QzRVp1REHwCPcelUrJrANQpzpAemDN0m9JHRo96En8VZCnkm9jIAlSdiil_Tbi_J_gb_whFrTqsUVb8VbSFYYE/s320/IMG_7007.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVfZrI5yCIRb4cGGSslEewm2RVyMftTfURXtcTovRwhmVqizkVIGfgDL6VeEBfjzWvwdiKVOv4DD3XD5VmCJbc6iE4rOblTtbTWifNFDftQ7tL_Udzz9ZlzmbmuSIECm0F6zNx8f1qOtBs7-nwXB6spd3NhyphenhyphenPJhAjdUoIdMRw_X4ZCGq4u21iSrAZJ9qI/s1600/IMG_7009.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiVfZrI5yCIRb4cGGSslEewm2RVyMftTfURXtcTovRwhmVqizkVIGfgDL6VeEBfjzWvwdiKVOv4DD3XD5VmCJbc6iE4rOblTtbTWifNFDftQ7tL_Udzz9ZlzmbmuSIECm0F6zNx8f1qOtBs7-nwXB6spd3NhyphenhyphenPJhAjdUoIdMRw_X4ZCGq4u21iSrAZJ9qI/s320/IMG_7009.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEie9k2TfCMrMjgMO9w3P4LmkOWxidGPkPvXIJIaH7ynvQpNBUj34oFiog_huMphfq7v2vZx2dlkqgNVJQDbcb6v5CVgZerjsP6JMOp4QDX7jXi7OHCkCDj9sRODpZlq6jBLNZlLjdJ6KAyohEIji5HtpqIJbQlqEGeLDAHk6mDBjjtK-4kopO_RT80Mk-g/s1600/IMG_7010.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEie9k2TfCMrMjgMO9w3P4LmkOWxidGPkPvXIJIaH7ynvQpNBUj34oFiog_huMphfq7v2vZx2dlkqgNVJQDbcb6v5CVgZerjsP6JMOp4QDX7jXi7OHCkCDj9sRODpZlq6jBLNZlLjdJ6KAyohEIji5HtpqIJbQlqEGeLDAHk6mDBjjtK-4kopO_RT80Mk-g/s320/IMG_7010.jpeg" width="240" /></a></div><p></p><p>It was at this point that the sins of yesterday started catching up to me:</p><p>First, I borrowed the speedo drive from the front wheel for the summer wheel, which I only found out AFTER installation. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibHPO-fY4XYQtUFFQqMh8EFN8n6DXKaTTxEQy7HJnT9IFwQbPQK4AYAuhWz5uL4AGDfZubj2-p413nVNPNKBMpkjxUn8WimAvdw1Avn7PJDlHy9TAbs3xzjG78aCrAZA_rRtQ8TUo9izQGCz6s32DnWU-ks0c9umLTcry9g-jYGgtB6KUEqsVhz5rCPzg/s1600/IMG_7015.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibHPO-fY4XYQtUFFQqMh8EFN8n6DXKaTTxEQy7HJnT9IFwQbPQK4AYAuhWz5uL4AGDfZubj2-p413nVNPNKBMpkjxUn8WimAvdw1Avn7PJDlHy9TAbs3xzjG78aCrAZA_rRtQ8TUo9izQGCz6s32DnWU-ks0c9umLTcry9g-jYGgtB6KUEqsVhz5rCPzg/s320/IMG_7015.jpeg" width="240" /></a></div><p></p><p>Luckily there's a very straightforward repair kit available and aside from the new seal actually being tight around the speedo drive there weren't any challenges to be overcome.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPAMu8tgKrai3dIgk1_FxxyxszbH15-O7vbXwjEFbW8I7Rn0Qkzwp06uqec-9Q_MYlH5haW5ARlwaKjQMTemExJgCwzQRD4edhGeYqk4WKdW19RtOUqvMKfZE6z1I-ZMUVIWWSGW3s6LnZaW68JM9GfSaSzPCcfxcmjoVDzBEzQ2NAMEl_FSdxOmRqOcA/s1600/IMG_7016.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPAMu8tgKrai3dIgk1_FxxyxszbH15-O7vbXwjEFbW8I7Rn0Qkzwp06uqec-9Q_MYlH5haW5ARlwaKjQMTemExJgCwzQRD4edhGeYqk4WKdW19RtOUqvMKfZE6z1I-ZMUVIWWSGW3s6LnZaW68JM9GfSaSzPCcfxcmjoVDzBEzQ2NAMEl_FSdxOmRqOcA/s320/IMG_7016.jpeg" width="240" /></a></div><p></p><p>And then there was this bolt that holds the chainguard onto the swingarm, which after reinstallation reduced the amount of unhealthy noises attributed to the engine significantly. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9s2azpJ7UYoGmZZRh2UpPFFbFvGo5TKNt-dlDCPLmfO0wq-IZsSxTmlGNyVSOyYhQELQYr8fKyUm0X6LevqbCpnUc07YnHAP_ULGDt5s8cerYqMdD91jQL_8WlFW1ijpBICFiVeJM4-7jBCTYEp6mlUtVIpK3F8wDuD3odrrMIZcSwAaOn5kkqGJA530/s1600/IMG_7014.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9s2azpJ7UYoGmZZRh2UpPFFbFvGo5TKNt-dlDCPLmfO0wq-IZsSxTmlGNyVSOyYhQELQYr8fKyUm0X6LevqbCpnUc07YnHAP_ULGDt5s8cerYqMdD91jQL_8WlFW1ijpBICFiVeJM4-7jBCTYEp6mlUtVIpK3F8wDuD3odrrMIZcSwAaOn5kkqGJA530/s320/IMG_7014.jpeg" width="240" /></a></div><p>So in the end there was only thing left to do:</p><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen="" class="BLOG_video_class" height="266" src="https://www.youtube.com/embed/0LhYhd3UFCE" width="320" youtube-src-id="0LhYhd3UFCE"></iframe></div><p>Interestingly enough the new rear tire appears to be of a slightly smaller circumference, which together with the sprocket carrier not wobbling around and most likely the cold weather favoring my bad habit of jetting slightly on the rich side all in all yielded new top speed records and the little sidecar feels a lot quicker than before. (If you're more into hard facts: I gained more than 10kph in top speed and there was still a bit left.)<br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-13599216600295283402023-11-14T20:00:00.092+01:002023-11-17T19:38:19.131+01:00Project overview late 2023/24<p>
Whilst being stuck at home due to not feeling quite top-notch, I thought
I might as well make a list of what's on the to do list(s): <br /></p><table><tbody><tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMjjqngy5-GBi_UMLNZ-bcit977nCLLdB6nuTYNyJyuL9EkxFAG0v8UquI84XRZfUPWK14biB-1zSINJJp7UE_HlTLtCJZujrlZNwtPk0m1JXRI6NyC4wMLKg-y4ncT9uchgobV0ETBvjNdZ_3hSR6jyLO7u-XWe2_H3nhcHkNjpn0krsdZSOYkme814U/s4032/IMG_6913.jpeg" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMjjqngy5-GBi_UMLNZ-bcit977nCLLdB6nuTYNyJyuL9EkxFAG0v8UquI84XRZfUPWK14biB-1zSINJJp7UE_HlTLtCJZujrlZNwtPk0m1JXRI6NyC4wMLKg-y4ncT9uchgobV0ETBvjNdZ_3hSR6jyLO7u-XWe2_H3nhcHkNjpn0krsdZSOYkme814U/w240-h320/IMG_6913.jpeg" width="240" /></a>
</td><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgP60Y1DklQLt3BxJRJEK3K-LeWR_8Ep1LISHBkb01zpLWBhkXlFi9B8zwP6poxCSoXdHxkWtjpW5CU57lWmoYkvJR0skcS3we-bopLSLKQuECxbq1YFQM44HcPS7nny6B1PcdSzAK50VaOb28szEhOzu_KX8QbNwso9undiNfLFzIYeE8dqsBfXWroUkM/s4032/IMG_6914.jpeg" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" data-original-height="4032" data-original-width="3024" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgP60Y1DklQLt3BxJRJEK3K-LeWR_8Ep1LISHBkb01zpLWBhkXlFi9B8zwP6poxCSoXdHxkWtjpW5CU57lWmoYkvJR0skcS3we-bopLSLKQuECxbq1YFQM44HcPS7nny6B1PcdSzAK50VaOb28szEhOzu_KX8QbNwso9undiNfLFzIYeE8dqsBfXWroUkM/w240-h320/IMG_6914.jpeg" width="240" /></a>
</td></tr></tbody></table><p>
<u>Let's start with my own stuff (it's ordered by priority)</u></p><p>Everyday TR1 (Tractor):</p><ul style="text-align: left;"><li>fit spare BT46 rear tyre to spare wheel<br /></li><li>
clean and grease brake sliders on front brake</li><li>improve mounting of engine breather-filter</li><li>modify XS1100 (rear) brakedisks, so I can use them as spares for either TR1 or Sidecar</li></ul><p>SR500 Sidecar:</p><ul style="text-align: left;"><li>(finish) the sprocket carrier conversion to XT600 style aka. 6006 method</li><ul><li> Make a spacer for the sidecar axle so the modified rear wheel will still fit</li><li>Swap over to Winter wheels and tyres <br /></li></ul><li>clean the airfilter (apparently I have been postponing this since before last Winter)</li><li>build a 535cc engine</li><ul><li>evaluate my spare engine</li><li>order a 90mm Wössner piston and have my spare cylinder bored to suit</li><li>MAYBE get a 48T head</li></ul></ul><p>Machinery:</p><p>Lathe: <br /></p><ul style="text-align: left;"><li>make a backbplate for the 160mm 3-jaw chuck I have</li><li>identify the pitch of the crossslide leadscrew and see if I can get the correct screw and nut as they are terribly worn out in one spot</li></ul><p>Mill:</p><ul style="text-align: left;"><li>turn that huge lump of ally into a suitable riser-block</li><li>fit a DRO to the quill and maybe look into affordable DROs for all the other axes</li></ul><p>Misc:</p><ul style="text-align: left;"><li>Make a guard and bushings for the wire-wheel for the large benchtop grinder</li><li>find out what's wrong with my old CRT-oscilloscope (most likely just a blown cap)</li></ul><p>Dre-XT-Stück</p><ul style="text-align: left;"><li>temporarily hookup the engine breather to a can to see how much blow-by the engine actually produces</li><li>air-filter check (as I have the nagging suspicion that the breather puked quite a bit of oil onto the air-filter)</li><li>check AFR with both stock and ARROW muffler as last time it seemed to like the stock muffler a lot better and I would like to see what kind of AFR this was at</li><li>brake-line and brake-pad swap prior to getting it inspected in Summer</li><li>make a new pannier rack from 18/3mm tubing as the current one, is officially not road legal because of all the pointy bits</li></ul><p>Hotrod TR1</p><ul style="text-align: left;"><li>in essence make it usable for something</li><ul><li>take off turbo kit and build a staggered 2in2 exhaust (because I think that would look cool)</li><li>cleanup the wiring and fit front indicators to the handlebar</li><li>fit the v-star oilfilter-cover</li><li>and the MikuniOz 2in1 manifold and VM38 to do some back-to-back testing <br /></li></ul><li> marginally related: use one of my spare heads and grab the cam specs from the set of hot cams I got ages ago</li><li>same goes for fitting that other oilpump sprocket</li><li>build a new left-side turbo setup (and ask two very friendly people in Germany to help me legalize it - but that's probably for next Winter)</li></ul><p>Uber-Rat-Z - shocker I have a secret Kawa GPZ1100B1 that only few people knew about 😁<br /></p><ul style="text-align: left;"><li>assess the engine and wiring</li><li>reassemble the VM29SS</li><li>depending on the two prior steps find a suitable tank in my stash and see what happens</li></ul><br /><u> Stuff for my dad:</u><br /><div><p>XT500 4-valve (The Pretty One):</p><ul style="text-align: left;"><li>fix the threads for the headbolts and install a new headgasket</li><li>adjust the clutch rod, now that I figured out how it is supposed to work on my XT (and how touchy it is)</li></ul>VX800:<div><ul style="text-align: left;"><li>replace clutch lever, because it is completely worn out after close to 80,000km and is flopping in the breeze</li><li>fix a saggy footpeg</li><li>sync carbs</li><li>make fuel valve lever-plate<br /></li></ul></div></div><div>Goldwing</div><div><ul style="text-align: left;"><li>fix the wiring</li><li>assemble carb and airfilter and fit the headers</li><li>see what happens, when one tries to start it up (should give the necessary motivational boost</li><li>cobble together a brake-system, which works like a normal one <br /></li></ul></div><div>Moto 6.5:</div><div><ul style="text-align: left;"><li>check the charging system and probably fit a more decent voltage regulator</li></ul>Bandit 1200:</div><div><ul style="text-align: left;"><li>check the fluids, especially for the hydraulic clutch</li><li>recheck the valves</li><li>remove rear-sets and bend back the bent footpeg</li></ul><br /></div><div><u>How & when:</u></div><div> </div><div>TR1-stuff aside from the brakedisks and the sprocket carrier on the Sidecar (plus the stuff that's directly related to it like fitting the Winter wheels) are the things that are underway already. Same goes for the airfilter- and breather topics on Dre-XT-Stück mainly because they are done very quickly and assuming that the odd dry and cold day will be available that should give me some insights on where we are with the old girl and make sure I won't break stuff again next year. (The old girl has quickly become the most expensive bike to run, I have ever had in the last two years.)</div><div> </div><div>On my dad's side, his XT is first, mainly because I have already made the threaded inserts to sort the situation on his engine and if it works there I know that when the time comes on my XT that I'll do just the same fix. Second on the list is most likely the VX800 as it's just a case of buying a new clutch lever and adding a single blob of weld to the left footpeg to stop it from sagging. </div><div><div class="separator" style="clear: both; text-align: center;"> </div><div class="separator" style="clear: both; text-align: center;">And then there might be a special project coming up that'll slot in right at this point. 😎</div><div class="separator" style="clear: both; text-align: center;"><br /></div><div class="separator" style="clear: both; text-align: left;"><u>Goals:</u></div><div class="separator" style="clear: both; text-align: left;"></div><div class="separator" style="clear: both; text-align: left;"><ol style="text-align: left;"><li>Have my two- and three-wheeled sh*te in a state that for the first half of the year I only have to do planned regular maintenance and can just use them</li><li>Tackle the low-hanging fruits of my dad's projects: Get his XT back on the road and make the VX800 (the bike he used the most this year) better/turn it into a proper daily.<br /></li><li> Get those machinery tasks out of the way.<br /></li><li>Depending on how the secret project works out, I have that one ready for use in Summer.</li></ol></div></div>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-2269485141017917682023-10-28T20:00:00.001+02:002023-10-28T20:00:00.150+02:00Martha II - no more banana-threads<p>
As I pointed out a year ago,
<a
href="https://greasygreg.blogspot.com/2022/02/martha-ii-matra-mdr2a-for-every-need.html"
target="_blank"
>in my first post on Martha II</a
>, whilst bearing a very German name (Matra standing for Marx & Traub), is
actually either "heavily influenced" or a more or less licensed copy of a
<a href="http://www.lathes.co.uk/regal/index.html" target="_blank"
>LeBlonde Regal 10inch/12inch</a
>. So why would such a reputable German manufacturer choose a US design, which
has a strong emphasis on cutting all sorts of imperial threads? The answer
lies in the very first customer. The newly founded German Bundeswehr was well
equipped with a plethora of US-made tanks, which quite obviously, were
equipped with pretty every imaginable thread, but metric. As they also were
rather worn, mobile tank repair units were formed and these were equipped with
exactly these Matra MDR2A lathes.
</p>
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<a
href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_v1EefJ_oU5tEchhm_OiVDrnD3wdu0w0ndrB3k1wQUTbtkHDxtKRE7hooOmVIfLSkLj-nRZj_QAPTuXFbcYQN8RkdDOodRzad-OPlsJVUi9Kw1-zaOTp1DCxqznc3hV-X1UH53KToMZcAar2mu0EmMFYy4UPEQeAEe86VJyD966METciqiyqAI5TjkTA/s1600/IMG_6787.jpeg"
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<p></p>
<p>
To make these lathes substantially more useful for use in a metric country,
one of the oldest engineering tricks in the book was employed: slap on a 127
tooth wheel and see how you can turn that 8TPI leadscrew into something that
can at least produce some vaguely useful metric threads. Unfortunately going
down the metric route means that the Norton-box on the front can't be used.
Still, in the end a very useful spread from 0.5mm to 7.5mm thread pitches can
be created. (Special honorable mentions for 0.50, 0.75, 1.00, 1.25, 1.50, 1.75
and 2.0 pitches spanning pretty much everything one can find on regular and
fine thread pitch metric bolts in typical machinery applications.) With that
incentive in mind, I set out to make the metric feeds work again.
</p>
<p>
A quick rummage through the boxes of small bits (and some large bits),
revealed that the axles for the metric gear scissor were absent, one of the
stub-axles on the tumbler reverse lacked a means of retention and the plunger
of the selector was broken as well and a few small bits like missing shaft
keys and the like.
</p>
<p>
I started with the shaft keys, because I had to start somewhere anyway, it was
Sunday and I had some stock in the form of a bit of angle iron
available.
</p>
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src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj04Hky1e9opcg3SCjjvjfp8jYWy7DXjalBJvp1dCGk14KiqAYzej0-P4BTCQyhjh35JbMP7vpxLPfZHaj6svb8m1nbmBH6mXm9VwhIB-D4MwBG-Gzt5WPPrdsd8FhROpwoTHa9FhKDYeJ6jR8GDncF2loaE8CFVLcDkga8hbpfxMfQtWYZiPze4IXekiM/s320/IMG_6725.jpeg"
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<p></p>
<p>
In reality it would have been a pretty standard 5x4x25mm shaft key, as is
available form any bearing store, which I suspect was part of making this
machine somewhat metric, just like the spindle nose which sports a very
typical (for the time) Din800 M33 spindle nose (M33x3.5mm).
</p>
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<p></p>
<p>
As I had no drawings of what the original axles would have looked like, I sort
of had to wing it and design them from scratch, with the only real limitations
being that the slot in the scissor was around 15mm wide and the milled out
groove on the back around 23mm, which made M14 a sort of logical choice. As
all the other gears where held on with M12 nuts that was sort of a given as
well.
</p>
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href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6M4cKu4MqyRUNu86zLjK6BP8pmoOdfCo4MwPZ_W0tC5OD0B7PNfcrnPz0iP9-7Myq0Kg-BGCo5ED5CrgsNVNI7nXlyuLUvEAT-sOncvHCwD4BI1eywSo4En3oYvVzdUF6GU-CImxTNtqZJUtmHs2XudLDIdlFjMsqp7XwdBSSu1JPv5A3xP8LpbSOs4k/s1600/IMG_6737.jpeg"
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<p></p>
<p>
One of the things I absolutely wanted was to have a way to lube the gears
internally, so the axle shafts were drilled out and had an oil-groove cut in.
<br />
</p>
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<p>
One thing I had sort of missed was that the step in the rear was maybe good
enough to locate and space out the gear on the axle, but it was definitely not
good enough to positively locate it on the scissor. Then again as nothing on
such a lathe is allowed to only serve one purpose, I chose some M16 nuts (the
axle diameter is 17mm). Step one was to part off the M16 nut to the correct
width.<br />
</p>
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<p></p>
<p>
Put it back in the chuck and use that same bit of M16 all-thread to align it
properly and then bore it out to a nice press-fit on the shaft.<br />
</p>
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<p></p>
<p>
Which was quite literally a case of *tap-tap*. (And then tig-weld them in
place, just to be sure.)<br />
</p>
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><img
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src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_0cNEzzcKJyP1aj_DHQ_jOgQwA-El3OgJtNwaHauFeSblWuQIgS80twMvf-zmG5X0S4sicBE9QvOI82y64algoMboRajSV7viclZ93gOGZWUBuuGFexqvClLhEqeLgSD4X7Q0Affj4qq8zLQ8MQ9pZOGs4MRXIaNTeauKb8nvzqGF2GUIs6rhbX0Y8g4/s320/IMG_6765.jpeg"
width="240"
/></a>
</div>
<p></p>
<p>
Getting the whole lot set up, requires roughly 3.5 hands, but once you figured
out it goes: lower gear on the scissor, top gear-set on the scissor and then
tighten the scissor once it is engaged, it is actually manageable.
</p>
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href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjD4FC_L6Mfy74PUgY4OFjGzk-2vxZNyjCcDtSP_CkMJOrS14M8T0QoOD8D1l2LfFQ-kj_Rpb0Ry8TmidtUR2FW-_ZZJgxHJTE1XikZCayFZ2ItVlz7JjsqZVNLCe5G737bXaW_yZPjgJqGty-QJBfNm6qmHCYIKgxi5qydh5BEC8P2vU74aFSlh2m-H_U/s1600/IMG_6766.jpeg"
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><img
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src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjD4FC_L6Mfy74PUgY4OFjGzk-2vxZNyjCcDtSP_CkMJOrS14M8T0QoOD8D1l2LfFQ-kj_Rpb0Ry8TmidtUR2FW-_ZZJgxHJTE1XikZCayFZ2ItVlz7JjsqZVNLCe5G737bXaW_yZPjgJqGty-QJBfNm6qmHCYIKgxi5qydh5BEC8P2vU74aFSlh2m-H_U/s320/IMG_6766.jpeg"
width="240"
/></a>
</div>
<p></p>
<p>
Now the geared head on the Matra isn't exactly quiet to start with, but the
video only vaguely gives you an idea of the amount of noise that is generated
by the whole gear train.
</p>
<div class="separator" style="clear: both; text-align: center;">
<iframe
allowfullscreen=""
class="BLOG_video_class"
height="266"
src="https://www.youtube.com/embed/CVxE13eDOPk"
width="320"
youtube-src-id="CVxE13eDOPk"
></iframe>
</div>
<br />
<p>
When trying to switch the tumbler around and into reverse I realised two
things: The reverse gear only had stayed in place so far because it wanted to
and the locating pin on the plunger was missing.
</p>
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href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCiAKnIEK2diwSwlqgT-o3ecRxE7o90_8mLXGvuT9ruj0BM_OVKlLie452Ag6d1DnstBCs3t424_8IcW8nTpTSXh61vs7GtpX3_j5Qs1ExMKFiwp0DbdNFbp8Ia5Td2j8qJOTUVOODyZnHByw3PKObsUZsEIHq6Ni7mAI31hWZ4paFgogu_YQg8fJviLE/s1600/IMG_6769.jpeg"
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><img
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src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCiAKnIEK2diwSwlqgT-o3ecRxE7o90_8mLXGvuT9ruj0BM_OVKlLie452Ag6d1DnstBCs3t424_8IcW8nTpTSXh61vs7GtpX3_j5Qs1ExMKFiwp0DbdNFbp8Ia5Td2j8qJOTUVOODyZnHByw3PKObsUZsEIHq6Ni7mAI31hWZ4paFgogu_YQg8fJviLE/s320/IMG_6769.jpeg"
width="240"
/></a>
</div>
<p></p>
<p>
I decided against fabricating this stub-axle from scratch as it turned out not
to be hardened and the only trick bit in making it work was how to hold it in
the chuck to drill and tap it for M8.<br />
</p>
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><img
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/></a>
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href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOPKOHvpIlsn7uXD7HpA4NeVhtJcF0XLA4qhLhu2iJYrFi_3qXahnILllpU72fxRIzM3BrNaoEY9wKzRcrFIUpt4TXseukxiALc7oJ9H6asQkfts7C6qpaK8THCeIY4-CBJLTSjIaBYZ2oQPlo3wvgzHk4futwRyIugS2TxEiWezI9NpRFYvrSVtWTeC0/s1600/IMG_6771.jpeg"
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><img
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width="240"
/></a>
</div>
<p></p>
<p>
A bit of M8 allthread loctite'ed into the stub axle and it was good to go
again.
</p>
<div class="separator" style="clear: both; text-align: center;">
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href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj02VdcVgwjULo0GJs8nBhY3l9ctL4ctGvkbr4CbiAli-xtpbT4w7Hq7E9T0DroJrmzOV8AlYAhBMG2EiiKGLOUmZ1Y7QaM05pQ4NZj8gJtL2vXOGR3ToIKDxURsWsNo__U-tznXnhzNFzS-_daAhOlgWaVHOB9sw8f9YP8uogJp27SMf7Gv-si6s6pvjg/s1600/IMG_6772.jpeg"
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width="240"
/></a>
</div>
<br />
<p>
Which left *just* the plunger to get fixed and have everything working again.
Except there was nothing *just* in this process as it took way longer than it
even remotely should have.
</p>
<div class="separator" style="clear: both; text-align: center;">
<a
href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEinOTsbY2_SeypwOxE18Vf6IdIjz_isvRw_baeNn8wRww21l2dfFXeDdUvNqx2tuklLoipfTtH3PORRD1UELLjTWzZGPk7gWXWnD3tl-SY5mpkBJtuaK4NBgaFycOBQ1_ibAfumvKBDEJGbuFT7AAID4waziFXxmFJ_92VrLdz9bokPUZnqPeDnv6sp9eA/s1600/IMG_6778.jpeg"
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><img
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href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmgykuDr9xTUHXLHyWSr039V6NwztGhzrVPLFfzsC89Nb7uMM6m_angSQApwaahJI-DjTnXhpWyoYoJXS_92LBhdznbRQnxPcq0WlbbGDEUksEaIyqZk5JB5rY8Mh0N0TyO4-KDr2NABlwVNVHnkvvq4oPt9i1axe0DIip6xdKD6KiT8UczUxU718v9_I/s1600/IMG_6780.jpeg"
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><img
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width="240"
/></a>
</div>
<p></p>
<p>
After some casual inspection it became apparent that fixing the old plunger
rod was not going to happen, so I made a fresh one from 10mm silver steel.
Except there were two other ones I made. One on which I ignored the fact that
whilst it was an M8 bolt, it had a 7mm shank (no idea why) and the other one,
also from silver steel, when finishing the cross slide was sucked in and this
elegantly removed the whole thicker section. <br />
</p>
<div class="separator" style="clear: both; text-align: center;">
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href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgk6TsP3WuVnNcqL9M8Ulxb9xBJL8BZ8isQzEbiDoUXu5ppeyi-h0W-yoZYYM7ngqFQ8Vv7ms0Z9DKtBjetl0D8aJI-7iNqNmqpDqnsE0-Y7IfbALZsQzmO_w5mvdjarbo810nM3QfKIFvUY3X0lgvXe05bpYrbpMrx4MVgDAoC52PfaNYQ6F_YP33FlDk/s1600/IMG_6782.jpeg"
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width="240"
/></a>
</div>
<p></p>
<p>The plunger testfitted without a spring.</p>
<div class="separator" style="clear: both; text-align: center;">
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href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiD9zjf30vtTUGdzdxZx58xjPUCBTScbxsep3zqwCa-pubeXHa1H2XQJcj0So4FqAtsehV96IULk_g6XFaLyGn_UbzCceD4Ij-8AM9TVx5uuedqDhWqRaeCDq99mm7v_J65OlGVxW1t6rWGONPYZrrwo7nDgwRKXRDKh2Sm0yN7y5Q2guh0N5CCrpvleIk/s1600/IMG_6781.jpeg"
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src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiD9zjf30vtTUGdzdxZx58xjPUCBTScbxsep3zqwCa-pubeXHa1H2XQJcj0So4FqAtsehV96IULk_g6XFaLyGn_UbzCceD4Ij-8AM9TVx5uuedqDhWqRaeCDq99mm7v_J65OlGVxW1t6rWGONPYZrrwo7nDgwRKXRDKh2Sm0yN7y5Q2guh0N5CCrpvleIk/s320/IMG_6781.jpeg"
width="240"
/></a>
</div>
<p></p>
<p>
And lastly two glamour shots - finally with the metal enclosure for the change
gears reinstalled and rather unusual for me, with the chip tray somewhat
cleaned from the majority of the chips.<br />
</p>
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<a
href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQrQ3ymcAwQFbI9M0wFvJiQRb-g7p_2LY8MRRBKCQXiyZfsVh6NurF_THv-WcepV8mr-WAMhBYVNSUyCSFAxLd_m_8P5ZTDIneHZ95CPTRXC3YJbeKe1A4oCuQ_nHnJntOV9sTWu8rOmSSJDAW-EgJb3CkdVgoGosn2fymDuaFgqSrkgaYl1j5cwwPLHo/s1600/IMG_6786.jpeg"
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><img
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src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQrQ3ymcAwQFbI9M0wFvJiQRb-g7p_2LY8MRRBKCQXiyZfsVh6NurF_THv-WcepV8mr-WAMhBYVNSUyCSFAxLd_m_8P5ZTDIneHZ95CPTRXC3YJbeKe1A4oCuQ_nHnJntOV9sTWu8rOmSSJDAW-EgJb3CkdVgoGosn2fymDuaFgqSrkgaYl1j5cwwPLHo/s320/IMG_6786.jpeg"
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_v1EefJ_oU5tEchhm_OiVDrnD3wdu0w0ndrB3k1wQUTbtkHDxtKRE7hooOmVIfLSkLj-nRZj_QAPTuXFbcYQN8RkdDOodRzad-OPlsJVUi9Kw1-zaOTp1DCxqznc3hV-X1UH53KToMZcAar2mu0EmMFYy4UPEQeAEe86VJyD966METciqiyqAI5TjkTA/s1600/IMG_6787.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_v1EefJ_oU5tEchhm_OiVDrnD3wdu0w0ndrB3k1wQUTbtkHDxtKRE7hooOmVIfLSkLj-nRZj_QAPTuXFbcYQN8RkdDOodRzad-OPlsJVUi9Kw1-zaOTp1DCxqznc3hV-X1UH53KToMZcAar2mu0EmMFYy4UPEQeAEe86VJyD966METciqiyqAI5TjkTA/s320/IMG_6787.jpeg" width="240" /></a>
</div>
Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-60934614252962099842023-10-15T20:00:00.001+02:002023-10-15T20:00:00.142+02:00Comrade Car - the final chapter (part 13)<p>
Final chapter, final stand, final piece of cake... sounds dramatic eh?
Well, if you're just interested in that one answer did it pass - well yes of
course it did, but it wasn't nearly as straightforward as you think.<br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikckV-SzUgtvOFx55f2DDqaosRt5NFTX4nqnxewKHFfwRm2KeCIMzBFX0pB7UCbgtNmiwh9uypQaLqfkr4NsNwFSDGCCWzBeN4t2MiykA_ZR9ubHx9zue_u1Sh_W67El0Tx8ZCyFd9cNAE8h6PtALbMHA4GdNfdIHmgbuUQK1RUsUH3poHee7NOXTlpE0/s1600/IMG_6619.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikckV-SzUgtvOFx55f2DDqaosRt5NFTX4nqnxewKHFfwRm2KeCIMzBFX0pB7UCbgtNmiwh9uypQaLqfkr4NsNwFSDGCCWzBeN4t2MiykA_ZR9ubHx9zue_u1Sh_W67El0Tx8ZCyFd9cNAE8h6PtALbMHA4GdNfdIHmgbuUQK1RUsUH3poHee7NOXTlpE0/s320/IMG_6619.jpeg" width="240" /></a>
</div>
<p></p>
<p>
At the end of the last post, lil' comrade looked pretty complete. As a matter
of fact he was pretty close, but for example the front bumper wasn't bolted
down and he was still missing at least one of his tow-hooks. (Sounds easy
enough, but means you have finesse a bolt into a LARGE hole, to hit a nut,
which from previous engagements with nature sits at a funny angle (should be
perpendicular to the lower frame rail) and all of that will touching up those
bumper mounts with a die-grinder.)
</p>
<p>
Nothing you can't fix with a decently sized Newtonian particle accelerator.
<br />
</p>
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<p></p>
<p></p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGsYcnW_U0KFS9oZHUDQPPJFqyBY2f8VHR2SN2mWh8AnwvJ1SqpxO8RrOJerIBLBnh13fqgJPE2Lb800LULnrS_h_6vOLlRZ7fft3P4XYvXZwT8upCHpqRvvRSyHOoKuI_4fyTbeOnv8T0nuQEQRQepC1zYWCjnwG9nR07IfR27Zws_gDz8OUlbf9StQg/s1600/IMG_5844.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGsYcnW_U0KFS9oZHUDQPPJFqyBY2f8VHR2SN2mWh8AnwvJ1SqpxO8RrOJerIBLBnh13fqgJPE2Lb800LULnrS_h_6vOLlRZ7fft3P4XYvXZwT8upCHpqRvvRSyHOoKuI_4fyTbeOnv8T0nuQEQRQepC1zYWCjnwG9nR07IfR27Zws_gDz8OUlbf9StQg/s320/IMG_5844.jpeg" width="240" /></a>
</div>
<p></p>
<p>
On to the next issue - so I dialed in the front wheel alignment as good as I
could reasonably get it, but when I hooked up the steering box, it wasn't
perfectly in the center position. No big deal, right? Well, that's one of the
first times I actually messed something up. Turns out, not all splines are
created equal and there's one, which should act as a zeroing spline. So in
hindsight, I should have undone the lower joint and reset that one to be
correct and not the steering wheel.
</p>
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</div>
<p></p>
<p>
Next thing on the list - the fog light. Mandatory on all cars overhere and if
your taillights don't have one built in, well you have to have an extra one.
The one installed is the original one, it wasn't watertight and thus was in
absolutely incredible condition. (I bought a new one, but that wouldn't fit
and was open on the backside, because it was meant to be countersunk into the
bumper, i.e. it was no good for me.) With no real other options, it was a case
of make this one happen.
</p>
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</div>
<p></p>
<p>
As the actual lamp socket was so rotten it wouldn't hold contact, I decided to
solder the +12V cable directly onto the bulb.<br />
</p>
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</div>
<p>
A lot less obvious, but swapping the hood latch (and thus the cable) would
eventually mean a lot more fun with a locking mechanism, than I'd care to
admit. My personal tip for this: get a 2mm clutch cable (highly flexible) for
a motorbike and feed that into the original outer. Cable is a lot smoother
than solid wire and with a proper locknut... well... it'll just work.
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivM5PsJoQ2ipWyBVHYjd5ED7LU1PHqTUKIYAvHVHa_4yriGWhyphenhyphenrPlfEM-iCyskGjwOtFrsVv-ougsKsnNidlzNtT5ySt0q2RAAQ1eSzsiCbiPSAHaA7YrznMK_MaXHVWeyzQfsdHmjpnZ8zx-9WRrnzGm7P3B7vMWpHmTMrbTarMibGlA9zrBCUv08xms/s1600/IMG_5863.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivM5PsJoQ2ipWyBVHYjd5ED7LU1PHqTUKIYAvHVHa_4yriGWhyphenhyphenrPlfEM-iCyskGjwOtFrsVv-ougsKsnNidlzNtT5ySt0q2RAAQ1eSzsiCbiPSAHaA7YrznMK_MaXHVWeyzQfsdHmjpnZ8zx-9WRrnzGm7P3B7vMWpHmTMrbTarMibGlA9zrBCUv08xms/s320/IMG_5863.jpeg" width="320" /></a>
</div>
<br />
<p>
Next up was tackling the interior. Now if you don't like a bit of let's call
it rather rustic charm of the Lada insides, this might not quite be the car
for you. (Fun fact, Soviet propaganda saw this vehicle as a competitor to the
Range Rover.) But it can get a bit more homely, if you fit some of the panels
etc. Before that: spray everything down with cavity grease. Plenty of it.<br />
</p>
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</div>
<p></p>
<p>Rear seatbelts installed as well.<br /></p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqja23rzCYhEaJdkf4K0wqCkgvisg7mrvFyHkzf6QEc6wbmibbcXpPuFJ8I2GCgcXO41Yu7x1rvm1AeAxvCLEqY0_OVwVwL0gYAk6r-RFdO7Xo5fT4nQd4aVKXpBmMIguv2jKHsN7XuC3NpdP_h2X79sBmfyUlHUFuR_GbGppuR8inisnUHOU_FyWCUtE/s1600/IMG_5847.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqja23rzCYhEaJdkf4K0wqCkgvisg7mrvFyHkzf6QEc6wbmibbcXpPuFJ8I2GCgcXO41Yu7x1rvm1AeAxvCLEqY0_OVwVwL0gYAk6r-RFdO7Xo5fT4nQd4aVKXpBmMIguv2jKHsN7XuC3NpdP_h2X79sBmfyUlHUFuR_GbGppuR8inisnUHOU_FyWCUtE/s320/IMG_5847.jpeg" width="320" /></a>
</div>
<p></p>
<p>
And just to top it off (only to realise I had to take the rear bench out to
fit that one), the rubber floor mat.
</p>
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</div>
<p></p>
<p>
The first testrun to a nearby petrol station was rather sobering. It would pop
and stutter, hardly make it beyond 85kph on level ground. Admittedly I was
shocked, underwhelmed and questioned this whole endeavor (again).
</p>
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</div>
<p></p>
<p>
4 Bar, not great, actually pretty terrible, if one's honest. Speaking of
honesty this gauge reads about 1.5 to 2 Bar low every since it was used to
test the compression on a high comp diesel engine. Still, 6 bar isn't exactly
the kind of compression to write home about.<br />
</p>
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</div>
<p></p>
<p>Especially as the other ones are consistently in the 6 Bar range.<br /></p>
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</div>
<p></p>
<p>
The solution in the end would be about as Soviet as one can imagine. Mumble a
quiet "ah pizdec", flood all four pots with plenty of WD40 and expect miracles
to happen. Guess what, it actually worked. I suspect that the rings were just
stuck in their grooves and it has stopped running on three pots ever since.
(The fresh plugs might have helped a bit as well.)
</p>
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</div>
<p></p>
<p>Copious amounts of cavity grease...</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6dNVyBeSTw4mYwEScA5BlNk2p4bKG4BXqb7-Sm7s-YsbB3uWLJ1pbMTpcTJQI947rAOfSR7vntyeFpIJ00l6Bm-2KOskGwv9QP-oUr0ROrhHRxIZC-PoA45zUV_YM4-x5-Dv947ZWvxp8bBUyfhnxu8ifb4eX_F9TYFlxpnyLCMD-LlnXm9qAxdoJYQY/s1600/IMG_5882.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6dNVyBeSTw4mYwEScA5BlNk2p4bKG4BXqb7-Sm7s-YsbB3uWLJ1pbMTpcTJQI947rAOfSR7vntyeFpIJ00l6Bm-2KOskGwv9QP-oUr0ROrhHRxIZC-PoA45zUV_YM4-x5-Dv947ZWvxp8bBUyfhnxu8ifb4eX_F9TYFlxpnyLCMD-LlnXm9qAxdoJYQY/s320/IMG_5882.jpeg" width="240" /></a>
</div>
<p></p>
<p>... a fresh set of brake pads ...<br /></p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZdBsPf8ShCiqdgONb0J2EOJfebcNzZlnUHXG7nSNwt3HbUH1NWyGhBy9xkY1b4puCSFgWCd8_stKxVOF5NzklZliPju9zb__JsBdl28oimRqO_vevw7biD6ayo6g-3oRTzgkkyq1F_VL5o-Ol8oa-QTtLGE3KYgiMAp4JMR2b5Q7-FeLH3oxiZEqoIa0/s1600/IMG_5884.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZdBsPf8ShCiqdgONb0J2EOJfebcNzZlnUHXG7nSNwt3HbUH1NWyGhBy9xkY1b4puCSFgWCd8_stKxVOF5NzklZliPju9zb__JsBdl28oimRqO_vevw7biD6ayo6g-3oRTzgkkyq1F_VL5o-Ol8oa-QTtLGE3KYgiMAp4JMR2b5Q7-FeLH3oxiZEqoIa0/s320/IMG_5884.jpeg" width="240" /></a>
</div>
<p>Unsurprisingly those pads netted some nice results.<br /></p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgn9oYEj33DRcWBXs9qF7Z9OkPTWzQqbzf90_gFNBwJnzsxewdvF7hD7Gh6n7HzhpRIQG4pnSC9SLmtMb-doOvBAo7I_VUl1rQkKvkBiG55Fljvdc-Cix23s_fhOgsyZY6Lt3OcTjouRg6xgz0RJLN5cA0i10q65k9K9FJ2QdjHewMRTeNCIid5z8DsQxg/s1600/IMG_5887.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgn9oYEj33DRcWBXs9qF7Z9OkPTWzQqbzf90_gFNBwJnzsxewdvF7hD7Gh6n7HzhpRIQG4pnSC9SLmtMb-doOvBAo7I_VUl1rQkKvkBiG55Fljvdc-Cix23s_fhOgsyZY6Lt3OcTjouRg6xgz0RJLN5cA0i10q65k9K9FJ2QdjHewMRTeNCIid5z8DsQxg/s320/IMG_5887.jpeg" width="240" /></a>
</div>
<p>
... and a bit more tidying up should have Comrade Car ready for some fun with
the authorities. <br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwFBvhx9sBaOt7jSuS5xoTDhBB9w-n7Dn0_MAaOtJtA7SLiTnvQyPzrKwshOkVdCxDKUCajD0hxA7uTI2MJLIeYmkfU-FjuMn0CM4azUfHSKgdDoJqZHpyzZtfceL8dtbrNF0GEGcSvJcBv-zJ9VfwLLXRZg6RbBaG_d5LSgGk5IxBShtL2XC-xyX6Mt0/s1600/IMG_5917.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwFBvhx9sBaOt7jSuS5xoTDhBB9w-n7Dn0_MAaOtJtA7SLiTnvQyPzrKwshOkVdCxDKUCajD0hxA7uTI2MJLIeYmkfU-FjuMn0CM4azUfHSKgdDoJqZHpyzZtfceL8dtbrNF0GEGcSvJcBv-zJ9VfwLLXRZg6RbBaG_d5LSgGk5IxBShtL2XC-xyX6Mt0/s320/IMG_5917.jpeg" width="320" /></a>
</div>
<br />
<p>
Only to realise that a battery hold down would probably go quite well with the
man in charge. (Marvel at the elegance and sheer beauty of a bit of angle iron
(zinc plated of course) and two pieces of M8 threaded rod.
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHo-kGizJnu-FXh7grtzOKxVf_qxYIpdbMCI76Ki3Nul5jgcPU6jTaBR2FC_CVrhW-CcFXeMeNSvH7T1RhTYsVVDMZF80CDVOiN_ttglpkyJtcAlkHutgeoLfNUCRnWRkzhC7XUStv7PnY3iuTMvn4CvFBhSru5EhIPTkiwOEa3_wAPX5rCjbcRtJ-oB0/s1600/IMG_5919.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHo-kGizJnu-FXh7grtzOKxVf_qxYIpdbMCI76Ki3Nul5jgcPU6jTaBR2FC_CVrhW-CcFXeMeNSvH7T1RhTYsVVDMZF80CDVOiN_ttglpkyJtcAlkHutgeoLfNUCRnWRkzhC7XUStv7PnY3iuTMvn4CvFBhSru5EhIPTkiwOEa3_wAPX5rCjbcRtJ-oB0/s320/IMG_5919.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Surely a vehicle that has seen so much loving care can only do one thing at
the inspection - exactly, it failed miserably and I even got shouted at for
having the audacity to bring "something like this" to the inspection. I later
on went to another garage, got a list of faults and started tackling them one
by one.
</p>
<p>
Not a fault per se, but a fresh fan belt, because the one installed was way
too short and "well" run in.
</p>
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</div>
<p></p>
<p>
As I had to take off the fan-shround anyway, I cut out one section in order to
make room for the 38mm socket that is used to turn over the engine for when
you want to adjust valves or the like. (Mind you this one is still
handcrank-able.)<br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0nh8qFPZ1HncEYc8iXePjt4R8-FXtIvhsReeJWPwEL_ACDLqiWVs0rCDQpBY77jd3yc_kwGk9oo-8WHPDtKykCjyNjuOMAr0HEAvF3ih5AlhXfuZfnh89QcdO8zoMZ0GPKlwm7GAMGlpVEqPhGIiYjHkLL-djXCdx3CBhyj_GS8o5gSP8fM_g-JiQs0Q/s1600/IMG_5935.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0nh8qFPZ1HncEYc8iXePjt4R8-FXtIvhsReeJWPwEL_ACDLqiWVs0rCDQpBY77jd3yc_kwGk9oo-8WHPDtKykCjyNjuOMAr0HEAvF3ih5AlhXfuZfnh89QcdO8zoMZ0GPKlwm7GAMGlpVEqPhGIiYjHkLL-djXCdx3CBhyj_GS8o5gSP8fM_g-JiQs0Q/s320/IMG_5935.jpeg" width="240" /></a>
</div>
<p><br /></p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2_nCKYjGXH5efomTOnh_UITktuNdx0omF_DLRL5ur37sh1WF62sX4TYfLqEaQl0NPONoKciE6FfLXL5-_RlWJGq09jMSlsOrmZhPPsjT4Qx435cpC59XvoAvJ2Nlm3Af56ZlXCbWbzD3GZS4M7IRWEEclglR72QJII9JVNtqrgkDnrT-gtuJxtacjrts/s1600/IMG_5937.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2_nCKYjGXH5efomTOnh_UITktuNdx0omF_DLRL5ur37sh1WF62sX4TYfLqEaQl0NPONoKciE6FfLXL5-_RlWJGq09jMSlsOrmZhPPsjT4Qx435cpC59XvoAvJ2Nlm3Af56ZlXCbWbzD3GZS4M7IRWEEclglR72QJII9JVNtqrgkDnrT-gtuJxtacjrts/s320/IMG_5937.jpeg" width="240" /></a>
</div>
<p></p>
<p>So what did Comrade car fail on:</p>
<p>
1)rear brakes - rear drums have warped liners (but otherwise were working
fine)
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcaqTKeTkRhuE7LMJhiCWmvV6L1ZonaDBB_Bgbmdl-gskOvjdwQ5gDjmPHAG7K1eM6F8-1xEbCNeaR6AXP-h-VWI3t_npK_sACLsZqw3R09Bd55TKOkzVwNw7cd6L0PFyuEmp_pMK41RkKdLQbgU0fDgBQv6bGdPa10sTIQtgKOSKcsYGUps0RMBD7j3w/s1600/IMG_6499.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjcaqTKeTkRhuE7LMJhiCWmvV6L1ZonaDBB_Bgbmdl-gskOvjdwQ5gDjmPHAG7K1eM6F8-1xEbCNeaR6AXP-h-VWI3t_npK_sACLsZqw3R09Bd55TKOkzVwNw7cd6L0PFyuEmp_pMK41RkKdLQbgU0fDgBQv6bGdPa10sTIQtgKOSKcsYGUps0RMBD7j3w/s320/IMG_6499.jpeg" width="240" /></a>
</div>
<p></p>
<p>
As I already had them off before, pulling the drums off was easy peasy.<br />
</p>
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</div>
<p></p>
<p>
De-rusting the locating ring and the mating surface, probably would have been
sufficient to make them run true again, if you ask me.<br />
</p>
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</div>
<p></p>
<p>
In order to prevent this, a generous amount of ceramic anti-seize should keep
things in good shape for a while. <br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb81vT4d9M6Ot8GhtSR5K90WyJEOZSLoiHObxMCICtiJdPCNuDJD6UuDy41QB_i3cv4LiVjOkgCQmfxvNkfSgZ_Ze0QKRGLdKn9XWxXYpa5ZJiYjHVGYAkkBZEAVeMXdWj_U6cEgF1AFz5D30StbXVYskpxwhtT51LefYGgnPeaUNBdF8g4JsqHQbmXc0/s1600/IMG_6504.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb81vT4d9M6Ot8GhtSR5K90WyJEOZSLoiHObxMCICtiJdPCNuDJD6UuDy41QB_i3cv4LiVjOkgCQmfxvNkfSgZ_Ze0QKRGLdKn9XWxXYpa5ZJiYjHVGYAkkBZEAVeMXdWj_U6cEgF1AFz5D30StbXVYskpxwhtT51LefYGgnPeaUNBdF8g4JsqHQbmXc0/s320/IMG_6504.jpeg" width="240" /></a>
</div>
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</div>
<p></p>
<p>
2) rear shocks - well in all fairness, all four of them were as dead as Count
Dracula and still rocking... To be fair, those red shocks must AT LEAST be
worth five horsepower. (Also they had a rather dramatic effect as I suspect
that the shocks installed include a slight lift and it handles rather stiff
for a vehicle like this.<br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAArZ0iQwbZHVTRgHbA2ADzsAGLoJ_AeHIpyd9eOQ_sK8OGCXWr3rhW8SrLk3oo-uRsTcm4shPPSTDK8_epJomj8IUbQAL7Xv5zuLEvQbVbzoCwuLcCqsKuXarn2RMHll1sJmMPKuJmsKQdRS5kDlU-1dLPOeC1oMqohPEuWPBniIRdjABPrJbUn_-XAw/s1600/IMG_6506.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAArZ0iQwbZHVTRgHbA2ADzsAGLoJ_AeHIpyd9eOQ_sK8OGCXWr3rhW8SrLk3oo-uRsTcm4shPPSTDK8_epJomj8IUbQAL7Xv5zuLEvQbVbzoCwuLcCqsKuXarn2RMHll1sJmMPKuJmsKQdRS5kDlU-1dLPOeC1oMqohPEuWPBniIRdjABPrJbUn_-XAw/s320/IMG_6506.jpeg" width="240" /></a>
</div>
<p></p>
<p>
They look dead-nuts cool. Don't even try to argue. Also they were the cheapest
ones available.<br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoJKlv2ql5axv-U9Z1gIHsLktp-E7oF88Xw_IQ3KbKoQep7gFqP69GGPAKTsEOjM9Z9ySqOrPKkzLIQXcxpYwWAPybCStll0bHmba4yk5F4FRKK1jSXqtqR6pyhzp_Dyq8a5-Q2LMM3NmFz32cNtbgSt9tOYEZAqEXBEetfXZV1TUqt6T7PZOgu-e5sVs/s1600/IMG_6509.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoJKlv2ql5axv-U9Z1gIHsLktp-E7oF88Xw_IQ3KbKoQep7gFqP69GGPAKTsEOjM9Z9ySqOrPKkzLIQXcxpYwWAPybCStll0bHmba4yk5F4FRKK1jSXqtqR6pyhzp_Dyq8a5-Q2LMM3NmFz32cNtbgSt9tOYEZAqEXBEetfXZV1TUqt6T7PZOgu-e5sVs/s320/IMG_6509.jpeg" width="320" /></a>
</div>
<p></p>
<p>
3) Front brakes - both the disks and lines (all round). Strictly speaking,
there's not much to it, except that the disk is held on to the hub with
press-in wheel studs. This could be a bit annoying, when you just want to do a
quick brake-service, but as the old Comrade needed more love anyway.
</p>
<p>
The important bits when knocking out studs: Put the nut back on proper, i.e.
not just 1-2 threads but wind it down to the point where the stud is just 2-3
threads low in the nut (in order to avoid mushrooming) and use a BFH (big
f*cking hammer) to give it a whack-a-holio.
</p>
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</div>
<p></p>
<p>
Again, my opinion, at least part of the runout comes from the fact that
moisture will get between hub and disk and as rust takes up more room than,
well, no rust... <br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1FbOsWOahswLc39g7KPx3W1ZT1r_T1QELmeojjyNmmzQmjqVUrD3GxoIvbg2lTVMNSBenuJDUu1OSxXZj5U2A5sLVHBmAVxzwoGNYzj_XLjAYLbg8d4AmZqZqmX8jks7Ol8r9Sf3mbB_vfXDEryYabdv5SKTUsHHnRkX6vwkzj3em4l_eH9H0QVOAMqU/s1600/IMG_6543.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1FbOsWOahswLc39g7KPx3W1ZT1r_T1QELmeojjyNmmzQmjqVUrD3GxoIvbg2lTVMNSBenuJDUu1OSxXZj5U2A5sLVHBmAVxzwoGNYzj_XLjAYLbg8d4AmZqZqmX8jks7Ol8r9Sf3mbB_vfXDEryYabdv5SKTUsHHnRkX6vwkzj3em4l_eH9H0QVOAMqU/s320/IMG_6543.jpeg" width="240" /></a>
</div>
<p></p>
<p>
I debated with myself whether or not to use anti-seize there and decided
against it, because it was dry to start with. To be honest in hindsight, it
might have been a smart move.<br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHgNUBM7QPjjyvccIS7AD5tgfeP2knFFPgztm56v9Z-R1mRB9SW-T1IBKtWqsZV-Ix1eM5rx-JFxuX2z7JY0WScofBbJiIQhbpJk3f1SXZnEcEid1XlN6aw0p6qBiCQaXKlNj1nV2Y-Of6_tmWPJ3SkvAL2HrD3tjUy9eWoHDZdkaN_G2MJXWRKEkZm6g/s1600/IMG_6544.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHgNUBM7QPjjyvccIS7AD5tgfeP2knFFPgztm56v9Z-R1mRB9SW-T1IBKtWqsZV-Ix1eM5rx-JFxuX2z7JY0WScofBbJiIQhbpJk3f1SXZnEcEid1XlN6aw0p6qBiCQaXKlNj1nV2Y-Of6_tmWPJ3SkvAL2HrD3tjUy9eWoHDZdkaN_G2MJXWRKEkZm6g/s320/IMG_6544.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Reinstall of the studs isn't too hard, just tap two or three lightly in place
from behind and then use a spacer and a wheel nut with a ratchet (to be able
to feel when stuff goes wrong) and pull them in tightly. "Full pull" comes by
installing the wheels. Some people will only tap them in from behind, but if
you bump into one of the studs with one of those incredibly heavy steel
wheels, I suspect it would be rather easy to knock it back out. And sneaking
that sucker back in, without taking the whole hub-assembly off once more, I
suspect that could be a good reason for a dose of very flowery language.<br />
</p>
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</div>
<br />
<p>4) Shocks and ball-joints</p>
<p>
Getting rid of the old shocks was a case of take no prisoners. The lower bolt
was no real issue, the upper one got to know Mr. 5-inch-anglegrinder.
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgT1hHXZWnMYWs4VNH38w7IKsJ2FpMMptw5D4CMpTTc0JpVqpKUVyFSovkUB0hf20X1T3GIngvPR26gdYEFF9tS8bZPwNbebJPt9CzbZyiMuHFk6mpY1y2hCjof95-ZDsflFx3RY8QGW9XtLxjYSFe7zRIx4sCrp_qXKMzDIBxkg6RNa0nUaVCRuTCNiWM/s1600/IMG_6552.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgT1hHXZWnMYWs4VNH38w7IKsJ2FpMMptw5D4CMpTTc0JpVqpKUVyFSovkUB0hf20X1T3GIngvPR26gdYEFF9tS8bZPwNbebJPt9CzbZyiMuHFk6mpY1y2hCjof95-ZDsflFx3RY8QGW9XtLxjYSFe7zRIx4sCrp_qXKMzDIBxkg6RNa0nUaVCRuTCNiWM/s320/IMG_6552.jpeg" width="240" /></a>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhv7DhSyWl9x3xzTrW0N7r0AofsP8_4mmi6dtzawMugRvx12ekLVRe2BUXGQGyac4ifX1H69fAf1CyhgsaftupReGqffdytMe5Yw6kgxTqolhk-4S1cWqggkHSLKkgZQGi3fYCVecS3zkpjlyN6ONyIQR9mJTxIAGFXqpRC5s3QZLO_GdkMfcD-9df6Y_M/s1600/IMG_6554.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhv7DhSyWl9x3xzTrW0N7r0AofsP8_4mmi6dtzawMugRvx12ekLVRe2BUXGQGyac4ifX1H69fAf1CyhgsaftupReGqffdytMe5Yw6kgxTqolhk-4S1cWqggkHSLKkgZQGi3fYCVecS3zkpjlyN6ONyIQR9mJTxIAGFXqpRC5s3QZLO_GdkMfcD-9df6Y_M/s320/IMG_6554.jpeg" width="240" /></a>
</div>
<p></p>
<p>
The upper ball joint is relatively easy to do and you only have to jack up the
lower control-arm and everything will (quite literally) fall in place. For the
lower one a spring compressor would probably come in very, very handy. (I did
it without and after seeing some videos, this was more the way you'd do it at
the side of the road due to some catastrophic failure.)<br />
</p>
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</div>
<p></p>
<p>
5) Rubber brake hoses - probably the part I dreaded the most due to some very
nasty experiences in the past. But, nope no real drama. This car is meant to
be worked on and thus, not stupidly difficult. Mind you there's a longer and a
shorter line on the front, clean up the hardlines where the nut will have to
go and a spritz of penetrating oil won't do harm either. But no nasty tricks
with blow-torches or anything.
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh8jOX1Mnf7lHGI4iWQNBxE570fQyX5NypExiaSVpS1SeM5QNAIYG6-SyCpHhXHCaA0lyC3AZjyr5t91RLoSRyF-IEEz6lTf-o85kDxNB6fBPcJ61Ac3M-oFNcU6PuCzr0xx8LiE5Bz5s3U3dnLfslkONJVfec6db4Xba906Ve3DsPCmnNtZtphArPUDw/s1600/IMG_6566.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh8jOX1Mnf7lHGI4iWQNBxE570fQyX5NypExiaSVpS1SeM5QNAIYG6-SyCpHhXHCaA0lyC3AZjyr5t91RLoSRyF-IEEz6lTf-o85kDxNB6fBPcJ61Ac3M-oFNcU6PuCzr0xx8LiE5Bz5s3U3dnLfslkONJVfec6db4Xba906Ve3DsPCmnNtZtphArPUDw/s320/IMG_6566.jpeg" width="240" /></a>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi59Q6rXjKke7vGv1cJ1WA4wwjynSK8rQg1cWymygzhfu7WXGgjfteSGpk6k0sXae-LYL1hGsrem7wg3YSdTSU2ZsN_yMsxDNawrIMcEX9anL_uIEiSazYJhalBOfQ8tguhShL8nzMBOQhDYnZFPs_r8Dj6pukrui04Sb1bny4kYnoWumq8fLnNBDTtNQY/s1600/IMG_6567.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi59Q6rXjKke7vGv1cJ1WA4wwjynSK8rQg1cWymygzhfu7WXGgjfteSGpk6k0sXae-LYL1hGsrem7wg3YSdTSU2ZsN_yMsxDNawrIMcEX9anL_uIEiSazYJhalBOfQ8tguhShL8nzMBOQhDYnZFPs_r8Dj6pukrui04Sb1bny4kYnoWumq8fLnNBDTtNQY/s320/IMG_6567.jpeg" width="240" /></a>
</div>
<br />
<p>
6) It needed new tyres. So it got "new" tyres - actually they are off a newer
Niva 1700, because the owner swapped them out for some real offroad
tyres.
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiB4TFpZoLXIMwRIghPeJXGL4oV-u56Wwor-XoTIgSVBgHhrnTkbsbC6bUw-i2De0d3VVDFath6fnZeQ6XP1ZrtnMCyxyQyofaER8sX6qyg8ebluI4RUOHdFIPHfswL3i7rNZQWmzaO6hZItiEbDirtjOtrvxnfg-hRguAsYDvbkX0W9yy7CUAnernSsA/s1600/IMG_6590.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiB4TFpZoLXIMwRIghPeJXGL4oV-u56Wwor-XoTIgSVBgHhrnTkbsbC6bUw-i2De0d3VVDFath6fnZeQ6XP1ZrtnMCyxyQyofaER8sX6qyg8ebluI4RUOHdFIPHfswL3i7rNZQWmzaO6hZItiEbDirtjOtrvxnfg-hRguAsYDvbkX0W9yy7CUAnernSsA/s320/IMG_6590.jpeg" width="240" /></a>
</div>
<p>And just like that, Comrade Car passed. </p>
<p><br /></p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikckV-SzUgtvOFx55f2DDqaosRt5NFTX4nqnxewKHFfwRm2KeCIMzBFX0pB7UCbgtNmiwh9uypQaLqfkr4NsNwFSDGCCWzBeN4t2MiykA_ZR9ubHx9zue_u1Sh_W67El0Tx8ZCyFd9cNAE8h6PtALbMHA4GdNfdIHmgbuUQK1RUsUH3poHee7NOXTlpE0/s1600/IMG_6619.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikckV-SzUgtvOFx55f2DDqaosRt5NFTX4nqnxewKHFfwRm2KeCIMzBFX0pB7UCbgtNmiwh9uypQaLqfkr4NsNwFSDGCCWzBeN4t2MiykA_ZR9ubHx9zue_u1Sh_W67El0Tx8ZCyFd9cNAE8h6PtALbMHA4GdNfdIHmgbuUQK1RUsUH3poHee7NOXTlpE0/s320/IMG_6619.jpeg" width="240" /></a>
</div>
<p>Just like that? Well, the moment the engineer hopped into the car and drive it from the parking lot to the inspection booth, this happened:</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMLbgYTdQpcN-iBRPCyzPQnF2nCP20EWUumrGpR8v0j1437SvUoONVPtKifM536WiSbfPLLPktSQPYDbodE4pVTmebNHTlQeD98zBAGM3KyxPKlVFCdEhdkvk7BHo6k67W3su0WWpN6rLt49xGlwwfKQhDI0ZJI7ZzOmJNdHU-14dVGHN2PrA-svdYqRk/s1600/IMG_6615.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMLbgYTdQpcN-iBRPCyzPQnF2nCP20EWUumrGpR8v0j1437SvUoONVPtKifM536WiSbfPLLPktSQPYDbodE4pVTmebNHTlQeD98zBAGM3KyxPKlVFCdEhdkvk7BHo6k67W3su0WWpN6rLt49xGlwwfKQhDI0ZJI7ZzOmJNdHU-14dVGHN2PrA-svdYqRk/s320/IMG_6615.jpeg" width="240" /></a></div><p></p><p>With the inspection and registration passed successfully, I found a rather simple (yet not quite cheap) way to fix fuel gauge - a filled tank does wonders.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEXoLObxm_yx8pNvTtXo1vWKMt4u1HVL2FOdQEZGu5L8jR7_Yh87kxmxaSXJXwcnRIaTdH5vCxq82ukDsTrFDF0x0oX5IETLR4vzFGSltpo2EX1gEEPxBaCQIY79m0GdkQCPpNFgM8OlIaXCsshULSX5SEd7LEj3CvDkJF5Ju1LrgTveshbAmyJeBwYJs/s1600/IMG_6648.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEXoLObxm_yx8pNvTtXo1vWKMt4u1HVL2FOdQEZGu5L8jR7_Yh87kxmxaSXJXwcnRIaTdH5vCxq82ukDsTrFDF0x0oX5IETLR4vzFGSltpo2EX1gEEPxBaCQIY79m0GdkQCPpNFgM8OlIaXCsshULSX5SEd7LEj3CvDkJF5Ju1LrgTveshbAmyJeBwYJs/s320/IMG_6648.jpeg" width="240" /></a></div><p></p><p>29 liters later the gauge showed full and that was the end of the "broken" fuel gauge. In hindsight this also means that realistically the fuel consumption was around the 12-14L/100km mark, which is pretty good for a carb'ed Lada Niva. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicke8-w8p6Rj3Zmf5zVal4UiGsbC6aXZGcZdPJPS-Z5pbHU49v4MtZXfiXviRZ4t8IV-kxxMPC2RaFuT_vhAjeR67eL_TZsguWJ7bqQVKln9fFtfF5uQTe9q7nYjIs-Vg_zIf0zII-ty4ZiJUeOi1xvMjfzxWzclR3iDJfrJeqTHcmOHIZ-g8FdpLpzGQ/s1600/IMG_6649.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicke8-w8p6Rj3Zmf5zVal4UiGsbC6aXZGcZdPJPS-Z5pbHU49v4MtZXfiXviRZ4t8IV-kxxMPC2RaFuT_vhAjeR67eL_TZsguWJ7bqQVKln9fFtfF5uQTe9q7nYjIs-Vg_zIf0zII-ty4ZiJUeOi1xvMjfzxWzclR3iDJfrJeqTHcmOHIZ-g8FdpLpzGQ/s320/IMG_6649.jpeg" width="320" /></a></div><br /><p>And then there was a bit of this - see where that gravel road takes us that I passed by at least a hundred times on my way home. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgtuRnzTY4Y4idIhDKqPS_Wqe9Qn8-dmqKGmDEfUEFBfAmjjzEAX33c94q0k1NOmHFjusvfohyphenhyphenLmmEDnDARFxcQJiFjJLXvo_qiXlvD00vBtetFkMTmBAjsb5IGxp2xiG_OPqo1vwsQ_pC5VOvL_E4Doav-0ZC0Ag8jfeJ0UMrgeUMYAc0NNF862IXPCw/s1600/IMG_6650.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhgtuRnzTY4Y4idIhDKqPS_Wqe9Qn8-dmqKGmDEfUEFBfAmjjzEAX33c94q0k1NOmHFjusvfohyphenhyphenLmmEDnDARFxcQJiFjJLXvo_qiXlvD00vBtetFkMTmBAjsb5IGxp2xiG_OPqo1vwsQ_pC5VOvL_E4Doav-0ZC0Ag8jfeJ0UMrgeUMYAc0NNF862IXPCw/s320/IMG_6650.jpeg" width="240" /></a></div><p>So why the dramatic title? Well to be honest, I put it up for sale, not expecting much and then someone came, bought it and now...</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUiXhOTY6Z728kh7Z8mJbxTBAA2_hXr3SzU0rW7aT00w-lgytVgarCCF88RFRdSF5hyWUiTqH0fEuecZupTnwv5ar44JEta86HGlGa-9UECd1O_WhdY79wKG4KyWBxiNefdIp4RUhIvkN4yFloLZaoyzQlUs77bOlvjld9TJ3R2OtpF_NHTLjIAvwuMWM/s1280/byebyeLada.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1280" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUiXhOTY6Z728kh7Z8mJbxTBAA2_hXr3SzU0rW7aT00w-lgytVgarCCF88RFRdSF5hyWUiTqH0fEuecZupTnwv5ar44JEta86HGlGa-9UECd1O_WhdY79wKG4KyWBxiNefdIp4RUhIvkN4yFloLZaoyzQlUs77bOlvjld9TJ3R2OtpF_NHTLjIAvwuMWM/s320/byebyeLada.jpeg" width="240" /></a></div><p>So what's the verdict on the Lada. It's complicated and thus I might write a separate post on the subject. Maybe also it'll take a bit until that happens.<br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-72125556175149789462023-10-08T20:00:00.004+02:002023-10-08T20:00:00.144+02:00Dre-XT-Stück - head(er)s or tails<p>
Let's assume you have a bike that is working (moderately) fine and it even has
a stainless steel aftermarket header installed. What would you do? Obviously
you would leave it the hell alone, especially as there are plenty of other
issues that have to be tackled in other areas. But as the TT600 header will
not bend the headstuds (as much) and is generally a lot nicer... Also I put
the port for the wideband AFR probe at a very vertical angle, which is good
for the wideband sensor, but bad for my right leg as the plug will touch my
leg ever so slightly.
</p>
<p>With all that in mind I marked a good/better location for the port.</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpmf8u_BDgebPV90o8buyxXd-EAqa59-gEFO06_Z2KHeT7AyQ2QtmMqs7gxCRrnwSh367oxxAGnk1XF5IQPeIGS24mNxvaBt8R24Ur7Yei4M6zZCJanlXfqTMoSQ2m-7L5gGhB2_LkdcEJ0CvEnoQsas_jL5rluqPKyCrjyh3arBItJ7WUNH1EDhbAKtc/s1600/IMG_6049.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpmf8u_BDgebPV90o8buyxXd-EAqa59-gEFO06_Z2KHeT7AyQ2QtmMqs7gxCRrnwSh367oxxAGnk1XF5IQPeIGS24mNxvaBt8R24Ur7Yei4M6zZCJanlXfqTMoSQ2m-7L5gGhB2_LkdcEJ0CvEnoQsas_jL5rluqPKyCrjyh3arBItJ7WUNH1EDhbAKtc/s320/IMG_6049.jpeg" width="320" /></a>
</div>
<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDHBDb9U42_TnPJQ8sbgJJqV2bWQE4ydw6CvA-7Mu8uESbLBVB9MkHsxr5uhcjvqZ8dQ_-GQzx_Zo1kAcqzk2FAfVTQ6ynM6bchJyke9M4ujiJntvUXCN2JYqabR9ea8xvGQbLiXJ29bQRBsJfo4P3nJjJBSXM6RpCZn2vPhz1ebYfaB2B6CkunRdpgDs/s1600/IMG_6050.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDHBDb9U42_TnPJQ8sbgJJqV2bWQE4ydw6CvA-7Mu8uESbLBVB9MkHsxr5uhcjvqZ8dQ_-GQzx_Zo1kAcqzk2FAfVTQ6ynM6bchJyke9M4ujiJntvUXCN2JYqabR9ea8xvGQbLiXJ29bQRBsJfo4P3nJjJBSXM6RpCZn2vPhz1ebYfaB2B6CkunRdpgDs/s320/IMG_6050.jpeg" width="320" /></a>
</div>
<p></p>
<p>
What followed next is probably best described with it being the equivalent of
a frontal assault on the castle gate, but with step drills and a die grinder.
In short, on large diameter tubing this would quite literally just be a job of
poking a relatively round hole and call it a day, but on this comparatively
small diameter, it's more of an oval than anything else. Then again, if the
hole is somewhat neat, welding is an absolute breeze.
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZWokXHELG4Zbc8BEJTCRbV0CVWAE5-ENeqz29HuPWaHH1xayLop8Ac5NgrHT5WXLErrB_nPh4U4joykdolXW9wbQdF0xSRoMLqMtlFOCDJKJRcNhdqK8jE0YDLhNh_hbF_lY-k4VKyAbsjEj1WFDpG9hlC8TM8Dybynx6243thB535fOxySI_Z0jgYdI/s1600/IMG_6051.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiZWokXHELG4Zbc8BEJTCRbV0CVWAE5-ENeqz29HuPWaHH1xayLop8Ac5NgrHT5WXLErrB_nPh4U4joykdolXW9wbQdF0xSRoMLqMtlFOCDJKJRcNhdqK8jE0YDLhNh_hbF_lY-k4VKyAbsjEj1WFDpG9hlC8TM8Dybynx6243thB535fOxySI_Z0jgYdI/s320/IMG_6051.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Admittedly cheating a bit, with pulsed TIG welding here to limit heat input
and using the plug as an additional heat sink, but that came out lovely.<br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcAOfV__C68Qnsv6DQe_j7O7gyk0CM-i66JM9OFtLU8N4KoIm1kcdaTF1Xej13u_hQUM-BDJC26Kctw4YzaA4YHu7tYsen75sTL-FtI1hx__wyq-muyvDf4sbrFBdGbfxaranFmFGW-OFj7rc4WhjwG87vIKUPyN0HBU0L6eum54PboFHg0T2Qo8XPPWE/s1600/IMG_6052.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcAOfV__C68Qnsv6DQe_j7O7gyk0CM-i66JM9OFtLU8N4KoIm1kcdaTF1Xej13u_hQUM-BDJC26Kctw4YzaA4YHu7tYsen75sTL-FtI1hx__wyq-muyvDf4sbrFBdGbfxaranFmFGW-OFj7rc4WhjwG87vIKUPyN0HBU0L6eum54PboFHg0T2Qo8XPPWE/s320/IMG_6052.jpeg" width="240" /></a>
</div>
<p></p>
<p>
With the exhaust back in place, I reinstalled the plug with PLENTY of copper
grease, just to be sure it wouldn't seize in the bung.
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrktf_Gwf6rCNLyIERCuJT8zL46UWZqG0AcOssnm0ARtzh4_B_jkUTUIwlMbTdQYVzLQFIhpc6RgRYGL1ZMMTWDLV7jkbBhMZ20MZ3dBe61dcqu5M-UAio7pbf-chQMDvJP5pRErAW7UYi8QKc-mFUYjt9ZyyRgbQaItgCAybm8c-o_u8PuidYJGY8OQM/s1600/IMG_6057.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrktf_Gwf6rCNLyIERCuJT8zL46UWZqG0AcOssnm0ARtzh4_B_jkUTUIwlMbTdQYVzLQFIhpc6RgRYGL1ZMMTWDLV7jkbBhMZ20MZ3dBe61dcqu5M-UAio7pbf-chQMDvJP5pRErAW7UYi8QKc-mFUYjt9ZyyRgbQaItgCAybm8c-o_u8PuidYJGY8OQM/s320/IMG_6057.jpeg" width="240" /></a>
</div>
<p></p>
<p>
... and with the wideband installed just to check fitment. Bit difficult to
get it started, but once it is in, it's in.
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoXBH9DDh0NJiy3-h7RenxmaDqlYNtpKCOZPZ0Vx3NamzKeGr3ZEoFj9XAS-xR2FY1x1xq6IL1WD1Kx2Mi-VrcTTFzC5NnAqExDNkOvyw_Yo2p-Zsp7a0ngzkzIKJMDrRQ-wPr1QGhcX3TltvpYsSJQn2_APADFrUpwL5dz_qTFuY_H76j2edETWurRHw/s1600/IMG_6059.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoXBH9DDh0NJiy3-h7RenxmaDqlYNtpKCOZPZ0Vx3NamzKeGr3ZEoFj9XAS-xR2FY1x1xq6IL1WD1Kx2Mi-VrcTTFzC5NnAqExDNkOvyw_Yo2p-Zsp7a0ngzkzIKJMDrRQ-wPr1QGhcX3TltvpYsSJQn2_APADFrUpwL5dz_qTFuY_H76j2edETWurRHw/s320/IMG_6059.jpeg" width="240" /></a>
</div>
<p></p>
<p>
With the sensor installed, it would be kind of rude to not put it through its
paces and check the AFR-values with the current setup (stock exhaust). Yes,
compared to a modern EFI bike the XT is running a tad on the rich side, but
this is also in part to help with internal cooling. (One can jet it leaner,
but will then have to face the thermal consequences.)
</p>
<p>
Idle - starts great with it being slightly on the rich side, after rejetting
lately, high 11s appears to be the sweet spot for brilliant hot and cold
starting. <br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRfIFmwuoExXzqezmzAXE0Y8rkx5mZm6dVIG_8RCPme09QuMRTCohqUfSoe6pxVwt2U0HwwRV1k4H7032lbZ_E-R-AXXhyypBweCazk83y8ZpnmKgVfddovIl85uKt1EDXXhrECMXzyG5qgwsj5Oi1h0RIIOo1b8pvQQvv3ULkmFBPRWaUAvInA8LzuYY/s1600/IMG_6079.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRfIFmwuoExXzqezmzAXE0Y8rkx5mZm6dVIG_8RCPme09QuMRTCohqUfSoe6pxVwt2U0HwwRV1k4H7032lbZ_E-R-AXXhyypBweCazk83y8ZpnmKgVfddovIl85uKt1EDXXhrECMXzyG5qgwsj5Oi1h0RIIOo1b8pvQQvv3ULkmFBPRWaUAvInA8LzuYY/s320/IMG_6079.jpeg" width="240" /></a>
</div><p>
</p><p>Approx. 1/4 turn on the throttle "running on the needle" as the old-timers would say - going lean here helps with fuel economy as this is actually where you end up most of the time when riding on the road.<br />
</p><div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcVHaFi3xF5zjcEKIxZc-vmRj49p0Pyv3_uBn-jIx_-sgCxH1IJhgn5YQI7eAZsCWqjGPw2Q_POdxHm5v1KfUCJyY59TYH7rQXAsG6GAutrRhzuwRB4Ep3bxKGklNlCOdyQpWG-Mkf6Ic-g4fGuUOkZ4kY9ilGM6cq-IdPvFQWz9zK1yM4sx9XBWBkq-4/s1600/IMG_6080.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcVHaFi3xF5zjcEKIxZc-vmRj49p0Pyv3_uBn-jIx_-sgCxH1IJhgn5YQI7eAZsCWqjGPw2Q_POdxHm5v1KfUCJyY59TYH7rQXAsG6GAutrRhzuwRB4Ep3bxKGklNlCOdyQpWG-Mkf6Ic-g4fGuUOkZ4kY9ilGM6cq-IdPvFQWz9zK1yM4sx9XBWBkq-4/s320/IMG_6080.jpeg" width="240" /></a>
</div><p>Probably 1/3 to 1/2 throttle - the dip towards lean is a bit of an oddity that is necessary on XT600s, because up to roughly this point you only run on the left (slider) carb. If you jet it richer, you will have one hell of a time once the second carb opens.<br /></p><div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX_ArsnY2aAQF-2b89hqbBRrAI5IXEqifoNpXJSswVUCf9CXHeVRDD2NjceSbW_CnRQdVp-aRdHSWXbH7MFNn3svCguDUJwvQ_hl6ejYGhqzSav5qXT5WeoYuGl64mb7g956PIFAz4cGLj8FKbTBtDppnsjwCtD8Y5cQgq0uBbqmRF_UMvRy4SkzEuxMY/s1600/IMG_6081.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjX_ArsnY2aAQF-2b89hqbBRrAI5IXEqifoNpXJSswVUCf9CXHeVRDD2NjceSbW_CnRQdVp-aRdHSWXbH7MFNn3svCguDUJwvQ_hl6ejYGhqzSav5qXT5WeoYuGl64mb7g956PIFAz4cGLj8FKbTBtDppnsjwCtD8Y5cQgq0uBbqmRF_UMvRy4SkzEuxMY/s320/IMG_6081.jpeg" width="240" /></a>
</div><p>
</p><p>Wide open throttle - aiming for 12:1, which is on the rich side, but again the Dre-XT-Stück is based on a 43F and thus has no oil-cooler, so jetting it on the rich side is mandatory to avoid big problems, when I have my moments and want to see how much she can do. <br />
</p><div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiMnvL2YT7d0cc6954oB3Ug0ee41mEXbTd8DTMXA7sqXFiCaTJVBMOS1734rY7vU5MyutR9xS3frSFz3P6_D3t0bgM6Vw4tIprcTyIY9DPcOOXmuZQ3-E86VGysm8O9fQQAGvkfu8hUmeSbGTzfKaWaAdlgNj56Dvpw5AY6EgO7x31frdCmNpO1j7GHUY/s1600/IMG_6082.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiMnvL2YT7d0cc6954oB3Ug0ee41mEXbTd8DTMXA7sqXFiCaTJVBMOS1734rY7vU5MyutR9xS3frSFz3P6_D3t0bgM6Vw4tIprcTyIY9DPcOOXmuZQ3-E86VGysm8O9fQQAGvkfu8hUmeSbGTzfKaWaAdlgNj56Dvpw5AY6EgO7x31frdCmNpO1j7GHUY/s320/IMG_6082.jpeg" width="240" /></a>
</div><p> In the not too distant future a very similar post will come up, as the AFR values shown here were photographed, when the ignition was playing up REALLY bad and thus the last four paragraphs you just read are technically worthless, as I jetted a bike with an ignition that was running without any ignition advance. 😛<br />
</p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-17299497110607180202023-10-07T20:00:00.003+02:002023-10-07T20:00:00.145+02:00Dre-XT-Stück - no ignition advance & ignition pickup waveform analysis<p>If you're just interested in the solution, look at the picture below, spot the brown cable and smirk, because there's a red cable plugged in. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbJZDqlkOEzLhDw6waXODGoeZz6TooXWv0LC2msjn6WFYzXra63zDTzSmzlE8pZeA9MaCPyYTWhj4wGzJZWsA127u6gPxlB5bJwb202A9Vd50nSKwv2CzT6zUTcpY3nDoLgRv_n5RMVGYBOs_tjcON7CTOH9moLsvak-ylfVng9G0Cm2dVPThyLj39XFA/s1600/IMG_5997.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbJZDqlkOEzLhDw6waXODGoeZz6TooXWv0LC2msjn6WFYzXra63zDTzSmzlE8pZeA9MaCPyYTWhj4wGzJZWsA127u6gPxlB5bJwb202A9Vd50nSKwv2CzT6zUTcpY3nDoLgRv_n5RMVGYBOs_tjcON7CTOH9moLsvak-ylfVng9G0Cm2dVPThyLj39XFA/s320/IMG_5997.jpeg" width="240" /></a></div><p></p><p>With that out of the way should you ever be in the position to question whether your stator was wound incorrectly, here's a few things to know beforehand:</p><ul style="text-align: left;"><li>common ground for the pickups is green</li><li>12 degree pickup connects to white-green</li><li>36 degree pickup connects to white-red</li></ul><p>If you hook up an osilloscope and have the polarities of the AC-supply mixed up like I did, this is the waveform you'll see at idle (and also higher revs, because the ignition will not advance), i.e. around 11V peak to peak:</p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDhJ6cs9mPMbmGC1IF-HjILfrLmtKipe4NtO5ybizWWfxM8_l9LYR5ja4HY8xqAJ99NzmRU66oGfysU7OKoIISt79QV_1FaKoc26S4irQwQ6I79BgDytG3ywwiCd0611Ctazz9txkYXCG76NW5R6oC3E32qM8IJSPt9iKHPfpll8qiuaovP7TR8uJ3Otw/s1600/IMG_5998.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDhJ6cs9mPMbmGC1IF-HjILfrLmtKipe4NtO5ybizWWfxM8_l9LYR5ja4HY8xqAJ99NzmRU66oGfysU7OKoIISt79QV_1FaKoc26S4irQwQ6I79BgDytG3ywwiCd0611Ctazz9txkYXCG76NW5R6oC3E32qM8IJSPt9iKHPfpll8qiuaovP7TR8uJ3Otw/s320/IMG_5998.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjG2Al6IPyRkbTjwRfumd1Lan4NVj_DWha7cFngG3lbqKn_NtpAwOj0eTHZeQzXP50qopXmgmTaw9_07CJdWt-c90q3s4WcD1RKqnGkIyxcwthtwWh2ybX0431c94sRFMR6qKT6oHAib34DZ2HSLjEgsHT36SzR7WB6HhQ6WkAPJGRFhfTmkvyNwKSoASU/s1600/IMG_5999.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjG2Al6IPyRkbTjwRfumd1Lan4NVj_DWha7cFngG3lbqKn_NtpAwOj0eTHZeQzXP50qopXmgmTaw9_07CJdWt-c90q3s4WcD1RKqnGkIyxcwthtwWh2ybX0431c94sRFMR6qKT6oHAib34DZ2HSLjEgsHT36SzR7WB6HhQ6WkAPJGRFhfTmkvyNwKSoASU/s320/IMG_5999.jpeg" width="240" /></a></div><br /> Once hooked up correctly, the peak-to-peak voltage will be under 9V and with a much more civilised wave form<p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-NWiNMQAFXub7FkgGENpMTEYZviSWh9di4RoYnkUTuMF-ySDbdmrp-N70QDnNEGbnlDFE4pQaungS6O-C6c4FJcS7t6OSEmNATgpKk2DEy2w2KCRUTMhMlhBRLPJzhIp3PXdSZTrfkkH7yJs-10LMq6581f8ll_LkSknDMYjlk8UzGV-w3e7kg-MO6D0/s1600/IMG_6003.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-NWiNMQAFXub7FkgGENpMTEYZviSWh9di4RoYnkUTuMF-ySDbdmrp-N70QDnNEGbnlDFE4pQaungS6O-C6c4FJcS7t6OSEmNATgpKk2DEy2w2KCRUTMhMlhBRLPJzhIp3PXdSZTrfkkH7yJs-10LMq6581f8ll_LkSknDMYjlk8UzGV-w3e7kg-MO6D0/s320/IMG_6003.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGeDaqlhzCME-ebA6bbMqdyrIW4nv07maNoIUWWEK2CjVnlYgpip8sijGmEl0CNEfp949MSCaTHHfGfHtebes_Fri0HqDUa121qvNE0chPsjr4IWdy4iUORy7OheyTAkRh4vFe94_HsXEauiSIeM5ZDLai6kzR4L9hydbVmUmVBUYedRATMvQ-6OSw_-U/s1600/IMG_6004.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGeDaqlhzCME-ebA6bbMqdyrIW4nv07maNoIUWWEK2CjVnlYgpip8sijGmEl0CNEfp949MSCaTHHfGfHtebes_Fri0HqDUa121qvNE0chPsjr4IWdy4iUORy7OheyTAkRh4vFe94_HsXEauiSIeM5ZDLai6kzR4L9hydbVmUmVBUYedRATMvQ-6OSw_-U/s320/IMG_6004.jpeg" width="240" /></a></div><p></p><p>And here in the form of a video to show how I set up my equipment and how the waveforms change depending on RPM, i.e. if you're troubleshooting, what to expect.<br /></p><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen="" class="BLOG_video_class" height="266" src="https://www.youtube.com/embed/9BE5LzgEyyU" width="320" youtube-src-id="9BE5LzgEyyU"></iframe></div><br /><p>For more information on the background on how the actual ignition works check out transmic's website, which has some lovely graphs and pictures of the CDI: <a href="https://transmic.net/2016/07/14/yamaha/" target="_blank">Transmic</a><br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-76192490684015575702023-10-01T20:00:00.009+02:002023-10-01T20:00:00.143+02:00Dre-XT-Stück - brakefluid sightglass swap<p>One could kick this post off with some sleazy remark how sightglasses are the vision ports into the brake-system's soul or some rubbish like that. But as a matter of fact, they are actually quite useful in checking the fluid level inside the reservoir and assuming they are clear enough allow you to avoid having your bike's brakefluid tested at the inspection, because it looks fresh after all.</p><p>This is not a clear sightglass or in other words, this is the one that has to be swapped out. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhunVSDGW-qQjDZQt3Xxv_BFvXCTRuasGeCwrPwLjiC8pJIHxoHKzFQjjxvwZDXRh_FYxwqNdiSnq30He48HAkz84Mc6683DvchDrsiP8cCUPNEA3azNYRDdNVHjdeF-u0YbenmRvWKTnbyw8nJXgk7sQXnCdY3rLVqZyuJpRmUvChkGs8jSG2mwsYgqrY/s1600/IMG_5941.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhunVSDGW-qQjDZQt3Xxv_BFvXCTRuasGeCwrPwLjiC8pJIHxoHKzFQjjxvwZDXRh_FYxwqNdiSnq30He48HAkz84Mc6683DvchDrsiP8cCUPNEA3azNYRDdNVHjdeF-u0YbenmRvWKTnbyw8nJXgk7sQXnCdY3rLVqZyuJpRmUvChkGs8jSG2mwsYgqrY/s320/IMG_5941.jpeg" width="240" /></a></div><p></p><p>I drained all the brakefluid from the reservoir and stuffed it with a paper towel to avoid dirt and metal shavings to get into the actual brake pump.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgP2be50KFFA3dMqdjtPDu088jYXMSixw_DNcU5cZZ-AsFk3rqxi2gdiUmPy7vW5fLo86siCrg-ju5NYmXE6pcar_rLUt1adBvgQNzvAxm6hpDnwsIHZ9CrwpNTRKR20mwA8IViz9NFJzqlbTy-qk7nZOikMEQb46xCGIhjCkB0lCt28LjBg0W2GHcMfMM/s1600/IMG_5940.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgP2be50KFFA3dMqdjtPDu088jYXMSixw_DNcU5cZZ-AsFk3rqxi2gdiUmPy7vW5fLo86siCrg-ju5NYmXE6pcar_rLUt1adBvgQNzvAxm6hpDnwsIHZ9CrwpNTRKR20mwA8IViz9NFJzqlbTy-qk7nZOikMEQb46xCGIhjCkB0lCt28LjBg0W2GHcMfMM/s320/IMG_5940.jpeg" width="240" /></a></div><p></p><p>In order to get the actual sightglass out, I decided to drill a hole ...</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH2OOUPV9yIue9H1xP90HizzUzDG84WLHPBKZ8-iv7zNZx2YTgym29tG1n2q6ctmaLgQ0GGRHxqtvH4mTB6ss6GjLBxDJXhpCeRllLj3mvtAcxGeVBW4z07XpZxjWDbFyuvFrOBY5VVMrTdaMrU4Q9BmGXg3gDorntSpkCR9kL2tyfbCXhL-9VVG0_OZo/s1600/IMG_5942.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH2OOUPV9yIue9H1xP90HizzUzDG84WLHPBKZ8-iv7zNZx2YTgym29tG1n2q6ctmaLgQ0GGRHxqtvH4mTB6ss6GjLBxDJXhpCeRllLj3mvtAcxGeVBW4z07XpZxjWDbFyuvFrOBY5VVMrTdaMrU4Q9BmGXg3gDorntSpkCR9kL2tyfbCXhL-9VVG0_OZo/s320/IMG_5942.jpeg" width="240" /></a></div><p></p><p>Put an M8 bolt through and used a slidehammer to yank it out.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzQq6GSS3ZJxfuOTPP-rM7rsbOG43bP407pxvwt_2WmmBW5GkIOPFRh52fTufvLE70OQK_BNL_VVNB2qNLxPTualHfRqVq2m6xOACCsFtw83xJ21vbzKZ6r8h9f2iV_tWYqtEGotJP-cYoT8V8lTAIpdNEMPDUpc6W-P0fBUaJPl6pI9QvxWcfQKWHgGc/s1600/IMG_5943.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgzQq6GSS3ZJxfuOTPP-rM7rsbOG43bP407pxvwt_2WmmBW5GkIOPFRh52fTufvLE70OQK_BNL_VVNB2qNLxPTualHfRqVq2m6xOACCsFtw83xJ21vbzKZ6r8h9f2iV_tWYqtEGotJP-cYoT8V8lTAIpdNEMPDUpc6W-P0fBUaJPl6pI9QvxWcfQKWHgGc/s320/IMG_5943.jpeg" width="240" /></a></div><p></p><p>Worked a treat, except the metal ring around the glass stayed in place.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYIfzbwMNL_OR2T65_f2dbRE6yoZ0ByNw0eU0uPSuJVLh_GdTV0RAy5I-Cu2EzrRTpBWW3WlQm2S7WTeeW6QU5PEZ7Iy_5jeZabhqfL41BxNkgRH7_ZKfsLgMI260VHCzJ_RF77Jtu6o2czP1PvyKpJjnvqyEb0lskM2vzGji0eAswn846y1ijt3Nwk5Q/s1600/IMG_5944.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYIfzbwMNL_OR2T65_f2dbRE6yoZ0ByNw0eU0uPSuJVLh_GdTV0RAy5I-Cu2EzrRTpBWW3WlQm2S7WTeeW6QU5PEZ7Iy_5jeZabhqfL41BxNkgRH7_ZKfsLgMI260VHCzJ_RF77Jtu6o2czP1PvyKpJjnvqyEb0lskM2vzGji0eAswn846y1ijt3Nwk5Q/s320/IMG_5944.jpeg" width="240" /></a></div><p></p><p> This was less hassle than I anticipated though. I warmed up the housing with a hot air gun and with the lightest bit of prying it came out. (Thanks to the o-ring it's very easy to get behind it.) Using the O-ring as a guide it was also rather easy to avoid damaging the bore.<br /></p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRJxOyOc5yF-Tr2NGSPj9JhvgmZnQSduOYkxWn5ecpoFSQ8bm4WPepT1sx9uCwUrmFYnDAHyAaeL_f59sRuu7JiXlygH7gIyZyG8ue-24pg3w4kT0KnJjW75_yzdVBVDTlhmX6fZHUIO5SQcgSo-q5ZK2hQYeX1RfgQJdw9bCGt96CP1Hzy73UjBrTiB4/s1600/IMG_5946.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRJxOyOc5yF-Tr2NGSPj9JhvgmZnQSduOYkxWn5ecpoFSQ8bm4WPepT1sx9uCwUrmFYnDAHyAaeL_f59sRuu7JiXlygH7gIyZyG8ue-24pg3w4kT0KnJjW75_yzdVBVDTlhmX6fZHUIO5SQcgSo-q5ZK2hQYeX1RfgQJdw9bCGt96CP1Hzy73UjBrTiB4/s320/IMG_5946.jpeg" width="240" /></a></div><p></p><p>I bought the new sightglass "on that site" and it came in a bag of three. Don't woryy, they are standardized, so just check the diameter and order a bag of two or three. As I am pretty sure, if you don't, the one you're trying to push in will break. <br /> </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTL8vGgx7MjfOfJu5BGAyWsHH9T-axt4oX3Fs176JnIVY9H0x_LxMt8RrPF21aQV1htQE_f4i9dNbEbdsPyVTf_vjjLOEVT9C-DQIySIyeZw8qJA1g4zRT-K_upH1Cdij3vxEzELLFg8DQbq5OxYCqjeL2u_U-XfmOX8OWNU0BrKbU_RptCY_5dICphno/s1600/IMG_5945.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTL8vGgx7MjfOfJu5BGAyWsHH9T-axt4oX3Fs176JnIVY9H0x_LxMt8RrPF21aQV1htQE_f4i9dNbEbdsPyVTf_vjjLOEVT9C-DQIySIyeZw8qJA1g4zRT-K_upH1Cdij3vxEzELLFg8DQbq5OxYCqjeL2u_U-XfmOX8OWNU0BrKbU_RptCY_5dICphno/s320/IMG_5945.jpeg" width="240" /></a></div><p></p><p>Warmed up the housing once more with the hot air gun and with a bit of cardboard (to avoid scratching the plastic lens) on one side and a spacer on the inside it pushes in with reasonable force. I used some parallel pliers, but woodworking clamps or C-clamps will definitely work just as well.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK9uFxMza8A4cWe5NtujT1DlfZHehPBIaKjsoS_zOOWuHpSnoy-SmwgDLRlQkhKJ-8EHamh_uHOCvP2tMJwXl14iBUNj3oz1GL8itR5uygixEC0FGY440Moa5CaToaTC-87yeWPhgIpm8rZm2oaBjixt-rb6T1cwFNgk_jR9RyGHJPF-dEklDploATxso/s1600/IMG_5947.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK9uFxMza8A4cWe5NtujT1DlfZHehPBIaKjsoS_zOOWuHpSnoy-SmwgDLRlQkhKJ-8EHamh_uHOCvP2tMJwXl14iBUNj3oz1GL8itR5uygixEC0FGY440Moa5CaToaTC-87yeWPhgIpm8rZm2oaBjixt-rb6T1cwFNgk_jR9RyGHJPF-dEklDploATxso/s320/IMG_5947.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_lXmbhT8ifMOi8Onwb21l1fjwCOl1-jhbJ9DUIBelWCudUAZHtyCc8j6iB3Bds9g-d6oof3oxa2stQERLbqjjOph5cC6hnROJ-St85tIB5JqR1JSYyqPSD70DietUfappb7zACrV_ybNt5tDsHT9sjSkdGeZspnpyp-LM_hqvnhVBylTLT9rdr8VNgwc/s1600/IMG_5948.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_lXmbhT8ifMOi8Onwb21l1fjwCOl1-jhbJ9DUIBelWCudUAZHtyCc8j6iB3Bds9g-d6oof3oxa2stQERLbqjjOph5cC6hnROJ-St85tIB5JqR1JSYyqPSD70DietUfappb7zACrV_ybNt5tDsHT9sjSkdGeZspnpyp-LM_hqvnhVBylTLT9rdr8VNgwc/s320/IMG_5948.jpeg" width="240" /></a></div><p>Looks a lot better than before and the engineer at the inspection only glanced at it and didn't even remotely consider checking the actual boiling point. (Which would have been fine as I had to refill the reservoir anyway...)<br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-9211324916711006422023-09-08T20:00:00.001+02:002023-09-08T20:00:00.148+02:00Comrade Car - when the steering wheel only sends suggestions towards the wheels (part 12)<p> Now it has to be said beforehand: Given the era in which this car was designed, the steering box is definitely en par with what would be fitted to a Series Land Rover or Jeep of the same vintage. But fortunately it's not the 1970ies anymore and Comrade was fitted with the deluxe French steering box, which was rather vague from the and has a very slow ratio. (But is admittedly quite a bit lighter than the stocker that I fitted in its place.) Unfortunately not only was it worn quite badly, but also rustproofing the underside of the car. </p><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSJb7jkBOCwDeEI3Hv4qD0-7kCt5VyBJ3zfWaASSE9a0xNpQb5h-WIsyM487ZXQgRfZa0Mndm-vgXZJ4hZeZkLV8BhtGEGJXSltcre0xRxHpB1ZiMlr_V-zqMC2l9O3QoUYB8UzEfQU85jxtDu8_UwARqHJaPYw2b1j3Jmw_3FrRVYvuEGdGLSR2AgrNE/s1600/IMG_5621.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSJb7jkBOCwDeEI3Hv4qD0-7kCt5VyBJ3zfWaASSE9a0xNpQb5h-WIsyM487ZXQgRfZa0Mndm-vgXZJ4hZeZkLV8BhtGEGJXSltcre0xRxHpB1ZiMlr_V-zqMC2l9O3QoUYB8UzEfQU85jxtDu8_UwARqHJaPYw2b1j3Jmw_3FrRVYvuEGdGLSR2AgrNE/s320/IMG_5621.jpeg" width="240" /></a></div> <p></p><p>For rather obvious reasons, when digging into the steering, there's little point in not swapping all the tie rods at the same time. When browsing around for spare parts, I found these reinforced track rod nuts. It should be rather apparent that they are quite a bit beefier than the stock bits (on the left), but also should save me from a bit of headache down the line considering that they fully enclose the thread and with some rather generous application of anti-seize adjusting the toe-in should still be doable without massive headaches in a year or two.<br /></p><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlow1a9f15nGz2MsEP4aYIvOXWgo6alv8BZvCoOhFlDaCENUKkiK6m6kx7UzYQC8r_7QUXEB7kBMHresbDw2T0fJtMp0h9bOucJbcmvhb100S8estNLWTDkzJXZuII6rmEgqegEzw-tFey7ESzI5YyujiNKF27F0Qa-cI7SCrzwkEsVUmZh3bX9oqNR5Y/s1600/IMG_5543.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlow1a9f15nGz2MsEP4aYIvOXWgo6alv8BZvCoOhFlDaCENUKkiK6m6kx7UzYQC8r_7QUXEB7kBMHresbDw2T0fJtMp0h9bOucJbcmvhb100S8estNLWTDkzJXZuII6rmEgqegEzw-tFey7ESzI5YyujiNKF27F0Qa-cI7SCrzwkEsVUmZh3bX9oqNR5Y/s320/IMG_5543.jpeg" width="240" /></a></div><p></p><p>Surprisingly the old stuff came apart with relative ease.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaLbeRKBdrHaiAobF1Zw5kPufr0RnYIhJxzIGwKNhHzmu5vhXrSZHCSrMyh8nWCJVU-XHZTbo5c4YaPC36Ev7x2PUQsop_ixE53YVX_IJdHQWHkQdzMt48ZtxIzj5zyOs50QhvlM67HRreYiad0eP1YfPmGzRKCPwnWM2y8Tr0sDPZrV5tt0Ii8yi1L1A/s1600/IMG_5571.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhaLbeRKBdrHaiAobF1Zw5kPufr0RnYIhJxzIGwKNhHzmu5vhXrSZHCSrMyh8nWCJVU-XHZTbo5c4YaPC36Ev7x2PUQsop_ixE53YVX_IJdHQWHkQdzMt48ZtxIzj5zyOs50QhvlM67HRreYiad0eP1YfPmGzRKCPwnWM2y8Tr0sDPZrV5tt0Ii8yi1L1A/s320/IMG_5571.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh-1Q1x4P-8mwD5sXeqqT70EKD50H2GWosGSA-hsMU_K9p3Rrm_1EPB85s3n_YsXYOypdv9v9rPr361KdqKcHlPCmVqGjrcz0AOp1xHiFRht4FFqciL8lLGIkpulO95qJA_sgzIyIiy6LvIB14UDgdeGOAC47FBHFv4XDGJ_usQgg4v6FMBiaRZev5iLE/s1600/IMG_5596.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjh-1Q1x4P-8mwD5sXeqqT70EKD50H2GWosGSA-hsMU_K9p3Rrm_1EPB85s3n_YsXYOypdv9v9rPr361KdqKcHlPCmVqGjrcz0AOp1xHiFRht4FFqciL8lLGIkpulO95qJA_sgzIyIiy6LvIB14UDgdeGOAC47FBHFv4XDGJ_usQgg4v6FMBiaRZev5iLE/s320/IMG_5596.jpeg" width="240" /></a></div><p></p><p>Installation of the actual steering box though, is truly a two person job and yes the nuts have to be on the side of the wheel or you lose a lot of steering angle.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9WoaQpKZ303r_HNtRpvNoiPfJ3XKryfmpjg_vTcr29ehu6Vi2w_5ClnFCMdQMhwRMrsJgtt4wyB0ao1m3l96WR42VhCIvA5ZJI6Ea24Z7gSEBBSvzD9FSNqFDUZxzLQNpOsWLxfcwdxRtF5xjZGjNvkMx4vEx4WjEbGol_l4Fhbkpe2LTdKhLC0u47j8/s1600/IMG_5623.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9WoaQpKZ303r_HNtRpvNoiPfJ3XKryfmpjg_vTcr29ehu6Vi2w_5ClnFCMdQMhwRMrsJgtt4wyB0ao1m3l96WR42VhCIvA5ZJI6Ea24Z7gSEBBSvzD9FSNqFDUZxzLQNpOsWLxfcwdxRtF5xjZGjNvkMx4vEx4WjEbGol_l4Fhbkpe2LTdKhLC0u47j8/s320/IMG_5623.jpeg" width="240" /></a></div><p></p><p>And with the steering done and the wheels aligned, it was time to do a bit more cosmetics. The steel wheels are pretty awesome - heavy, robust and... rusty.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLZmwJKLMOv-ZTSXdc6-TdutuT4gtU7gGmZbDfwH9Qi9RnYV72h92L-Y01VACPAbG28xql0m_LTU46GAd9m3SFTcBbhBsUfhu6VC8ZJCPo_XoSnA1UMMRZxMI4e7GnDqvvs8ehDeKRuBfBd4z_2KssBT6nfCY503i1DGHao1Am3s05JHPz0e5nH1GXaGs/s1600/IMG_5627.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLZmwJKLMOv-ZTSXdc6-TdutuT4gtU7gGmZbDfwH9Qi9RnYV72h92L-Y01VACPAbG28xql0m_LTU46GAd9m3SFTcBbhBsUfhu6VC8ZJCPo_XoSnA1UMMRZxMI4e7GnDqvvs8ehDeKRuBfBd4z_2KssBT6nfCY503i1DGHao1Am3s05JHPz0e5nH1GXaGs/s320/IMG_5627.jpeg" width="240" /></a></div><p></p><p>A bit of black (gloss) Hammerite makes them look a million times better though. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPx2Ri9hJAsICofMecVqgL-W8Ic66bnYpe5r7Yh1xVasL6jqEh_WQjkeWp-Hc0NumyB2Ab_ZZZowAiJiO7hc08S4_zCQHsgsBeZO8FZK6mR8ZWD75zHXVN0wtqABMvo7cD9i8Id1UiUj0dKmXnJzQrqYxpD5gEDujc8AwO8tK1Rmadm50Q2lew8KPEZfQ/s1600/IMG_5631.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPx2Ri9hJAsICofMecVqgL-W8Ic66bnYpe5r7Yh1xVasL6jqEh_WQjkeWp-Hc0NumyB2Ab_ZZZowAiJiO7hc08S4_zCQHsgsBeZO8FZK6mR8ZWD75zHXVN0wtqABMvo7cD9i8Id1UiUj0dKmXnJzQrqYxpD5gEDujc8AwO8tK1Rmadm50Q2lew8KPEZfQ/s320/IMG_5631.jpeg" width="240" /></a></div><p></p><p>And three and a half cans of underseal later, the underside of the car looked the part again as well.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvaRN_HS8zFoJ4NfBSg21Ft9KbIjzqNpDjwlvGeWA-bHgZIsT6yEq1i7H8KM8fqNSUkMt0msKwlz8apaIU66jbTPkoMZvuG-oksli3ZxlbAWhpL2LljcYRaAFeCAg1Oboyc1HBfAF6ZOtmf0x1a8FytAIPCHu2Sgrn7D2MFmH2G4eKJlx9KVYkvlEaFCM/s1597/IMG_5624.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1597" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvaRN_HS8zFoJ4NfBSg21Ft9KbIjzqNpDjwlvGeWA-bHgZIsT6yEq1i7H8KM8fqNSUkMt0msKwlz8apaIU66jbTPkoMZvuG-oksli3ZxlbAWhpL2LljcYRaAFeCAg1Oboyc1HBfAF6ZOtmf0x1a8FytAIPCHu2Sgrn7D2MFmH2G4eKJlx9KVYkvlEaFCM/s320/IMG_5624.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfnGgbO-Hm5nsSDjyqWCAyhiSrahlCb7ZE8WVhDdd_cEdWIvHYuNNuFzmTsrlZRJCrbE8eWZ1EUPPZnrYF0sn0LefInMKyo6RR9iTJQ8rbuajVQHo1X6NitLRYitnsFIHDNC_qVjhWN5ObGl8t4r8uIEvApbmwrqabKxjhzI8zrMN_z2-lGRh56Ka4dAw/s1600/IMG_5629.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfnGgbO-Hm5nsSDjyqWCAyhiSrahlCb7ZE8WVhDdd_cEdWIvHYuNNuFzmTsrlZRJCrbE8eWZ1EUPPZnrYF0sn0LefInMKyo6RR9iTJQ8rbuajVQHo1X6NitLRYitnsFIHDNC_qVjhWN5ObGl8t4r8uIEvApbmwrqabKxjhzI8zrMN_z2-lGRh56Ka4dAw/s320/IMG_5629.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKt34vi5h1nYckWFge28gvEBKH1VPgW0udIdAVzYk04TdscWzqvDH1cSYv8cM1PMAKc86QEm_zTb2o0X35ECsYlQoh_Fo-adj6K5W52GT5HhnTgqqgiVUgLBqV24bbxjP6iwfgsZUmT-lhiI8S95v-kQUuDSbEr1PnFfrwXW4SD-H8-UZKew-PqCZWnR4/s1600/IMG_5630.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKt34vi5h1nYckWFge28gvEBKH1VPgW0udIdAVzYk04TdscWzqvDH1cSYv8cM1PMAKc86QEm_zTb2o0X35ECsYlQoh_Fo-adj6K5W52GT5HhnTgqqgiVUgLBqV24bbxjP6iwfgsZUmT-lhiI8S95v-kQUuDSbEr1PnFfrwXW4SD-H8-UZKew-PqCZWnR4/s320/IMG_5630.jpeg" width="320" /></a></div><p>Finally Comrade car wears his best clothes and looks the part. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8NJNlm8qnrtVOy0nVUro_sy7bz-DBYD_fFPxVQVH22nO1v9KnDFr8a-v4ZjvHEFiLTtIyIPzPwmJAX6ePCaMKrg5rOgfm5jgAQDeL-pvq7o6pRPwL3w8Dl7GRF59412J0fwulphtFAmV4xwqsf3BY5fxG2R9U7YMH4Pjz0kVx_dLLntZDWzCyAtbcZQE/s1600/IMG_5637.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8NJNlm8qnrtVOy0nVUro_sy7bz-DBYD_fFPxVQVH22nO1v9KnDFr8a-v4ZjvHEFiLTtIyIPzPwmJAX6ePCaMKrg5rOgfm5jgAQDeL-pvq7o6pRPwL3w8Dl7GRF59412J0fwulphtFAmV4xwqsf3BY5fxG2R9U7YMH4Pjz0kVx_dLLntZDWzCyAtbcZQE/s320/IMG_5637.jpeg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhkrvl2v2gTd40Qt7XrfL4sU4eFVEVUPAIt9Dl9eLI-2OuLUyXE6RBV53JwoFt_Q5_LW42ep-CpYiRRvY9ymA1W9IyrlEcwfS5GCsvwNtlZw16ZvrLSLnkc04C9KUJtCPzUqoKKCYkzGW_l7briuWgyM4d0_W8YJ1kGxvedxNo2YqdBYcCqVEX6Cfy6ms/s1600/IMG_5638.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhhkrvl2v2gTd40Qt7XrfL4sU4eFVEVUPAIt9Dl9eLI-2OuLUyXE6RBV53JwoFt_Q5_LW42ep-CpYiRRvY9ymA1W9IyrlEcwfS5GCsvwNtlZw16ZvrLSLnkc04C9KUJtCPzUqoKKCYkzGW_l7briuWgyM4d0_W8YJ1kGxvedxNo2YqdBYcCqVEX6Cfy6ms/s320/IMG_5638.jpeg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXcKxuSxCyE7KVENpfyL_wJPwj7svmMPI1r6UtKLyCmMlB_p-bVplG-d7uuRV4SBEUfOdaFE2gwdzX7kk58qo37gcHYEZISncX-4u5RaISXgZ6HqTV7nRRTVCyLT_n3BgFG1vFv1FcsR30nXxxVRHEz0MtFbuwaOcigvnP4JCii2xPB6u1BmKuJnBNnuE/s1600/IMG_5639.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXcKxuSxCyE7KVENpfyL_wJPwj7svmMPI1r6UtKLyCmMlB_p-bVplG-d7uuRV4SBEUfOdaFE2gwdzX7kk58qo37gcHYEZISncX-4u5RaISXgZ6HqTV7nRRTVCyLT_n3BgFG1vFv1FcsR30nXxxVRHEz0MtFbuwaOcigvnP4JCii2xPB6u1BmKuJnBNnuE/s320/IMG_5639.jpeg" width="320" /></a></div><p>But will it pass the Austrian MOT, the infamous Pickerl?<br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-76030175641841046012023-09-04T20:00:00.017+02:002023-09-04T20:00:00.139+02:00Comrade Car - carbs and exhaust (part 11)<p> So the last post that dealt with a more close inspection of the old Comrade revealed that the exhaust hadn't magically healed itself and whilst shown quite a few times, I never showed off 😏 the cool carb I (unexpectedly) got. </p><p>Now this is a 1700 tube-style header, which is the one everybody tells you to avoid in favour of both its older and newer siblings made from cast-iron as they are the more performance oriented solution. This one came in at the right price though and unlike the cast iron stocker I had before this one does not have a (clogged up) SLS-system installed. Which means it is one more step towards getting rid of clutter under the bonnet. With a bit of high-temp paint it actually looks the part.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcJ4M7DZBfvFOfx-ANEzTx4-QdPapzcRSJQ7IzgXOzBm6KfI3TsyjKxI_U_Udc3HVPyJnA9aZEXN1Vmq97IiG-Z0Mt4l9pHIBN9vkBj3g9T1JNCOjV8PC7yM_UYZ6n_AlhmXztsRuC0W_7dDrppwBbpC20TIeKnyfAlw7T3kUWF-XaxzoPs8Y8JBaIN2U/s1600/IMG_4518.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcJ4M7DZBfvFOfx-ANEzTx4-QdPapzcRSJQ7IzgXOzBm6KfI3TsyjKxI_U_Udc3HVPyJnA9aZEXN1Vmq97IiG-Z0Mt4l9pHIBN9vkBj3g9T1JNCOjV8PC7yM_UYZ6n_AlhmXztsRuC0W_7dDrppwBbpC20TIeKnyfAlw7T3kUWF-XaxzoPs8Y8JBaIN2U/s320/IMG_4518.jpeg" width="320" /></a></div><p></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqRCSdsAMUfYfxpki4iFWdSK-rwOl0kIwsVIZlWZHtOHXnIFvDNj2TKlZDnEARxflH1Z3ruC6OpYNB42oH7dUOncjfcsIR0YliFStKW09Mg1Yqet19NmeUA1ToDC8TAkeD7nxfGXjY4awevpzTAies172frixyp9dEjeSoS4Redv6hu_Wwr-lngRuQDdw/s1600/IMG_4859.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiqRCSdsAMUfYfxpki4iFWdSK-rwOl0kIwsVIZlWZHtOHXnIFvDNj2TKlZDnEARxflH1Z3ruC6OpYNB42oH7dUOncjfcsIR0YliFStKW09Mg1Yqet19NmeUA1ToDC8TAkeD7nxfGXjY4awevpzTAies172frixyp9dEjeSoS4Redv6hu_Wwr-lngRuQDdw/s320/IMG_4859.jpeg" width="240" /></a></div><p>So initially I had my fine share of issues with both carbs that were on the engine so far. First the stock Solex with ECONOMIZER (you have to say this in a fake Russian accent - make sure to pull the corners of your mouth down for maximum effect) and then a used Weber. Unfortunately both were pretty much rubbish. But then, as luck would have it, someone put me in touch with someone else who said: I've got this 2106 fully mechanical Weber. It's not worn out, but I removed it for a later one with vacuum secondaries for better fuel efficiency. If it doesn't work, you can give it back to me.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjBTdpgcf2egD6nrjo6REBVpwBHBTnHB6fJzy58Pp0WyqgamlCHPWwQSYM8yI6zdsX_YpMnQJfM5bdD9q_Q7QSlIx3BB6SuTSpz84j6owm3NYl50KzSu4PdUzCVkGQh6e8SzDo4Izi-c9UoRBxz0aQqVm3TGRzbXl2gtf-AeQVO8Zh2khl4SZn0iHYIak/s1600/IMG_4613.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjBTdpgcf2egD6nrjo6REBVpwBHBTnHB6fJzy58Pp0WyqgamlCHPWwQSYM8yI6zdsX_YpMnQJfM5bdD9q_Q7QSlIx3BB6SuTSpz84j6owm3NYl50KzSu4PdUzCVkGQh6e8SzDo4Izi-c9UoRBxz0aQqVm3TGRzbXl2gtf-AeQVO8Zh2khl4SZn0iHYIak/s320/IMG_4613.jpeg" width="240" /></a></div><p></p><p>So this is it: the original bad boy carb of the Lada world. Manual secondary throttle blade, goes like stink, dirty as can be (on the outside, it was like new on the inside) and the performance... oh the performaaaaance. Seriously, makes you wonder why the Soviets chose a car that can best be described as "rather sporty sedan" as their standard means of four wheeled transport for the masses. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsxE17hgxYqj8xBeqtAmyHkXkfjT717JutPaqrNQBDwk1g3PYTb54Hg2zjt0QOqeSSzK00ASITqqpZeRBTDwNpeFNZH7UHrBQ2-bHYNEWNs7YIEPWI3A0B5rLY5cy_cBWPwpYtcKA6YKn6HxMEa0GRyM_3B_Bj_YZwFjuIit3FnLyf8IrzIenDjETTpdQ/s1600/IMG_4618.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsxE17hgxYqj8xBeqtAmyHkXkfjT717JutPaqrNQBDwk1g3PYTb54Hg2zjt0QOqeSSzK00ASITqqpZeRBTDwNpeFNZH7UHrBQ2-bHYNEWNs7YIEPWI3A0B5rLY5cy_cBWPwpYtcKA6YKn6HxMEa0GRyM_3B_Bj_YZwFjuIit3FnLyf8IrzIenDjETTpdQ/s320/IMG_4618.jpeg" width="240" /></a></div><p></p><p>... and then there was this thing with the exhaust. So the mid-section-muffler was well and truly eaten a live and once I started shaking the rear-most one, I could hear that most of the internals were loose as well. Thx to a not very aggressive model policy (read that as: almost none for the 1600 Niva) and the exhaust being nearly identical to the Lada Nova you can still buy them new. For very little money. And in even poorer quality than you'd expect. So with plenty of paint I hoped (at this point) that most of the stories would be somewhat exaggerated and I at least had it rust-proofed sufficiently to make it work for a while.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPOW9Sv2GQ4LdZT1_BKkkM7WG75OE-JJbOK0v8g6zXGRVoY4Vd_w6Lqt2PpCMjDuJJWeOtvU4j6FN59WcMIEBU2jB1xX1iwQxpcYLlfM502KL6gd3adQJWsGisGE5Vz5-D1ZBPvihgRYGvluM8rf8DIHkfbqxg1IvZT0xQCxHPMZmKQXt-qMgysXK7VaY/s1600/IMG_4868.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgPOW9Sv2GQ4LdZT1_BKkkM7WG75OE-JJbOK0v8g6zXGRVoY4Vd_w6Lqt2PpCMjDuJJWeOtvU4j6FN59WcMIEBU2jB1xX1iwQxpcYLlfM502KL6gd3adQJWsGisGE5Vz5-D1ZBPvihgRYGvluM8rf8DIHkfbqxg1IvZT0xQCxHPMZmKQXt-qMgysXK7VaY/s320/IMG_4868.jpeg" width="320" /></a></div><p></p><p>In order to make it work first the old exhaust had to come off. Given the very rusty nature the sawzall made quick work of what was left. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieT6NUEzY_4i8eBQn7XdtSEOXQ7op-aoSjk7WJ4U9rAArbHuQFI6kXbagddIw9I29rlp4t7AcUCvoI583pkCuUz88PMYpz0Zk1xWUKAYWLO-hVHkFgCUamZwwJfu9ORCTP2yo7XBfDhj32-ZmxGlswYIC2cKI338qiqwYn8-PQuPvCCB4y4UKxQ6bW5Ww/s1600/IMG_5109.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEieT6NUEzY_4i8eBQn7XdtSEOXQ7op-aoSjk7WJ4U9rAArbHuQFI6kXbagddIw9I29rlp4t7AcUCvoI583pkCuUz88PMYpz0Zk1xWUKAYWLO-hVHkFgCUamZwwJfu9ORCTP2yo7XBfDhj32-ZmxGlswYIC2cKI338qiqwYn8-PQuPvCCB4y4UKxQ6bW5Ww/s320/IMG_5109.jpeg" width="320" /></a></div><p></p><p>With Comrade being a post-1987 model, I also had to revert from the rather rare single-tube header to the much more common twin-long-tube header. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhF_QPALyAhEpJmpE-XH4fq5w79UsNlhv9WX0k12bLCF98He2u9OuK-lKWh4fbq1bKvKAe_LS-Sw4-7YN7alMDHy3nbHnPXUUO6yk0MVYZ-avcLSzwONmF4tkkN6Bm1RTlbZamSW2Bxlc957UazPpontq4QwMzEQLORGSRf1ffg9EOzL3CjpQOVotlWysM/s1600/IMG_5110.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhF_QPALyAhEpJmpE-XH4fq5w79UsNlhv9WX0k12bLCF98He2u9OuK-lKWh4fbq1bKvKAe_LS-Sw4-7YN7alMDHy3nbHnPXUUO6yk0MVYZ-avcLSzwONmF4tkkN6Bm1RTlbZamSW2Bxlc957UazPpontq4QwMzEQLORGSRf1ffg9EOzL3CjpQOVotlWysM/s320/IMG_5110.jpeg" width="320" /></a></div><p></p><p>When I was referring to clutter and the SLS-system, this is what I meant (please ignore the wiring mess - at this point I was still trying to sort out various bits in the loom):</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNKue7rimxDbI96_ZpU-vLoOQnuLCQ_v0lLussNSUDg7BjqOtMkD8zvNf3VNpxs0Ft7D5YDzHrgeOnPLjHM0ejSOGJ2VesuZg5YRz0X-54St4YkTwKIpHUrpET4HaCJImCeTZ668PqFqcsfm4EOVSS1cGH7wRvqM8mGx6tpZbYmBH7U326ZxbiJ76B4uA/s1600/IMG_5133.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNKue7rimxDbI96_ZpU-vLoOQnuLCQ_v0lLussNSUDg7BjqOtMkD8zvNf3VNpxs0Ft7D5YDzHrgeOnPLjHM0ejSOGJ2VesuZg5YRz0X-54St4YkTwKIpHUrpET4HaCJImCeTZ668PqFqcsfm4EOVSS1cGH7wRvqM8mGx6tpZbYmBH7U326ZxbiJ76B4uA/s320/IMG_5133.jpeg" width="320" /></a></div><p></p><p>The tube poking up so prominently is the secondary air system (SLS) that allows for some fresh air to bleed back into the exhaust to raise exhaust gas temps and thus improve emissions. A system so incredibly successful, every manufacturer has long since abandoned it. But it requires multiple vacuum lines and is a beautiful source for all kinds of exhaust/inlet manifold leaks.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgES37Dd_0hMu5ehcp_9pS5l5xgD2MTvTIyPqeRjHV7FV7j3uZREIllpkj8AKULhxm2fqrEGBpImU3Y5zOloSNIYiYB3srplbrv9wO7gocIO5HwaK7BnSc4B24mG7AR8eoEOqxrHh6OpCTT35rV9oViE5bt4YsTJ2qohYHnECG5MhaeMXltMVDEs9qvs70/s1600/IMG_5134.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgES37Dd_0hMu5ehcp_9pS5l5xgD2MTvTIyPqeRjHV7FV7j3uZREIllpkj8AKULhxm2fqrEGBpImU3Y5zOloSNIYiYB3srplbrv9wO7gocIO5HwaK7BnSc4B24mG7AR8eoEOqxrHh6OpCTT35rV9oViE5bt4YsTJ2qohYHnECG5MhaeMXltMVDEs9qvs70/s320/IMG_5134.jpeg" width="240" /></a></div><p></p><p>Freshly painted exhaust manifold in place. One thing I wasn't (fully) aware: the 1600 has got a heated inlet manifold to prevent carb icing, which is pretty cool, but also means, you're making a proper mess, when taking the inlet manifold off.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCTpmiuirtBgUnEmBFxv2kk6w_7BzD3A56HgZ8wrO_kYhLBXPsQrX7hoiZDxhDSYQXy-cfc_p4UqzhPpwVFxibD9JjCpRiSbpwZiQphbMBhMwy8mls3JMEhjSCxx1Q15y7t1WFAKQnhOsD2PESDiOdG6cDUW6zuD3uBw5t_aOoeosMNP_ALxbnRi430p0/s1600/IMG_5144.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCTpmiuirtBgUnEmBFxv2kk6w_7BzD3A56HgZ8wrO_kYhLBXPsQrX7hoiZDxhDSYQXy-cfc_p4UqzhPpwVFxibD9JjCpRiSbpwZiQphbMBhMwy8mls3JMEhjSCxx1Q15y7t1WFAKQnhOsD2PESDiOdG6cDUW6zuD3uBw5t_aOoeosMNP_ALxbnRi430p0/s320/IMG_5144.jpeg" width="320" /></a></div><p></p><p>Once cleaned the manifold definitely looks the part.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNNT6GGyxaCTANILGSAYX1hRs95fjwIvqGUxcirVWxxAZL-FuNqx0Zei9_4OynLv9bZDngEeYItz5rvkOQDy0XM6r8uH2Q__L7h1K8InCzvhtn6n--bZWr4PIPshGH-IMsH6ZYJ5A4MRw_WCPRImdvf-pvG-uuMs2Q1LS9ZUG9vuJPOpOv6gDgRvQn2yg/s1600/IMG_5146.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNNT6GGyxaCTANILGSAYX1hRs95fjwIvqGUxcirVWxxAZL-FuNqx0Zei9_4OynLv9bZDngEeYItz5rvkOQDy0XM6r8uH2Q__L7h1K8InCzvhtn6n--bZWr4PIPshGH-IMsH6ZYJ5A4MRw_WCPRImdvf-pvG-uuMs2Q1LS9ZUG9vuJPOpOv6gDgRvQn2yg/s320/IMG_5146.jpeg" width="320" /></a></div><p></p><p>... and with the SLS port blanked that should make starting a lot easier. (It did and prevented all sorts of other probably vacuum-leak induced malarkey.)<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaAT6YkIiAdjEPgCV4zSCQCiZaNRKNe4O421QuRECJbdpWcBxCa8Nh_j4P5AGmvRFUsEIXxZ_dIOU4DQieeGd4HTUklvQtGJgQVzu6OPdeYIBSbq3GYnmCZlakO_yTi_YVM5doqQSzsgmkl8HrcN5qYuVBIqJaxyEFA_X6tcWTwcv45N05vJZ5gkOgjzk/s1600/IMG_5147.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaAT6YkIiAdjEPgCV4zSCQCiZaNRKNe4O421QuRECJbdpWcBxCa8Nh_j4P5AGmvRFUsEIXxZ_dIOU4DQieeGd4HTUklvQtGJgQVzu6OPdeYIBSbq3GYnmCZlakO_yTi_YVM5doqQSzsgmkl8HrcN5qYuVBIqJaxyEFA_X6tcWTwcv45N05vJZ5gkOgjzk/s320/IMG_5147.jpeg" width="240" /></a></div><p>Things were looking pretty good until I attempted to install the actual exhaust header. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCd5z12UVxRC1QXVw_VqJz37MF-qHcACTbWEXO2GbDFT2dUmIx9MAERBhSubIP_nchx6lx_EiucngXXEGk8DNz4KATs0UhNL8l2XHZa1K4RorJfEoKA7n-Wpn5B9OT6szfUATNuyu5rhBZqCAtYjrAk55iW2D_djmhjavvF0uhnYlCxMeNdUJRD1C4ohw/s1600/IMG_5153.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCd5z12UVxRC1QXVw_VqJz37MF-qHcACTbWEXO2GbDFT2dUmIx9MAERBhSubIP_nchx6lx_EiucngXXEGk8DNz4KATs0UhNL8l2XHZa1K4RorJfEoKA7n-Wpn5B9OT6szfUATNuyu5rhBZqCAtYjrAk55iW2D_djmhjavvF0uhnYlCxMeNdUJRD1C4ohw/s320/IMG_5153.jpeg" width="320" /></a></div><p></p><p>I was forewarned that not only the finish, but also the fit would leave much to be desired. The best way I know of for finding the spots where it rubbed were to paint it, check for scrub marks and then some Newtonian persuasion. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgS7kKWVpvk0BpYSs1BO-GWeSbVqdconECwZGG99zEzsExTjHmXHnMkhjKJma0WjaZApH_qkR2ocnRj5AuMRIMs0so4NO5Fo6S14aNmTeNfDes7TvzClEaQiO8bb1CjbqY-K1cWVXL2g_wRqVqcdmDQr5sVXr3-lmLywfR1Vf6CUQ75mVA4bC93PORQsGI/s1600/IMG_5544.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgS7kKWVpvk0BpYSs1BO-GWeSbVqdconECwZGG99zEzsExTjHmXHnMkhjKJma0WjaZApH_qkR2ocnRj5AuMRIMs0so4NO5Fo6S14aNmTeNfDes7TvzClEaQiO8bb1CjbqY-K1cWVXL2g_wRqVqcdmDQr5sVXr3-lmLywfR1Vf6CUQ75mVA4bC93PORQsGI/s320/IMG_5544.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijSA1RgMBf6B1e85JBKNe0gqqq0Aexd8PUurilT8lTa1w9HYlNGZRfXmyHC7FDoDho2DCU3Y9HwkIj7bS08vVsAcf9K8tEx8jQH-Pypx77mgl_y7di-2CaqQUFfa3dwlDBso__3_2l1a05lBENiDcIY-JQ0CT5Zp-LVmxCFg-X6U4hlDGC1LxEp8UYKRg/s1600/IMG_5546.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijSA1RgMBf6B1e85JBKNe0gqqq0Aexd8PUurilT8lTa1w9HYlNGZRfXmyHC7FDoDho2DCU3Y9HwkIj7bS08vVsAcf9K8tEx8jQH-Pypx77mgl_y7di-2CaqQUFfa3dwlDBso__3_2l1a05lBENiDcIY-JQ0CT5Zp-LVmxCFg-X6U4hlDGC1LxEp8UYKRg/s320/IMG_5546.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFGqIs8dtvf1yifg0Jj9Sy_cihjuVJw9GSh9HSVfWvRv7fOf6oLT0btZsl1UGOoXp9Dada9ZG7-QJqHwE0GFRWplVgXpXaf5U9w4QiX0b13YwFQxfik-eG9i_G-dQfCdPOapaVjWBSxVREGut-RQzoWFsAEGMJl-SKgW049zJDKSu3tfYrdFDEy0uUqlk/s1600/IMG_5548.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFGqIs8dtvf1yifg0Jj9Sy_cihjuVJw9GSh9HSVfWvRv7fOf6oLT0btZsl1UGOoXp9Dada9ZG7-QJqHwE0GFRWplVgXpXaf5U9w4QiX0b13YwFQxfik-eG9i_G-dQfCdPOapaVjWBSxVREGut-RQzoWFsAEGMJl-SKgW049zJDKSu3tfYrdFDEy0uUqlk/s320/IMG_5548.jpeg" width="240" /></a></div><p></p><p>The mid-pipe wasn't exactly a perfect fit either, but then again only needed a single, well placed cut to point straight towards the back. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKrxZaGM6GHjaOSDZVfuIPoAx-I3WglqVm-wYqg5IfuY9v_dyXnwoi6IXsJmI50SiLvVdMtbRiAor69iWYqlbW-uMk9UbdbsW-gCK79Xl-j_gWtc7ZPwXNJq1dwrXg6_SxxhqgA1JfRNw_uHLCjGLlrt59Dd4Ulz4fHY4dGMgHVtkm4hhdJsvtgZWqeVY/s1600/IMG_5789.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKrxZaGM6GHjaOSDZVfuIPoAx-I3WglqVm-wYqg5IfuY9v_dyXnwoi6IXsJmI50SiLvVdMtbRiAor69iWYqlbW-uMk9UbdbsW-gCK79Xl-j_gWtc7ZPwXNJq1dwrXg6_SxxhqgA1JfRNw_uHLCjGLlrt59Dd4Ulz4fHY4dGMgHVtkm4hhdJsvtgZWqeVY/s320/IMG_5789.jpeg" width="320" /></a></div><p></p><p>And lastly the final muffler apparently isn't a huge fan of sitting very parallel under the car. I decided that this was absolutely intentional so that condensation would end up in one single corner. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz86wJXZvWA-o3cGfM0o0vN1Z9fzKkoiWFnIUjJVykufAEkaJo76IgCY_HINDHF-SWrGVIk31q4hLWzxDjVt4tjDe8O8hrJoSG7TVzCUg5Rbpt1RQ-uEeN4U2fL4moT5IIoENY_CAx-pOc4gRKSNhNFSk7v2lUKgRfTwISeJzuUdmnE1FxOfy9h3jiLiQ/s1600/IMG_5557.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz86wJXZvWA-o3cGfM0o0vN1Z9fzKkoiWFnIUjJVykufAEkaJo76IgCY_HINDHF-SWrGVIk31q4hLWzxDjVt4tjDe8O8hrJoSG7TVzCUg5Rbpt1RQ-uEeN4U2fL4moT5IIoENY_CAx-pOc4gRKSNhNFSk7v2lUKgRfTwISeJzuUdmnE1FxOfy9h3jiLiQ/s320/IMG_5557.jpeg" width="320" /></a></div><p>Compared to the rotten exhaust that was puzzled together from bits meant for various other cars this one is now leak free and oh so quiet. Really, really quiet. You know how a car gets even more quiet than quiet? Exactly, if it stops running. Turns out at least one of breather valves of the fuel tank was stuck, so a rather dramatic solution was found:</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjqDJPrkFUijHsnMeZftHacaHjrPSj7cztpNJqqYzVR0-XeFV1QEbHPJpjMPWwpni1pQ4PCeFh3lcMHTCVXmIUDKs9t_wp6YwPRLQqRMoCsixrag60-qcnXCJxcOKE32ZYCT0HDl14ROIPbjppkIJlGCn-fC8O_iYx-_8JftTYfj4UvXOXQIFZDdV1xGc/s1600/IMG_5106.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgjqDJPrkFUijHsnMeZftHacaHjrPSj7cztpNJqqYzVR0-XeFV1QEbHPJpjMPWwpni1pQ4PCeFh3lcMHTCVXmIUDKs9t_wp6YwPRLQqRMoCsixrag60-qcnXCJxcOKE32ZYCT0HDl14ROIPbjppkIJlGCn-fC8O_iYx-_8JftTYfj4UvXOXQIFZDdV1xGc/s320/IMG_5106.jpeg" width="240" /></a></div><br /><p>Obviously you don't want petrol seeping from the cap, so the rubber gasket was pierced in three locations which do not match the center hole in the gas tank cap. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKKTUvqNvLICVmmQkn8eVCo5DrU33Fz7sRUhkFzby4lQIc_UlbRttSl6TD2Fg0xOkd1CNsVDe97ObZ5I7seV_qR4y85KcjQAHjxXwqazqNmFzclVlcEvADGq5k9Vs_0grePIyA0odj1_rEOuY_4T0W05unegPEBfUfXREc_M8HPmpeDk0NAyZpDF04hj4/s1600/IMG_5100.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKKTUvqNvLICVmmQkn8eVCo5DrU33Fz7sRUhkFzby4lQIc_UlbRttSl6TD2Fg0xOkd1CNsVDe97ObZ5I7seV_qR4y85KcjQAHjxXwqazqNmFzclVlcEvADGq5k9Vs_0grePIyA0odj1_rEOuY_4T0W05unegPEBfUfXREc_M8HPmpeDk0NAyZpDF04hj4/s320/IMG_5100.jpeg" width="240" /></a></div><p></p><p>And with those changes applied Comrade needed a minor tweak of the idle screw and that was it. Starts like you'd expect it from a modern (fuel injected) car and runs very quiet. (At least as far as the exhaust noise is expected.<br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-24697869416650609072023-08-06T20:00:00.001+02:002023-08-06T22:37:33.036+02:00Dre-XT-Stück - exhaust rebuild (even better-er?)<p>During the engine rebuild it became rather apparent that the exhaust might be in need of "some" love too. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_BCXDnYKuH7E86qETJ4kpLnUoPKH6TsFCiMlvOxYOKT9TDjw6fQTOtyK85q4hT55HTWmwXDR4PxjS9g_9rbHI-iMWESyoz9olFeuI7eGYW56VZecBjWbHMzVRrslMS0lO8t1b7dizcASIJYVTHQhH80ovh1HFVs9xUp_eYVEe0ysTifspovCYa7swIn4/s1600/IMG_5601.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_BCXDnYKuH7E86qETJ4kpLnUoPKH6TsFCiMlvOxYOKT9TDjw6fQTOtyK85q4hT55HTWmwXDR4PxjS9g_9rbHI-iMWESyoz9olFeuI7eGYW56VZecBjWbHMzVRrslMS0lO8t1b7dizcASIJYVTHQhH80ovh1HFVs9xUp_eYVEe0ysTifspovCYa7swIn4/s320/IMG_5601.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi65KOnrhBojG8HqrQvjXQdep48YL6DDOJJqHPAfKvA9r-7mbZm3MW19LGbOV8I__0fhjWIRp3DMhoNwPnEqHqsrngfz_w9hwoL2xXQTKTZEHmAaND8NG1Qd3WGVctVBvvKdquXf4UMkbfvupoAXP0TxlReJTJUjTyKz8QfL6syzcwj1LFNM_nAfhJJVHg/s1600/IMG_5603.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi65KOnrhBojG8HqrQvjXQdep48YL6DDOJJqHPAfKvA9r-7mbZm3MW19LGbOV8I__0fhjWIRp3DMhoNwPnEqHqsrngfz_w9hwoL2xXQTKTZEHmAaND8NG1Qd3WGVctVBvvKdquXf4UMkbfvupoAXP0TxlReJTJUjTyKz8QfL6syzcwj1LFNM_nAfhJJVHg/s320/IMG_5603.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKQ4sL2xmezqPpnwnXXfjENxrBfA2rKe1Y9Zqf0vz3AEXFbvRtD7VUKNQiDT9fhjd2ZftUeN6Um5fH8nXndTLJO-MfB89GB5cLc1FmL1VjbBEEt98T4sJBmxuhylxnrOC7oC-YIqSOmsNM0ike3NxNyLclG03O4w5Bi7jTHBzN9w8Sr3_wp-6SYnzbNIw/s1600/IMG_5600.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKQ4sL2xmezqPpnwnXXfjENxrBfA2rKe1Y9Zqf0vz3AEXFbvRtD7VUKNQiDT9fhjd2ZftUeN6Um5fH8nXndTLJO-MfB89GB5cLc1FmL1VjbBEEt98T4sJBmxuhylxnrOC7oC-YIqSOmsNM0ike3NxNyLclG03O4w5Bi7jTHBzN9w8Sr3_wp-6SYnzbNIw/s320/IMG_5600.jpeg" width="240" /></a></div><p></p><p>So step one was to permanently weld the db-killer in place as previously it was only held in by one (semi-)seized bolt. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrT9gUkj3DR4r_Dp8g4LIneJZwV7C6Rtcb-QQKD1dwEA6aKjQHvcIWf-x3ACtePeZza-NYTu5-jz6a6BulyRkeUZ_2wXBQYZ-W0XOwCkGBqDEZYpa47He_2iB2URZB2C5a31WQ9jV_EOl70eC351wfl7yK44JTiuhcAir9DnnAmbWrLtcc2o2fGlqohQg/s1600/IMG_5677.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrT9gUkj3DR4r_Dp8g4LIneJZwV7C6Rtcb-QQKD1dwEA6aKjQHvcIWf-x3ACtePeZza-NYTu5-jz6a6BulyRkeUZ_2wXBQYZ-W0XOwCkGBqDEZYpa47He_2iB2URZB2C5a31WQ9jV_EOl70eC351wfl7yK44JTiuhcAir9DnnAmbWrLtcc2o2fGlqohQg/s320/IMG_5677.jpeg" width="240" /></a></div><p></p><p>Whilst fixing stuff that worked before, I also got a TT600S stainless steel exhaust header. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFmhERhdqVQtv2_eWDV_47Td4v8zqDkmQUcecL089CSgG79iYTIEKaR-qk4twmOtHyKsnUmh0MnmngsJrUfbZUC2TUa1sRL5e4kPPGSq1dKFpLu4ioY92ILYiumgnNJIY2VlXZueUp0eHUOrGTcOPGq5IdgAIn2k-Xj3fMkrcfQGg-ixkD6MGMOlChMv8/s1600/IMG_5739.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFmhERhdqVQtv2_eWDV_47Td4v8zqDkmQUcecL089CSgG79iYTIEKaR-qk4twmOtHyKsnUmh0MnmngsJrUfbZUC2TUa1sRL5e4kPPGSq1dKFpLu4ioY92ILYiumgnNJIY2VlXZueUp0eHUOrGTcOPGq5IdgAIn2k-Xj3fMkrcfQGg-ixkD6MGMOlChMv8/s320/IMG_5739.jpeg" width="320" /></a></div><p></p><p>The big benefit with one of these is that they have better flanges, which do not bend the exhaust studs. Unfortunately this also meant getting all the old ones out. Now call me a pessimist, but I installed all of them with copious amounts of copper-grease, so it was just a matter of double-nutting and winding them out.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgN-mAvGAXCfkJMKSgM3L6VRJVcCwoAnzIyn0uJ4qswZbGe-dKnYxEh2oO0BtjGBlPr2OPL5AwP0O-lZvuV-p0xxj79hw7PVl8P02QBrNfje34QTeRJpry9IGHl756wHNqg0GNmvmD7gC_jeZR9fogx5OoknrLM2wOzzi36B869XAeNVrFgg0-_E7y5ahI/s1600/IMG_5773.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgN-mAvGAXCfkJMKSgM3L6VRJVcCwoAnzIyn0uJ4qswZbGe-dKnYxEh2oO0BtjGBlPr2OPL5AwP0O-lZvuV-p0xxj79hw7PVl8P02QBrNfje34QTeRJpry9IGHl756wHNqg0GNmvmD7gC_jeZR9fogx5OoknrLM2wOzzi36B869XAeNVrFgg0-_E7y5ahI/s320/IMG_5773.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmDM83GJvGLPPJXpAY1xWgl7uEPRVEElrHrCwL9PMxpulo1FvBAkl0YBNczn29fnqh2s6-lppjnMpAekd402_bcQb-jxjAT5X9gV8q2idX3QrSSwk4XAHnaWCkbfLMAO2jpYjFBVe7pj3ZKu2OGmWiX4e85Wipv76SuFu8SC6fbk7VmSbhTibMMEwPuL0/s1600/IMG_5774.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmDM83GJvGLPPJXpAY1xWgl7uEPRVEElrHrCwL9PMxpulo1FvBAkl0YBNczn29fnqh2s6-lppjnMpAekd402_bcQb-jxjAT5X9gV8q2idX3QrSSwk4XAHnaWCkbfLMAO2jpYjFBVe7pj3ZKu2OGmWiX4e85Wipv76SuFu8SC6fbk7VmSbhTibMMEwPuL0/s320/IMG_5774.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSZsSS85xTTv9pKC14xzknMEPes5Dk6fOKoXsrDkYFweGMOHimZXqReIUu3GKQW6slHkI3bhqNppTL9SlAZNbekniatN56qH7jhhxPWT97Cf8Y2M4zHFmkBoboaFEy9J5ge7yyyyuLCR3vbj8vQUcSoRMjdnKJTbOpzehmOxLcMLFR78AwQ8lY-i7L-jM/s1600/IMG_5775.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSZsSS85xTTv9pKC14xzknMEPes5Dk6fOKoXsrDkYFweGMOHimZXqReIUu3GKQW6slHkI3bhqNppTL9SlAZNbekniatN56qH7jhhxPWT97Cf8Y2M4zHFmkBoboaFEy9J5ge7yyyyuLCR3vbj8vQUcSoRMjdnKJTbOpzehmOxLcMLFR78AwQ8lY-i7L-jM/s320/IMG_5775.jpeg" width="240" /></a></div><p></p><p>Stock studs are M6x32mm. I, following some advice from the XT-Forum, installed M6x45mm studs. Those are too long and I later on replaced them with M6x40mm (stainless) studs later on.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgivYWBekL9LHduchKHF6oReGFNeD4-9x3ni6ICUD6qmU3oQH3PTIjjOn__R2qVJl3IFVos4PyUdhkoSW9pXeEq4DcF8a2uV7UWOjE-VfV4iPPEN55ukdnrovbqm4_X2xWkKLFItERZj0uxk-vRUaLGhWYjBMYevDiN2J96V1jM-hEoEGbhHjyDkSfqurQ/s1600/IMG_5777.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgivYWBekL9LHduchKHF6oReGFNeD4-9x3ni6ICUD6qmU3oQH3PTIjjOn__R2qVJl3IFVos4PyUdhkoSW9pXeEq4DcF8a2uV7UWOjE-VfV4iPPEN55ukdnrovbqm4_X2xWkKLFItERZj0uxk-vRUaLGhWYjBMYevDiN2J96V1jM-hEoEGbhHjyDkSfqurQ/s320/IMG_5777.jpeg" width="240" /></a></div><p></p><p>The TT600 headers are too long by about 40-45mm. In my case (take that with a grain of salt as all exhaust bits on this XT are now homegrown), I had to cut off close to 50mm to get them to the right length...<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsEP-hGHI3-ra3VfnnrVj93PB7fEXugFPiZVeCB49mZ-8ApsG8R-5uSu73i-YFPPicGzXay1rNED1yfSFgqNn49hNa_LwAyBi34Ceoi13xUg9y_8Wyu-pfsxTee8F6q5TySgjKi0gjKRbc5a17mPW7Uuu76nILfdpsWs7Fy6STB-5aqWmcWIEfFJD1h6M/s1600/IMG_5783.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsEP-hGHI3-ra3VfnnrVj93PB7fEXugFPiZVeCB49mZ-8ApsG8R-5uSu73i-YFPPicGzXay1rNED1yfSFgqNn49hNa_LwAyBi34Ceoi13xUg9y_8Wyu-pfsxTee8F6q5TySgjKi0gjKRbc5a17mPW7Uuu76nILfdpsWs7Fy6STB-5aqWmcWIEfFJD1h6M/s320/IMG_5783.jpeg" width="320" /></a></div><p></p><p>... because it wouldn't clear the airbox, I cut off another 30mm. Guess what, it was now too short by about 30mm. Turns out, you have to undo the 3 bolts that hold on the airbox and then everything will fall into place nicely. Also high-frequency (120Hz, 33% on-time with a 15/70A split) creates absolutely stunning welds with no burn-through to the backside.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8vAgMHn8Ehfo9KKAhunGnLVnfeBh7wkn32ew4Sqcb3ZPIZbeIODEpf0IIppbuKXnphRZzcTL0AKlanpMS7bQKqDhHNaT8ys6XezRCmUC7Svmkh0JX2fH7L-WsN35MikuYxy8C05gOhjSD0aGVkydlUmCpFZgo34OezSsYKHO9_XZGebN_X9xTRzNmRyI/s1600/IMG_5787.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8vAgMHn8Ehfo9KKAhunGnLVnfeBh7wkn32ew4Sqcb3ZPIZbeIODEpf0IIppbuKXnphRZzcTL0AKlanpMS7bQKqDhHNaT8ys6XezRCmUC7Svmkh0JX2fH7L-WsN35MikuYxy8C05gOhjSD0aGVkydlUmCpFZgo34OezSsYKHO9_XZGebN_X9xTRzNmRyI/s320/IMG_5787.jpeg" width="240" /></a></div><p></p><p>With that out of the way it was time to turn my attention to the actual muffler. For that I bought some 2" and 55mm perforated tube. The bigger diameter tube was meant to locate the thinner tube, which slides over a hump on the far-side of the muffler. This way the inner tube is free-floating and can expand and contract depending on how hot it gets.</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvE45jqwHUQ7J2t7YkRD4aMJ5DcE_XbHyDda9D_VIltwkwmxbngBP9-ydrwltiZOO_R8vHEEe2jXcRsmBUa25ju5hXMgU-HL-dYoosy7XM2GNk1GAzsOsvw_5DINAcF01UmO62D2FaHsTmjtnXk-E0zau0-mkDA_xLGkHMG-nWfHW3bmyWVTlpOnXSO1w/s1600/IMG_5800.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhvE45jqwHUQ7J2t7YkRD4aMJ5DcE_XbHyDda9D_VIltwkwmxbngBP9-ydrwltiZOO_R8vHEEe2jXcRsmBUa25ju5hXMgU-HL-dYoosy7XM2GNk1GAzsOsvw_5DINAcF01UmO62D2FaHsTmjtnXk-E0zau0-mkDA_xLGkHMG-nWfHW3bmyWVTlpOnXSO1w/s320/IMG_5800.jpeg" width="240" /></a></div><p></p><p>Another benefit: trimming the inner tube to length is very straight-forward.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-kpQuuBqYTGi1WaRhwosh7IfZVYuLRu2zEBXbxRJd0IXA9axalG06NdPwJX_BehrE878irby6tlHJ5lRQdaj2MLgcafCU_RjSU561Bq8ZjrCTUGWww8DoZKmpzOZwHaXBhFC7dV_WeO8tsurU2EdNNxvfUAwqabuMnKVO21z2u4LI-5VdL6E8BcfBCv8/s1600/IMG_5801.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-kpQuuBqYTGi1WaRhwosh7IfZVYuLRu2zEBXbxRJd0IXA9axalG06NdPwJX_BehrE878irby6tlHJ5lRQdaj2MLgcafCU_RjSU561Bq8ZjrCTUGWww8DoZKmpzOZwHaXBhFC7dV_WeO8tsurU2EdNNxvfUAwqabuMnKVO21z2u4LI-5VdL6E8BcfBCv8/s320/IMG_5801.jpeg" width="240" /></a></div><p></p><p>As all four nuts where missing previously and the last guy who "fixed" the exhaust used the nutserts to hold both the cap and outer body together... a proper bit of welding was due.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjD6l7iJVil87_CdsRaAlqvOL546f05tH8KgYLJLcl8_tXPKp77bZ_j2gN26Wn0A7VYYk3vdUjg9Bk75MDl2w-oDm8NWfjerp0Koa71UMpvPwQl9ukvJG2CbmqIbU4H164negxrkwbQNl8NSkQcGdYVBrWSrAEJmzQz4CQZ7_R5vFChzqwFCtBuuowHBv8/s1600/IMG_5807.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjD6l7iJVil87_CdsRaAlqvOL546f05tH8KgYLJLcl8_tXPKp77bZ_j2gN26Wn0A7VYYk3vdUjg9Bk75MDl2w-oDm8NWfjerp0Koa71UMpvPwQl9ukvJG2CbmqIbU4H164negxrkwbQNl8NSkQcGdYVBrWSrAEJmzQz4CQZ7_R5vFChzqwFCtBuuowHBv8/s320/IMG_5807.jpeg" width="240" /></a></div><p></p><p>Probably the smartest trick for repacking exhausts I learned ages ago is to wrap the inner tube with some matt (or wool it works the same) and then tighten and wrap it with (paper-)masking tape. You end up with a VERY tightly packed exhaust. The masking tape will burn off and the packing will unfold a bit and fill the whole exhaust more evenly. This way it also lasts a lot longer.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2172417Kzvhncf3BUML0_NdBdj8YT-TfS-eSyn4XilelygooeA0O_uM57NgZV5pBRI832shhwm1j-aXHSLxin9pNfQ4vTzuKDw5gU7i63kB0PTWWjRg3N-v8hwdiD8QgLPp4H_56ZewlUHYUEoVxiVukqa1vQxDZWb2Lmh3DnnkKypIIQUMmngllqxPM/s1600/IMG_5808.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg2172417Kzvhncf3BUML0_NdBdj8YT-TfS-eSyn4XilelygooeA0O_uM57NgZV5pBRI832shhwm1j-aXHSLxin9pNfQ4vTzuKDw5gU7i63kB0PTWWjRg3N-v8hwdiD8QgLPp4H_56ZewlUHYUEoVxiVukqa1vQxDZWb2Lmh3DnnkKypIIQUMmngllqxPM/s320/IMG_5808.jpeg" width="240" /></a></div><p></p><p>It is a bit loud though, when freshly packed. </p><div class="separator" style="clear: both; text-align: center;"><iframe allowfullscreen="" class="BLOG_video_class" height="266" src="https://www.youtube.com/embed/-8nd7ThlSSQ" width="320" youtube-src-id="-8nd7ThlSSQ"></iframe></div><p>By the time I had come home from my workshop (about 15 to 20kms later), the masking tape had burned off and the sharp bark has all but disappeared. I actually think at around 2000-2500 rpm it is now more quite than my (leaky) stock exhaust.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEij72Zr-cYVE4JlFEKgjNHEvM9kKm1HokKfKETBzHhGfiQQ-7_eh1jdo1TvMC9eIWMlktQ853T5D70svB2NwFvuJZrK_nXOXtiQVZXJEqAJlgNBfzoNZOZguQV4z9VzgT-9PztvevgEJM7OR7pcnkPVkW3IVnVe4hqicE9O-KPMOEv9JMxxtO2ydurGJC4/s1600/IMG_5824.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEij72Zr-cYVE4JlFEKgjNHEvM9kKm1HokKfKETBzHhGfiQQ-7_eh1jdo1TvMC9eIWMlktQ853T5D70svB2NwFvuJZrK_nXOXtiQVZXJEqAJlgNBfzoNZOZguQV4z9VzgT-9PztvevgEJM7OR7pcnkPVkW3IVnVe4hqicE9O-KPMOEv9JMxxtO2ydurGJC4/s320/IMG_5824.jpeg" width="320" /></a></div><p></p><p>Just showing off the model number (this Arrow exhaust is so old, it sorts of predates E-numbers) and is stamped on the inside to make it easier to see where the marking is. (Without the need to remove any sidepanels.) <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghBBWxw1fCGR8Wi6wt5kV1vblCJGy4eBpFl4HHiPH6b5u4OlRQ5vfVYy35SnsNMqxHQ0630W3gSCjsAm1MH4m82NG_G57Ainy30CyEz-wuyYdBKGbOqkewSdxw_9eryg6HKogMcC2ICo2CCUQvLolum1-fheTiuDZ8PXCzmANJWyUnja95KJ7ixpZgZCc/s1600/IMG_5826.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghBBWxw1fCGR8Wi6wt5kV1vblCJGy4eBpFl4HHiPH6b5u4OlRQ5vfVYy35SnsNMqxHQ0630W3gSCjsAm1MH4m82NG_G57Ainy30CyEz-wuyYdBKGbOqkewSdxw_9eryg6HKogMcC2ICo2CCUQvLolum1-fheTiuDZ8PXCzmANJWyUnja95KJ7ixpZgZCc/s320/IMG_5826.jpeg" width="320" /></a></div><p>Also yes, it is a heavily modified item originally meant for a Honda XR600R. <br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-73667082774517335652023-07-28T20:00:00.009+02:002023-07-28T20:00:00.185+02:00Dre-XT-Stück - again, but better<p>
Hey, do you like riding your XT600? Don't know, it's broken at the moment.
This has been a sort of running joke between me and several people and quite
frankly it has gotten a bit old. Given the existence of this post, you can
probably guess: it's not really getting better.
</p>
<p>
But let me explain, the
<a href="https://greasygreg.blogspot.com/2023/04/dre-xt-stuck-more-like-dre-xt-jesus.html" target="_blank">the last time I overhauled the engine</a>, which was only roughly 3 months ago, I used a very inexpensive, cast
piston. Long story short that cheap piston had developed a nasty habit of
expanding rather erratically and semi-seized in the bore a few times, which
stopped the rings from moving freely in their grooves, which meant no power
and massive amounts of blowby through the engine breather. To top things off,
I went with a rather close tolerance, because I wanted to get some longevity
out of this case piston. The result was a mechanically quiet and completely
gutless engine, which started spewing oil out of the breather after less than
200kms.
</p>
<p>
After quite a bit of thinking, I decided to rebuild the engine and I put on my
thinking cap trying to remember what worked and what didn't. To be fair, the
old Wössner +1.00mm (501D100) oversize worked an absolute treat after the
Wiseco had failed previously .
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHaN7Zt7sgFQ-v2ykhXbHb1W26U2_wV0wr-g11UbuKb6B8reCaZdhrc-uAta3OmhiCxNDfeUPjFVsxxvMCOo80Z3onI7ruqXtDXUmgSdu023IrOAe-sC1kzQ-VgWW_XF16wlgDsaah2DGtRCss800ytcusR1GRsYAc3C892FJxt4E26TJzpzG6obdM7Gk/s1600/IMG_5207.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHaN7Zt7sgFQ-v2ykhXbHb1W26U2_wV0wr-g11UbuKb6B8reCaZdhrc-uAta3OmhiCxNDfeUPjFVsxxvMCOo80Z3onI7ruqXtDXUmgSdu023IrOAe-sC1kzQ-VgWW_XF16wlgDsaah2DGtRCss800ytcusR1GRsYAc3C892FJxt4E26TJzpzG6obdM7Gk/s320/IMG_5207.jpeg" width="240" /></a>
</div>
<p></p>
<p>
So I went ahead and bought it's bigger brother 96.50mm +1.50mm (501D150). I am
not absolutely sure just how much the coated piston skirt actually helps, but
it is a piston finished to a very high standard and unlike the JE-piston with
its 11.x:1 compression ratio, this one sports a more modest 10.8:1, which
should leave some breathing room for poor quality fuel or a bit of carbon
buildup on the piston crown.<br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCa3dbAwa9BcJAacMjue7rscU0AUedWXq_TOhdk2qhRMFI3JLbaxZ_Gn7kY-nVjIX0mm_fi46e1kGBWVc7d7JcLsEu-MLXKiGVosL5XWKf34Z9WKGeHo7DqFqKW0Qtb6WpQJA8B1MS98oR_LNhaz8AID7fY0yH8_u4OwoVg-MSct7NzGUwV5HFUCXbZk8/s1600/IMG_5373.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCa3dbAwa9BcJAacMjue7rscU0AUedWXq_TOhdk2qhRMFI3JLbaxZ_Gn7kY-nVjIX0mm_fi46e1kGBWVc7d7JcLsEu-MLXKiGVosL5XWKf34Z9WKGeHo7DqFqKW0Qtb6WpQJA8B1MS98oR_LNhaz8AID7fY0yH8_u4OwoVg-MSct7NzGUwV5HFUCXbZk8/s320/IMG_5373.jpeg" width="320" /></a>
</div>
<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJpDWytIdYSQILguni7Rr7DcZJFrZqDOVI8RLyHjmk6nHGsEOkjUgmgTEsYxlmHLKOJNBx3vNywzUoa4roC7jinDjLoAjwYrPl-p1nWkzm8XEov38erMLUPAvQI_kJJ4J74pln3IC17ZKZjgNf0V7aJoajQCS7TbNE8x2qhs3urziVwL45f1JJXlwW_d8/s1600/IMG_5374.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJpDWytIdYSQILguni7Rr7DcZJFrZqDOVI8RLyHjmk6nHGsEOkjUgmgTEsYxlmHLKOJNBx3vNywzUoa4roC7jinDjLoAjwYrPl-p1nWkzm8XEov38erMLUPAvQI_kJJ4J74pln3IC17ZKZjgNf0V7aJoajQCS7TbNE8x2qhs3urziVwL45f1JJXlwW_d8/s320/IMG_5374.jpeg" width="240" /></a>
</div>
<br />
<p>
Initially I played around with the thought of swapping the liners between my
reinforced 97mm cylinder and the older 96mm one, but as this would have meant
skimming the cylinder, I ultimately decided against it. (All the threads felt
good enough, so let's hope this isn't going to bite me at some point.) With a
gas-powered BBQ it's a ten minute job really. All you need is a couple of
fire-proof spacers.
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHNpQJdt7hP9LqHfHIkuK6s_WM_KzEJ7RVE_4fHxYbr2VdqQTkE8kGzsatSkthnqiL3XaCDFsspdBy81wt2FrlNk1E-dbGVwgHWwyxT9YlLdEFAri9POH1QAz-vv52z-KB4w1EVuEmhRKJfmSeID0gCHqzHt4RwIYEQB-2YMmpYE2cWJ7-q-Ie6ETtujU/s1600/IMG_5401.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHNpQJdt7hP9LqHfHIkuK6s_WM_KzEJ7RVE_4fHxYbr2VdqQTkE8kGzsatSkthnqiL3XaCDFsspdBy81wt2FrlNk1E-dbGVwgHWwyxT9YlLdEFAri9POH1QAz-vv52z-KB4w1EVuEmhRKJfmSeID0gCHqzHt4RwIYEQB-2YMmpYE2cWJ7-q-Ie6ETtujU/s320/IMG_5401.jpeg" width="240" /></a>
</div>
<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCF4e7FLaIZ3XrSDHY2aQZQkclzbT5XaXzGtbs3g8uFt8JM2pOxJZRLEEzRvcTR9wucXVuV7M3wMx4RMxnHfOvoCRD163KFdg8SYqdPVVUyBHBouO8dnKErCP8Kmp6qdxDiRFeVQkxfq1JoM24lqmkMC3YVJAYxgYje7lSePRyH-wXm4D3NiIF4FtT520/s1600/IMG_5402.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCF4e7FLaIZ3XrSDHY2aQZQkclzbT5XaXzGtbs3g8uFt8JM2pOxJZRLEEzRvcTR9wucXVuV7M3wMx4RMxnHfOvoCRD163KFdg8SYqdPVVUyBHBouO8dnKErCP8Kmp6qdxDiRFeVQkxfq1JoM24lqmkMC3YVJAYxgYje7lSePRyH-wXm4D3NiIF4FtT520/s320/IMG_5402.jpeg" width="240" /></a>
</div>
<p></p>
<p>
Flipped it over and once it came up to temp, you could hear when the liner
fell out. <br />
</p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwRrvXae0UmQqfrWQ0W5urCGrgcqqzt58dqrHbtXQxwwi94mlGJ-b4ZUoEsbS-kFtMk0AENTXVe2eBPdOBPceviU4pz76bSXNd47kdnocLkHquXtl9cfktOGyXnXlUSXh0UMRcSbmUREqdtzgkNc5hnFImZZLK1I9kT_B746fczChTq1pM2MxGHYTyJ4A/s1600/IMG_5403.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwRrvXae0UmQqfrWQ0W5urCGrgcqqzt58dqrHbtXQxwwi94mlGJ-b4ZUoEsbS-kFtMk0AENTXVe2eBPdOBPceviU4pz76bSXNd47kdnocLkHquXtl9cfktOGyXnXlUSXh0UMRcSbmUREqdtzgkNc5hnFImZZLK1I9kT_B746fczChTq1pM2MxGHYTyJ4A/s320/IMG_5403.jpeg" width="240" /></a>
</div>
<p></p>
<p>Then drop the cold liner into the hot cylinder.<br /></p>
<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiavUNpXIdPlo0gUViCAHXy7sCIMpVosWQUb8qwgJ0C82K4ZGudi8nrVCDfod00F0H2ZL7-4jteY57Lg8eEHQVSbXrgv0z6p7dFcKY-ycH0-lz9AsebKhHHE1fXABYGPawDpzhkF3X25gseM6vJ7CKlrWTHE1rOhdQfs71jkCUvw1KNzNr-1HTPoGU1raU/s1600/IMG_5404.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiavUNpXIdPlo0gUViCAHXy7sCIMpVosWQUb8qwgJ0C82K4ZGudi8nrVCDfod00F0H2ZL7-4jteY57Lg8eEHQVSbXrgv0z6p7dFcKY-ycH0-lz9AsebKhHHE1fXABYGPawDpzhkF3X25gseM6vJ7CKlrWTHE1rOhdQfs71jkCUvw1KNzNr-1HTPoGU1raU/s320/IMG_5404.jpeg" width="240" /></a>
</div>
<p></p>
<p>A left over liner.<br /></p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQc66x5F5ZcB98KhszU91xOlWjsyjiynvMkuBIhVPaYeIVWZQQgRC3W2L0dPdiTqOkhog8dv4E6eed4KwgCB9akHXoHk98E-sXGHsXMOCtIJHAoK3zlJSSMC1vOQpXhQZ7Me3cWq0KXBGggfd_bldpZCE2RN81gnGMNYEOFnqnvpfrAf__GvhJqj3czAU/s1600/IMG_5405.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQc66x5F5ZcB98KhszU91xOlWjsyjiynvMkuBIhVPaYeIVWZQQgRC3W2L0dPdiTqOkhog8dv4E6eed4KwgCB9akHXoHk98E-sXGHsXMOCtIJHAoK3zlJSSMC1vOQpXhQZ7Me3cWq0KXBGggfd_bldpZCE2RN81gnGMNYEOFnqnvpfrAf__GvhJqj3czAU/s320/IMG_5405.jpeg" width="240" /></a>
</div>
<p></p>
<p>
It has to be said that I gambled a bit, as up to this point, I hadn't taken
the engine apart. Bore didn't look too bad.<br />
</p>
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</div>
<p></p>
<p>
Conrod small-end showed no signs of damage and the conrod itself felt normal
as well.<br />
</p>
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</div>
<p></p>
<p>
But the piston had weird seize-marks on all four corners, indicating both a
rather tight bore (I knew that beforehand) and a somewhat erratic expansion.
Both compression rings were stuck in their grooves.<br />
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9qkb54upZIr5fhdecAlFwiEISRHp51uc9-_USFLlOQxUP5PizzVtc7jsT60tHjd5-8GyHLKAtFJlE0Z1QSbDhNQzErzcPjXipZ6vD-U8YDq-bn8Ql4--Gk_87uCL_2EFB6UasYZjWRIvKpWv-MRoeybLu6Vy4KzIhK4MuvykaNbJ1yNJV9c8HoIkyF1I/s1600/IMG_5526.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9qkb54upZIr5fhdecAlFwiEISRHp51uc9-_USFLlOQxUP5PizzVtc7jsT60tHjd5-8GyHLKAtFJlE0Z1QSbDhNQzErzcPjXipZ6vD-U8YDq-bn8Ql4--Gk_87uCL_2EFB6UasYZjWRIvKpWv-MRoeybLu6Vy4KzIhK4MuvykaNbJ1yNJV9c8HoIkyF1I/s320/IMG_5526.jpeg" width="240" /></a>
</div>
<p></p>
<p>
You know things are good, when some of the most important calculations of the
whole engine build are scribbled onto the packaging of the piston.
</p>
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</div>
<p></p>
<p>
Now all I had to do was to file/sand the rings to size. I used 400 grit paper
around a file as the top ring with its hard-chrome layer was way too hard to
file. (The second ring appears to be made from cast steel and is an absolute
beauty to get into dimension.)
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyc15U_UkWNCskbJSVDI0vgVghUoym43_LUcswL3ls512FEeSSMNA083RrtFyWs71x-gx_C6fiyhHwUa7IDq2VrulC4xjaN7msuRdBO6N--gsBNxHUTlLDIlfTeN0ZKB4EOeLf3STZdIw-JmppkISo73AjvD41XntvVG8b0njoWdEhi02m9pqrLcA6THY/s1600/IMG_5581.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyc15U_UkWNCskbJSVDI0vgVghUoym43_LUcswL3ls512FEeSSMNA083RrtFyWs71x-gx_C6fiyhHwUa7IDq2VrulC4xjaN7msuRdBO6N--gsBNxHUTlLDIlfTeN0ZKB4EOeLf3STZdIw-JmppkISo73AjvD41XntvVG8b0njoWdEhi02m9pqrLcA6THY/s320/IMG_5581.jpeg" width="240" /></a>
</div>
<br />
<p>
By the way, a stone on a dremel works really lovely to re-size the ring gap...
not. The rings will overheat and once hot literally vanish. Oh well, now I
have set of oil-scraper rings, should I need fresh ones down the line.
</p>
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</div>
<p></p>
<p>
Assembly was fairly straight forward, but have I mentioned that the gudgeon
pin (piston wrist pin for you 'Muricans) is machined conically on the inside?
Thing of art.
</p>
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</div>
<p>
The following pictures are mostly for me so I can look at them every time I
feel like the engine is lacking power and to prevent me from having to take
the engine apart "just to be sure that the timing is correct" or the like.
</p>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_YgsN33fzKxo9sOgU_XWChJFD5GvD_rDULF_vLv4cQj1Rc6Nlpy2XfuGZtAlanI2c_GM8wwuQvsjbSv2Lkrky2tDCM-0RDJ1ElktIDtDp4LzYBszvzFq0dJ_q3udtXJ9e_1u3A2VJ3gsUa1r7h-SUF1QFjD470q0tTdUBOOutr8irWufeINAgiL3sZUE/s1600/IMG_5587.jpeg" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj_YgsN33fzKxo9sOgU_XWChJFD5GvD_rDULF_vLv4cQj1Rc6Nlpy2XfuGZtAlanI2c_GM8wwuQvsjbSv2Lkrky2tDCM-0RDJ1ElktIDtDp4LzYBszvzFq0dJ_q3udtXJ9e_1u3A2VJ3gsUa1r7h-SUF1QFjD470q0tTdUBOOutr8irWufeINAgiL3sZUE/s320/IMG_5587.jpeg" width="240" /></a>
</div><p> Cam neither advanced nor retarded.<br />
</p><div class="separator" style="clear: both; text-align: center;">
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</div><p>
</p><p>Correctly timed on "T".<br />
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</div>
<br />
<p>At this point the question was still open: why did the JE-piston fail on the Autobahn. Please pay special attention to the head pipe in the following two pictures. (A fresh piston and rings will always create excessive heat...)</p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6GQrrpyFHX-fJi6p9UFNuzUJgz0eJS8BYR7xa5h9-WKs24jAJSUbfzlvaE4fe9347MIWk6yx4cb5WP37l8rfxtezrDKMF8D9_cKxjmi-UV309vPddc31Xx0woqMs2RT4HsUpZ0mvDYgbstrQxGHpj5EQFB6z6VuQZNoALS5QDbsZUCSWLxYbrxGvIUIA/s1600/IMG_5591.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6GQrrpyFHX-fJi6p9UFNuzUJgz0eJS8BYR7xa5h9-WKs24jAJSUbfzlvaE4fe9347MIWk6yx4cb5WP37l8rfxtezrDKMF8D9_cKxjmi-UV309vPddc31Xx0woqMs2RT4HsUpZ0mvDYgbstrQxGHpj5EQFB6z6VuQZNoALS5QDbsZUCSWLxYbrxGvIUIA/s320/IMG_5591.jpeg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjd-eyRkEHMvOaaxAx-zsegxtUT6sLxpojcX4aMdOpRfh6qObhk-8eLNyMl37PqN7IEEkI7-iqr2b133SSzwJJW1K67ODSN_-EGiK3cAu5nRG_kxo6EYJMddcvJiYNxOIsYDu7P_tHnjDzvAqpFvoIG2qdaMYTpmEJ45VPbEERtNxJFCMsACTohqfzSyMc/s1600/IMG_5597.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjd-eyRkEHMvOaaxAx-zsegxtUT6sLxpojcX4aMdOpRfh6qObhk-8eLNyMl37PqN7IEEkI7-iqr2b133SSzwJJW1K67ODSN_-EGiK3cAu5nRG_kxo6EYJMddcvJiYNxOIsYDu7P_tHnjDzvAqpFvoIG2qdaMYTpmEJ45VPbEERtNxJFCMsACTohqfzSyMc/s320/IMG_5597.jpeg" width="320" /></a></div><p>If you follow the header pipes to the actual muffler at one point exactly this bluing will stop. To be fair I bought the muffler as "rebuilt" and whilst not entirely sure how the did it, I have the nagging suspicion that it's not supposed to look like that. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLB9NLz0g8cP5-G_lO8U6UFSqS2nCOjhA5loSNNTzkRsvfyUdbrGKBc1FOtNTdp5-_ZhhHoPN8kPbmp8OI6JLOyGlS9liOOk3utZmmNfLqpGkaDgkSiLIRDjUab8sOZWiUQATyYEcVJjr94ARDcwRDr0GIkka-fxll0nul1m1pnF-xgJ832oMJvjXewPo/s1600/IMG_5600.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLB9NLz0g8cP5-G_lO8U6UFSqS2nCOjhA5loSNNTzkRsvfyUdbrGKBc1FOtNTdp5-_ZhhHoPN8kPbmp8OI6JLOyGlS9liOOk3utZmmNfLqpGkaDgkSiLIRDjUab8sOZWiUQATyYEcVJjr94ARDcwRDr0GIkka-fxll0nul1m1pnF-xgJ832oMJvjXewPo/s320/IMG_5600.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUDQSYutivV-Xo6Eccdcgb9RXCvWT8uHXi4CdFel9DN-8-ODnUBG4VjhgqxeeDHNJ0C-50sC7hBeDgEjfmrGs5qSAyrJ3PuJCUofDtgLpLHQtas0VzQEfn966s5XcTAeJ6G8nbIIopyiyRP10cEM2702VK909h_bhsZF27BOjl6_aXu8o8feDtwKfoQVQ/s1600/IMG_5601.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUDQSYutivV-Xo6Eccdcgb9RXCvWT8uHXi4CdFel9DN-8-ODnUBG4VjhgqxeeDHNJ0C-50sC7hBeDgEjfmrGs5qSAyrJ3PuJCUofDtgLpLHQtas0VzQEfn966s5XcTAeJ6G8nbIIopyiyRP10cEM2702VK909h_bhsZF27BOjl6_aXu8o8feDtwKfoQVQ/s320/IMG_5601.jpeg" width="240" /></a></div><p></p><p>Judging by the wool, it was definitely repacked.<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiz-CSIJ1kFzQ1Pkyg2gWCVtvzZMYudZBqnssEEUMZRJ8M51e0lqXU2EZ97Cj37vWRnuqVhZfFkuS0633EtrKZ7mckCmrvDsMyk1Oz2521Eh31WiC6VookRF9ww3QS4Dr-nhRbzZbBFpg9u32-pYyyOXFn3agYqSx-I3a8CHOkaYRt8DBwz7bS-t1mg-B8/s1600/IMG_5603.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiz-CSIJ1kFzQ1Pkyg2gWCVtvzZMYudZBqnssEEUMZRJ8M51e0lqXU2EZ97Cj37vWRnuqVhZfFkuS0633EtrKZ7mckCmrvDsMyk1Oz2521Eh31WiC6VookRF9ww3QS4Dr-nhRbzZbBFpg9u32-pYyyOXFn3agYqSx-I3a8CHOkaYRt8DBwz7bS-t1mg-B8/s320/IMG_5603.jpeg" width="240" /></a></div><p>Oh well, I still have a stock muffler. (Might be better for the "Pickerl"/Austrian MOT anyway.) By now I have bought some perforated tube and will rebuild the internals. So what else to do than to take the old girl for a quick spin and as the odd "up and down the road" didn't reveal any real nastyness, why not turn it up one notch and take it home?</p><p>I do have a talent to break down at some scenic locations and the lighting wasn't bad either. <br /></p><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkSnvsvLPpGbCz2l-o8AIVhMA5PP8bfc6tyIEiAcO9s4M9zJIq8oQMq4e5f-2XhCkl83LJRHQb7_nZAZjWpvlWhZuBP7lOCw4whhCe2A-Iaf4muH62Okg8p2aynAA18zBDzcNb7AJ2JMZJQoZXuaJaLI3VE3VaZyDSQ8ei1MlMtN15GsugGscCyxPKrRQ/s1600/IMG_5609.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="1600" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkSnvsvLPpGbCz2l-o8AIVhMA5PP8bfc6tyIEiAcO9s4M9zJIq8oQMq4e5f-2XhCkl83LJRHQb7_nZAZjWpvlWhZuBP7lOCw4whhCe2A-Iaf4muH62Okg8p2aynAA18zBDzcNb7AJ2JMZJQoZXuaJaLI3VE3VaZyDSQ8ei1MlMtN15GsugGscCyxPKrRQ/s320/IMG_5609.jpeg" width="320" /></a></div><p></p><p>Turns out it leaked some air past the left carb and thus got a bit tight and whilst I caught it just in time, it was still a bit too tight to kick over or in other words, I broke the kickstart lever. (Thanks to my dad at this point, who took off the one from his XT and came along with some tools.)<br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnsbzH7F28fPNVL6fF0g7Wun88OcU68RXltrXYen7h2nfZx86gUB_zFPidNiYuH6-bIsDTtF6XKev-QTg5RRjijXrMNRjkGjxX-n5bw142aVjEO5YOW4kKB8k7YCWMSwiBePO7tAvBqGFHBxKQbHPscXHk_Cw6SOJi3GhRsLsTr0DvyuUyW3Ko0JaBEAs/s1600/IMG_5610.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjnsbzH7F28fPNVL6fF0g7Wun88OcU68RXltrXYen7h2nfZx86gUB_zFPidNiYuH6-bIsDTtF6XKev-QTg5RRjijXrMNRjkGjxX-n5bw142aVjEO5YOW4kKB8k7YCWMSwiBePO7tAvBqGFHBxKQbHPscXHk_Cw6SOJi3GhRsLsTr0DvyuUyW3Ko0JaBEAs/s320/IMG_5610.jpeg" width="240" /></a></div><p></p><p>After realizing that the lower joint on the kickstart must be made from pure gold or the like (120 Euros), I decided to give it a shot and TIG-weld it together with some ER70S wire. Also no fancy cool-down procedures as for one I am sure that the thermal mass of this bit is just too small to make a difference (unless you chill it in water or oil) and also I am pretty sure this is just plain old cast steel. Closer inspection revealed that it had been welded before, which I thought was rather confidence inspiring. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEYbkgtOz7qoIxOKYjDwooc_Z9_6mLF2ADVNNkQHxxKJ3Y0It2RW-TCikLCoAe2UtKGJPQDtZyYO_eEtEb46O1-5COIT-QuyjlAvnrCLYqvj7dw-19WhLBv3rkxl5T8QxsWWQNfutgpJwimHadNaNaFlDu723UMGAIDhFtFtZa1ba4Q-KZuxb-uqGyAqE/s1600/IMG_5644.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEYbkgtOz7qoIxOKYjDwooc_Z9_6mLF2ADVNNkQHxxKJ3Y0It2RW-TCikLCoAe2UtKGJPQDtZyYO_eEtEb46O1-5COIT-QuyjlAvnrCLYqvj7dw-19WhLBv3rkxl5T8QxsWWQNfutgpJwimHadNaNaFlDu723UMGAIDhFtFtZa1ba4Q-KZuxb-uqGyAqE/s320/IMG_5644.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjACZQJNwBE070O7WKzYncGLbXDz-PoM6_BMkXM_xB1aZSszplalNZgNXoWlSQfxXiAOkwxyN44rOm08nRewGlbUXoJyIbBLeF06U8ukd-NUui9tnamjym7ibbWJQPKaL3Ftfq9faYgdQUu7ja0cR249jLvCdpnnWjL6bbyZz2RdQI80BbbctRMqCTyKPY/s1600/IMG_5645.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjACZQJNwBE070O7WKzYncGLbXDz-PoM6_BMkXM_xB1aZSszplalNZgNXoWlSQfxXiAOkwxyN44rOm08nRewGlbUXoJyIbBLeF06U8ukd-NUui9tnamjym7ibbWJQPKaL3Ftfq9faYgdQUu7ja0cR249jLvCdpnnWjL6bbyZz2RdQI80BbbctRMqCTyKPY/s320/IMG_5645.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWhpirWzCF7XtUObgRq61gXF0B2X6Qman59xqp9LKvVt1mFzy2mwNouodrAjE6KPyTTSgpyC70x5Q7OM3XqdlcsoVeXq3uX9nB038pLzUj7IDG3DXvzt_BJvpE7jpyiIqehYP_n9E6hv0H5J7fMFnXHzMHOYEM3zc-Mq78yvaaaFokxdDPZ8o4CdvZIBI/s1600/IMG_5646.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgWhpirWzCF7XtUObgRq61gXF0B2X6Qman59xqp9LKvVt1mFzy2mwNouodrAjE6KPyTTSgpyC70x5Q7OM3XqdlcsoVeXq3uX9nB038pLzUj7IDG3DXvzt_BJvpE7jpyiIqehYP_n9E6hv0H5J7fMFnXHzMHOYEM3zc-Mq78yvaaaFokxdDPZ8o4CdvZIBI/s320/IMG_5646.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2JctOyVBQpTl4qAtcnJG11Nm6LBlBrjxgEMwyRKWPTwtWAfF01bJKp997oisEvPsWnNJS4nyCxZk2R_HZvnOVreQ_u1QPFPl5gNsP13ti4XRAmwOWEkHCFQ52QhPskpaqwBEcBiG7oDpDEJ_oS0fcyTgIBxbDt1yOxsyaiojqvNb21o0zq5Lkw4wQFI0/s1600/IMG_5672.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2JctOyVBQpTl4qAtcnJG11Nm6LBlBrjxgEMwyRKWPTwtWAfF01bJKp997oisEvPsWnNJS4nyCxZk2R_HZvnOVreQ_u1QPFPl5gNsP13ti4XRAmwOWEkHCFQ52QhPskpaqwBEcBiG7oDpDEJ_oS0fcyTgIBxbDt1yOxsyaiojqvNb21o0zq5Lkw4wQFI0/s320/IMG_5672.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaqVpudu_g5QGhaA5IUL3K8pWIH4CBqFcE7F0a2M-HnwOE5iSRaCGiIB6PKlTWybHkl5kLFS2oOHtEC_MqwRWbLMpGhjoUO4aZv6f4WnUSHnba9OxqZ8-fIOpOukH5ae13UUa5PVQd8EQZBZhQ-s18ENAB_l6XD9jcIVcCPrP0mpXVQGeocRBphq1E4Rw/s1600/IMG_5673.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaqVpudu_g5QGhaA5IUL3K8pWIH4CBqFcE7F0a2M-HnwOE5iSRaCGiIB6PKlTWybHkl5kLFS2oOHtEC_MqwRWbLMpGhjoUO4aZv6f4WnUSHnba9OxqZ8-fIOpOukH5ae13UUa5PVQd8EQZBZhQ-s18ENAB_l6XD9jcIVcCPrP0mpXVQGeocRBphq1E4Rw/s320/IMG_5673.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiicnPuuZ1inHi6xaQafOa_Lb4jk6iYdD6mo5xXLjpwjbJJri5LpVvVfXLWad_NHm7KiZIKr1S27LOlrLrJWz8HLqSLze-dPc_ridy7jS6AmzMaI21ul4j9GhBjO_-s-qwGN51aIRRqcd5b0Acy79YVGtenuwRMVcYGq_ArmfNjdLZWjiwBRNxTcm541S8/s1600/IMG_5674.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiicnPuuZ1inHi6xaQafOa_Lb4jk6iYdD6mo5xXLjpwjbJJri5LpVvVfXLWad_NHm7KiZIKr1S27LOlrLrJWz8HLqSLze-dPc_ridy7jS6AmzMaI21ul4j9GhBjO_-s-qwGN51aIRRqcd5b0Acy79YVGtenuwRMVcYGq_ArmfNjdLZWjiwBRNxTcm541S8/s320/IMG_5674.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIi4i2twSJS2oQa9_a-_t3gdp6tG7wDDevOjgr185puqpoCjom_OM6IRuu_a36e9JMFPefmCfWSA8c5_Zck_KV-Vsit35cjF125ScEZfHZ9GhfmBettPC6a44_v5uRHLCMmrYtHSe2Cq_8f_6hGmtQv1YkLcnaqZx1nTVJoiAweInnOV0sWoleUBCqCno/s1600/IMG_5675.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIi4i2twSJS2oQa9_a-_t3gdp6tG7wDDevOjgr185puqpoCjom_OM6IRuu_a36e9JMFPefmCfWSA8c5_Zck_KV-Vsit35cjF125ScEZfHZ9GhfmBettPC6a44_v5uRHLCMmrYtHSe2Cq_8f_6hGmtQv1YkLcnaqZx1nTVJoiAweInnOV0sWoleUBCqCno/s320/IMG_5675.jpeg" width="240" /></a></div><p></p><p>This worked rather nicely and meant that all I had to do was tackle another elephant in the room: Whilst not an immediate MOT-failure, having no Neutral light was a tad annoying. Whilst I had visions of unwrapping the whole loom it turned out that the old neutral switch had failed and that was the only source for the catastrophic short. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEPBvFz6Qysl7ZOg3VMnSOE4mUhc_DayA_gb4IqAMR97EEbkIz-Q4_b0-Y0O92-RlpBDLUQJHeK5pEV2hE55tt7gNAZvNTDElOmbfJtw_wHJGO9udCECx9VMt9_RINvqIWnsXplMKx8ug6Txpp2kjdnvMeZf3D6I99ZZjcdjTDi3XuCkEKXH5xdImV8rQ/s1600/IMG_5648.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEPBvFz6Qysl7ZOg3VMnSOE4mUhc_DayA_gb4IqAMR97EEbkIz-Q4_b0-Y0O92-RlpBDLUQJHeK5pEV2hE55tt7gNAZvNTDElOmbfJtw_wHJGO9udCECx9VMt9_RINvqIWnsXplMKx8ug6Txpp2kjdnvMeZf3D6I99ZZjcdjTDi3XuCkEKXH5xdImV8rQ/s320/IMG_5648.jpeg" width="240" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje_uf_P5ZnDfb_e7Zskioc9Yb2-lIWK3XGkcAeGAbIFq4gBJqvLNcdt74TJltfh2ush82cWutYpUIgZqR9qpOGJ3ZXNDJK_37CN6yGeYnlvl4jiZms7DwUkZfaKpML6y-mB-_vhoW6kadFdMfgUfv-V2Xe1wlBqsCzsAviE1loK9pwRu6ygH1NQu85H9k/s1600/IMG_5652.jpeg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1600" data-original-width="1200" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje_uf_P5ZnDfb_e7Zskioc9Yb2-lIWK3XGkcAeGAbIFq4gBJqvLNcdt74TJltfh2ush82cWutYpUIgZqR9qpOGJ3ZXNDJK_37CN6yGeYnlvl4jiZms7DwUkZfaKpML6y-mB-_vhoW6kadFdMfgUfv-V2Xe1wlBqsCzsAviE1loK9pwRu6ygH1NQu85H9k/s320/IMG_5652.jpeg" width="240" /></a></div><p>To finish this post with a slightly sarcastic note: How do I make an XT600 engine last an extra two weeks? I don't ride the bike. 😐 Not entirely sure how things will progress in the long run, short term, I have a new downpipe and I will rebuild that muffler, because I have all the bits I need. I suppose, if someone threatened me with a handful of cash, I probably wouldn't say no. (Even though frankly I haven't got the slightest clue what to get instead.) On the other hand and that's the big dilemma, aside from the "reliability issues", I have pretty much molded it into the kind of 2-wheeled-walking-boot that I think is what truly the nature of this XT600 should be... <br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0tag:blogger.com,1999:blog-1405223789526143383.post-91840296302657263302023-07-19T20:00:00.004+02:002023-07-20T11:01:25.534+02:00Update & Outlook - a project overview<p>If the lack of posts on the blog indicates to you that I have stopped working on bikes and/or cars, I can assure you, quite the contrary is the case. As a matter of fact a metric sh*t ton of stuff is happening at the moment.</p><p><br /></p><p>1) Comrade Car</p><p>Well Comrade car is <b>very</b> close to being ready for registration. The main show-stoppers are that the workshop that has to do the inspection is currently enjoying their Summer break and the exhaust has to be wrangled in place a bit better. Other than that, he still needs a basic alignment, some electrical work and a new hose from the radiator to the expansion vessel. Oh yes and I'd better bolt that front bumper down and a testride that is more than a couple hundred meters in one direction might be a mighty smart move, before tackling the enormous distance of around 5 or 6 kilometres to the garage that will do the inspection. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJbdC17DIR0aV7UMP407JdcZvPOC6HtX-hSRd1Geavqru_YSp9AMPAe63W-7oZXvUSVRwQB2HL7gOsME9HYkAya6oRf3ZYgkKXzMauWYLj2P2-fKOjh52B5rmQ_0T9SuN2F5zK7ivfOt12ehgQwx9G_OSqV6-jDnU7TMmD-8J_AV5hEM54SHw9CM0Xf3E/s1280/Lada-all-painted-1.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJbdC17DIR0aV7UMP407JdcZvPOC6HtX-hSRd1Geavqru_YSp9AMPAe63W-7oZXvUSVRwQB2HL7gOsME9HYkAya6oRf3ZYgkKXzMauWYLj2P2-fKOjh52B5rmQ_0T9SuN2F5zK7ivfOt12ehgQwx9G_OSqV6-jDnU7TMmD-8J_AV5hEM54SHw9CM0Xf3E/s320/Lada-all-painted-1.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi73yFt2LH-EqTb0duBUajQstimdOKkIH3bsa5s8VoeQZ41-M1-Eg1t3VkU6WQ44H_-vC0dLXGhf5WKkNdYfMvNn1K9_yH_QFNlGEdeqSivWMLR5R1h2-0tY9zpoLCAcdvsQ6KrEEHCaXFW5VuxuTkKgHB-y1Ug8QbJDZaWpteEFOzUxhOg-2EbQAxH7pU/s1280/Lada-all-painted-2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi73yFt2LH-EqTb0duBUajQstimdOKkIH3bsa5s8VoeQZ41-M1-Eg1t3VkU6WQ44H_-vC0dLXGhf5WKkNdYfMvNn1K9_yH_QFNlGEdeqSivWMLR5R1h2-0tY9zpoLCAcdvsQ6KrEEHCaXFW5VuxuTkKgHB-y1Ug8QbJDZaWpteEFOzUxhOg-2EbQAxH7pU/s320/Lada-all-painted-2.jpg" width="320" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3P7bsG9_2SYZDyrXSEbqDUPEFxcQ4JUp2ASCCdu8dKpmbdZrwHaqXLlPDiEBwgVe5DE8fvHPAflb8oVHGveRuRAozCOmrtZmrp7cjItvUd7c_I20uU9DKnVYvhejZ519M8q4S7kcKa7OrA1p8fT2ZwQNf9Lay-GVv2Z4GlonTMNJxygOH7utasq8xwoE/s1280/Lada-all-painted-3.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1280" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3P7bsG9_2SYZDyrXSEbqDUPEFxcQ4JUp2ASCCdu8dKpmbdZrwHaqXLlPDiEBwgVe5DE8fvHPAflb8oVHGveRuRAozCOmrtZmrp7cjItvUd7c_I20uU9DKnVYvhejZ519M8q4S7kcKa7OrA1p8fT2ZwQNf9Lay-GVv2Z4GlonTMNJxygOH7utasq8xwoE/s320/Lada-all-painted-3.jpg" width="320" /></a></div><br /><p>2) Everyday TR1</p><p>About a month ago, I had to attend a business meeting in Salzburg and due to the heat the old girl's TCI (ignition box) decided to call it a day and most of the time only ran on one cylinder, so I limped it back home from all the way from Salzburg a couple hours later. I am now running a copy of the later twin-pickup plastic ignition box. Unfortunately this now sports a very different ignition curve and means I should dial in my carbs as it's running way too rich and that makes starting a real pain. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmECIyvKq3CuIHYKDQW2EYMukoo3KY7URVUQPQgN5DWuqAE_nEdKeGd4ujCSYmH4NLEn3tqMDosqs6r35mmNxw0QDzZ3sPdMoB7xkUmsQThXAk-w3fbc3nUl2sruG97YUPTvOZVYmwVzwQD4-BrbCHPDES11ynOHWJaWYflB4YX0_qEsKS4AYv7Iei0XQ/s1440/TR1-front.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="960" data-original-width="1440" height="213" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmECIyvKq3CuIHYKDQW2EYMukoo3KY7URVUQPQgN5DWuqAE_nEdKeGd4ujCSYmH4NLEn3tqMDosqs6r35mmNxw0QDzZ3sPdMoB7xkUmsQThXAk-w3fbc3nUl2sruG97YUPTvOZVYmwVzwQD4-BrbCHPDES11ynOHWJaWYflB4YX0_qEsKS4AYv7Iei0XQ/s320/TR1-front.JPG" width="320" /></a></div><p></p><p>3) Dre-XT-Stück</p><p>Guess what, the old girl killed another engine. The cylinder I bored must have been a) a bit too tight (well it was planned to be on the tight side for longevity), b) it was a cheap piston, which expanded rather and unevenly and c) I found the reason, why the previous engine overheated and which certainly didn't help during the last iteration. Words escape me to describe the level of butchering that the previous owner commenced in order to "repack it". Perforated tube in multiple sizes has arrived already and a few other "bodges" will be remedied shortly. <br /></p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8bdq2-camheD4ruVPfLWWml_OZRB11mWPnIsd8xTwjeFxf4Kw3YezipiYb8XYzuPuT9Ivgj-4WmXhS-zTCbDFUta65L6k_8PlP5ZMMTfBN-5ayOUEnYmRLMYicUZbv31PehBHn1QnnyB7kkeTYkyj_iEH5nYVg57HyM8kka9XKwiRdAO4u0Po5YDgCUA/s1200/XT-Auspuff1.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8bdq2-camheD4ruVPfLWWml_OZRB11mWPnIsd8xTwjeFxf4Kw3YezipiYb8XYzuPuT9Ivgj-4WmXhS-zTCbDFUta65L6k_8PlP5ZMMTfBN-5ayOUEnYmRLMYicUZbv31PehBHn1QnnyB7kkeTYkyj_iEH5nYVg57HyM8kka9XKwiRdAO4u0Po5YDgCUA/s320/XT-Auspuff1.jpg" width="256" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2r5N3aJq-kuU0o1wFLNd3rDkhAB_ZeppVP9ucMxFLQHt_Q91dXc5JcCBXMrIQTHf92YlVUiRcYumPXMhx51klDl9T3Rq-rjiAK40auyPnESYWJVtHlYYy2l6FGToVhsT1nHm6XfIoSnqyTiN7WSiJERpm8CNmoFblyOtejYKph7sdRj0fCHMjs-NE3oo/s1200/XT-Auspuff2.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2r5N3aJq-kuU0o1wFLNd3rDkhAB_ZeppVP9ucMxFLQHt_Q91dXc5JcCBXMrIQTHf92YlVUiRcYumPXMhx51klDl9T3Rq-rjiAK40auyPnESYWJVtHlYYy2l6FGToVhsT1nHm6XfIoSnqyTiN7WSiJERpm8CNmoFblyOtejYKph7sdRj0fCHMjs-NE3oo/s320/XT-Auspuff2.jpg" width="256" /></a></div><br /><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK-kkjyZ1MJg8pULbxT4_cCsyv1RGrE9iziXhEWqwxjvuQ5tmTKTIxmOsd7Dtdux8vUSkOBl44ttp9LstIHZxpLmt0QhVOJsvDZ7UCwlfwmnC34-Bu7xoG74DLciXwtrJkU5hoi5ZvzRgfJ1kd3wO8DgqNWTQncPUaXegZHmnwjpX1yNKc-w5R8P8iKkA/s1200/XT-Auspuff3.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1200" data-original-width="960" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK-kkjyZ1MJg8pULbxT4_cCsyv1RGrE9iziXhEWqwxjvuQ5tmTKTIxmOsd7Dtdux8vUSkOBl44ttp9LstIHZxpLmt0QhVOJsvDZ7UCwlfwmnC34-Bu7xoG74DLciXwtrJkU5hoi5ZvzRgfJ1kd3wO8DgqNWTQncPUaXegZHmnwjpX1yNKc-w5R8P8iKkA/s320/XT-Auspuff3.jpg" width="256" /></a></div><p></p><p>As the engine has died and I only had some good luck with exactly one type of piston so far, I decided to go with a forged 96.50mm Wössner with a moderate increase in compression (10.8:1) and had it bored at a local shop, which not only asked all the right questions, but also wasn't upset (after hearing the pre-text) that I wanted to check all the measurements myself. </p><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiv_JU_iobdNCIsVhAfnSfowW50K6u7vUT1VvsYw31tYWnAZyyTb_VZ3EEiEuSH2D4Pn_YaZQVJP1yLivu-TCsn2c65ow56I_3XYwrXAgV16hK8fcitZF4Iut79-7mM9lnZX4-4qhqEmfV0OJ5Dnm6dI-3kKfZfAgv0MWB_mrljm691EBo327xVLET0xcU/s1800/woessner8501d150.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" data-original-height="1800" data-original-width="1440" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiv_JU_iobdNCIsVhAfnSfowW50K6u7vUT1VvsYw31tYWnAZyyTb_VZ3EEiEuSH2D4Pn_YaZQVJP1yLivu-TCsn2c65ow56I_3XYwrXAgV16hK8fcitZF4Iut79-7mM9lnZX4-4qhqEmfV0OJ5Dnm6dI-3kKfZfAgv0MWB_mrljm691EBo327xVLET0xcU/s320/woessner8501d150.jpg" width="256" /></a></div><p></p><p>4) Little Miss Rat-a-Tat (SR500 Sidecar)</p><p>Yup, I have a smaller pilot and a slightly bigger main jet kicking about, which should help with fuel consumption and hot starting. Other than that I should really modify that sprocket carrier to work XT600 style as I am running on the only good rear wheel I have at the moment. <br /></p><p><br /></p>Nannohttp://www.blogger.com/profile/18115121287934034189noreply@blogger.com0