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Front suspension revisited


rockinroyston

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Thanks to a photo supplied by JIG I found the 'special Bolts' they were helpfully in the bag with all the rear brake pads... should have realised.. Also got another set in the post from Caterham so now I have spares....

So set to work on the front. No real issues & everything went on as expected.

Only drama of any note was the front ARB... as per everyones instructions I soaked with rubber lubricant & got the 1st rubber halfway down the first straight & then it seized solid... refused to move in any direction. Had it in the workmate & I could see I was starting to damage the powder coat... time to stop & have a cup of tea... once the brain cells picked up I decided to have a go on the other mount & this time I heated it up in some boiling water & the good idea of the day was to use washing up liquid instead of rubber lubricant. It almost ran onto the tube on its own! Just had to get the other one off so I tried the washing up liquid trick & eventually got it moving. My theory is the rubber lubricant is so thin it gets wiped off the inside of the rubber as you push it down the tube & then everything gets solid... the washing up liquid is thicker & creates better lubrication, well it did in my case!

So filled with over confidence I rushed to insert the plastic balls into the cups (which in my head would be easy...). First issue was the ball didn't want to go in at all.. pushed & shoved to the extent I almost knocked the car of its axle stands.. right stop... think. It appeared once I (cleaned the cup of grease) there was some powder coat getting in the way & also the ball had a bit of a casting mark around it... so out with the dremmel to do away with the excess. Tried again & it slid in fairly easily (unexpectedly)... but I hadn't put much grease in so I decided to take it out again... I must have twisted it & the ball crumbled into two halves... great... I had assumed the ball would be made of some high tensile nylon, but no it seems to be made with a hard crumbly plastic. e-mail to Derek admitting my failure & asking for another one :-(  Managed to get the unbroken one in once I had de painted (& greased up!). Not looking forward to putting the other one in tho. I hadn't taken on board how non compliant the ARB is, think I need to look at a few blogs before I try it...

So what else:

Horns... wow...

Dinotrolled most of the underneath of the car, few more cans required but the bulk has been done

Attached gearbox to engine, no issues

Attached engine to engine hoist & its apparent I need a couple of extra shackles for the engine leveler.

All in all a bit of progress made today & only one failure requiring Derek...

 

 

 

 

 

 

 

 

4 Comments


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Hi, Ive been reading your posts. Im coming to the end of my build now, and have shared many of the experiences that you have had so far. My advice for engine in based on my experience is take your time, right hand chain to load leveler needs to be shorter than left (the engine wont sit horizontally flat otherwise and will get caught on the transmission tunnel). I removed the alternator, plenum and r/h engine mounting bracket to aid getting it in. Also plenum off helps cooling pipe installation when you come to do that (mines a duratec). I also used a trolley jack to help get the gearbox into the final position. If you have the mazda 5-speed box then you may want to take the plug off the set of wires nearest the gear stick as these are not used and are pefect for when you connect up the reversing switch which is the set of wires furthest away from the gear stick (btw reverse switch is already connected on mazda box). Also not too much bubble wrap in the transmission tunnel as it gets all caught up. Its very tight going in. Hope this helps and enjoy. Getting the engine in is a massive milestone.

Nick

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Great to read your blog; keep going.

I think that too much grease on the ball joints can make them hard to get in. I made this mistake. Once I removed some, they slid in with less resistance.

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Thanks all just going through my bloggs & hadn't seen these replies, I thought you got an e-mail when people commented but obviously not!

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Thanks all just going through my bloggs & hadn't seen these replies, I thought you got an e-mail when people commented but obviously not!

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