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 Post subject: Little Will work
PostPosted: Sun Jun 09, 2013 9:41 pm 
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Group N

Joined: Tue May 01, 2007 9:21 pm
Posts: 212
Location: lancashire
Car Model: None
I had Wills car in for what was supposed to be just clutch and bc coilovers welding and fitting but on inspection of the car it proved that there was a lot of underlying problems so heres some more pics of problems and repairs for you all

Firstly onto the Bc coilovers and clutch renewal

Top ball joint boots split

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New top ball joints fitted with special tool I had made years ago to stop the risk of any damage to the new ball joint

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Bc coilovers fitted

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Martin

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 Post subject: Re: Little Will work
PostPosted: Sun Jun 09, 2013 9:56 pm 
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Group N

Joined: Tue May 01, 2007 9:21 pm
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Location: lancashire
Car Model: None
Old worn out clutch

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New helix clutch and genuine toyota release bearing

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Martin

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 Post subject: Re: Little Will work
PostPosted: Sun Jun 09, 2013 10:13 pm 
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Group N

Joined: Tue May 01, 2007 9:21 pm
Posts: 212
Location: lancashire
Car Model: None
While inspecting and dismantling subframe etc, a few issues were found one being very worn no.1 arms so heres a little video to show the wear in one of the arms

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Banana bar bolts loose causing crush tube failure

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Replacement no.1 arms fitted with my own uprated crush tubes

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Martin

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 Post subject: Re: Little Will work
PostPosted: Sun Jun 09, 2013 10:22 pm 
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Group B
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Joined: Sat Sep 02, 2006 3:13 pm
Posts: 3679
Location: Bournemouth
Car Model: None
I'm glad to see people using the genuine toyota release bearing on aftermarket clutches. Having witnessed Daryls failure after 18 months on a clutchmasters one (noisy within 6 months) I wouldn't touch anything else.

You say your own version of uprated crush tube. What do you do different to others out of interest ? I've thought about getting shoulder bolts made - getting round the problem of removing uprated crush tubes at a later date.

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 Post subject: Re: Little Will work
PostPosted: Sun Jun 09, 2013 10:41 pm 
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Group N

Joined: Tue May 01, 2007 9:21 pm
Posts: 212
Location: lancashire
Car Model: None
Exhaust was a 3" system and as usual it was jammed up on subframe, gearbox and rear floor pan, it had also been butchered to try cure this so it was time for it all to be cut out and remake a new system from front of subframe to the rear silencer.

Just so people know I do all this myself in house, ive never really shown that me and scott both do all types of custom fabrications ourself in house, I have mig and tig welders and thought it was about time I showed this side of my skills, been mig welding from an early age as I learnt myself by welding up cars at home and used to get all my tig welding done by a fabricator but decided a while ago to teach myself aluminium and stainless tig welding so that would be another thing we can do in house, I have to say I found it harder than mig welding but am sure you will all agree its now coming on nicely :D

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Due to the strain on the exhaust system it had near completely cracked off and also cracked the mid silencer

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Exhaust cat studs were damaged and some snapped when removing

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Turbo to manifold gasket was cracked and starting to blow very slightly

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So turbo was removed

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New gasket fitted

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Martin

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 Post subject: Re: Little Will work
PostPosted: Sun Jun 09, 2013 10:51 pm 
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Group N

Joined: Tue May 01, 2007 9:21 pm
Posts: 212
Location: lancashire
Car Model: None
Nibbles wrote:
I'm glad to see people using the genuine toyota release bearing on aftermarket clutches. Having witnessed Daryls failure after 18 months on a clutchmasters one (noisy within 6 months) I wouldn't touch anything else.

You say your own version of uprated crush tube. What do you do different to others out of interest ? I've thought about getting shoulder bolts made - getting round the problem of removing uprated crush tubes at a later date.


Hiya chris

Its the only release bearing I will use, every clutch I do I try my best to get the customer to let me fit a genuine toyota release bearing purely because of what you have mentioned, I have also come across this a few times

My crush tubes are aluminium as well but they are longer, so far I have found all people apart from mrbarry selling the uprated crush tubes have not actually measured what dimensions the tube actually needs to be, they are all too short and once you install them you have to mess about aligning everything, with mine they keep the arm perfectly lined up.

Imo the crush tubes main purpose is a guide to be sure the banana bar is locked up evenly and edges are flat together, ive not had any issues with mine locking up in the banana bar as I make sure everything is cleaned up properly and then plaster them with grease before installing them and its so far soo good :)

Martin

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 Post subject: Re: Little Will work
PostPosted: Sun Jun 09, 2013 11:44 pm 
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Joined: Thu Jul 14, 2005 12:44 pm
Posts: 4067
Location: drinking devil fuel
Car Model: ST205
One thing I'd like to see is a coarse square thread cut on the outside. It achieves two things
When the alloy and pig iron do fuse it's only 50% of the surface area
You have a chance of belting a torx/Allen bit up the bolt hole ans winding it out

I appreciate the extra cost would deter many but for a long termer like me it would be a USP worth paying for


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 Post subject: Re: Little Will work
PostPosted: Tue Jun 11, 2013 10:50 pm 
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Group N

Joined: Tue May 01, 2007 9:21 pm
Posts: 212
Location: lancashire
Car Model: None
two_OH_five wrote:
One thing I'd like to see is a coarse square thread cut on the outside. It achieves two things
When the alloy and pig iron do fuse it's only 50% of the surface area
You have a chance of belting a torx/Allen bit up the bolt hole ans winding it out

I appreciate the extra cost would deter many but for a long termer like me it would be a USP worth paying for


Could be a good idea that :)

Martin

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 Post subject: Re: Little Will work
PostPosted: Tue Jun 11, 2013 10:50 pm 
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Group N

Joined: Tue May 01, 2007 9:21 pm
Posts: 212
Location: lancashire
Car Model: None
So onto the exhaust repairs and fabrications, firstly I need to repair the cat studs or in this case drill out snapped studs and repair threads

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Then onto tig welding repair of the sheared exhaust at the front flange

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The rest of the pics are in no particular order but show the fabrication work I can do, this sia full 3" exhaust sytem that does not catch anywhere or vibrate at all, will can back me up on this

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Flanges were tack welded on the outside in 4 places purely to hold position and then seam tig welded inside so as not to interfere with bolting up plus it is much neater :D

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Stainless flexi welded in, these flexis are fully stainless apart from the external flanges which are galvanised

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Martin

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 Post subject: Re: Little Will work
PostPosted: Thu Jun 13, 2013 9:17 pm 
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Group N

Joined: Tue May 01, 2007 9:21 pm
Posts: 212
Location: lancashire
Car Model: None
Car also was in desperate need of brake pads also the tension clips were in the wrong orientation

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New genuine toyota brake pads fitted to front

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Then onto the rears which proved a bit more problematic as pad retaining pins were seized in the calipers so it was caliper off into the vice and drill them out

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Whilst caliper was removed discs were removed and handbrake shoes checked and deglazed then discs refitted and handbrake adjusted

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Then new genuine toyota brake pads and retaining pins fitted

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Martin

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