Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Tell us your ongoing tales and experiences with your French car here. Post pictures of your car here as well.
User avatar
Zelandeth
Donor 2024
Posts: 4982
Joined: 17 Nov 2014, 00:36
x 1494

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by Zelandeth »

A box of goodies arrived yesterday morning for the Cavalier.

Image

Which despite the best efforts of Yodel who judging from the condition of the outer box had defaulted to "drop it from low earth orbit" as the preferred delivery method, all appeared intact.

Image

In here we have:

[] Air filter.

[] Front brake discs.

[] Brake pads.

[] Rear wheel brake cylinders.

[] Distributor cap and rotor arm.

[] Thermostat.

[] Spark plug set.

[] Fan belt.

The thermostat hasn't given me any indication of issues, but I've had mixed luck with them sticking after a while in cars which have been laid up so changing it feels like cheap insurance against that happening on the first long run the car does.

Things started out well...predictably.

Image

Distributor cap: Wrong.

Image

Rotor arm: Wrong. Though to be fair the one on there looks pretty much new.

Of course being from Autodoc there's no point in even trying to return them.

The air filter was at least correct.

Image

The one that came out wasn't too dirty but had been thoroughly squashed and was a loose fit in the housing. Reckon someone had put the lid on without properly seating the filter element in the past.

Image

Fan belt was slightly longer than the one already on the car but was well within range of the adjuster, so that was a nice simple swap.

Image

Neither the bearings in the water pump or alternator feel bad. There's a tiny bit of play in the water pump, but we're talking really tiny. Think I'm going to need to find something to use as a stethoscope to see if I can more accurately pin down where the noise is coming from. Failing that, wait until it gets a bit louder and becomes easier to track...

I've been pointed at a couple of marque specialists who look to have some parts I'd not yet been able to track down in stock, plus things like the correct ignition system bits. So reckon there will be an order heading their way soon.
Current fleet:
07 Volvo V70 SE D5, 88 Renault 25 Monaco, 85 Sinclair C5, 84 Trabant 601S, 75 Rover 3500, 73 AC Model 70.
User avatar
mickthemaverick
(Donor 2025)
Posts: 15934
Joined: 11 May 2019, 17:56
x 6771

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by mickthemaverick »

Zelandeth wrote: 26 Aug 2022, 11:48 Think I'm going to need to find something to use as a stethoscope to see if I can more accurately pin down where the noise is coming from. Failing that, wait until it gets a bit louder and becomes easier to track...
I always use a long shafted flat head screwdriver with synthetic handle. Stick the handle end into your ear and you can place the blade very accurately to listen to bearings, points etc. Been using it for 55 years and I can still tell the difference between the various noises you hear!! :-D
I used to be indecisive, now I'm not so sure!
I used to ride on two wheels, but now I need all four!
User avatar
Zelandeth
Donor 2024
Posts: 4982
Joined: 17 Nov 2014, 00:36
x 1494

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by Zelandeth »

Today was the day of waiting for tradesmen who were meant to be coming to do survey/quote work. Out of the four, one turned up. So I was left with a day where I couldn't really go anywhere or do anything major as I was waiting for them. Of course the one who did turn up did so within two minutes of the end of their 2-4PM window.

This meant it was a day of small jobs on cars etc.

First up was an oil and filter change on the Cavalier. The oil which came out was a lot dirtier than it looked on the dipstick and reeked of fuel, but there was absolutely no metal in it and while it was dirty there weren't any chunks in it.

Filter was well and truly stuck on there but eventually relented and came off.

Image

That's definitely been on there a day or two and had very nearly rusted through around the base.

Can't say I'm that thrilled with the replacement.

Image

I've never had any issues with Napa stuff personally, but a filter that's been sourced from an OEM so cheap they've not even put any form of markings on it save for a wonky plastic label just doesn't instill confidence. Methinks I'll be buying the next one from elsewhere so it can be a Mann, Wix or Bosch one. Takes the same filter as the Invacar I now know which is helpful as it minimises the difference things I need in stock.

Did notice something less than ideal when crawling around for the drain plug (which is quite awkward to get to because it's towards the rear of the sump and the engine is a long way back already).

Image

While I'd poked several bits of surface rust in the vicinity of this bit, apparently I totally missed this crispy but of chassis rail. It's absolutely not the end of the world, it's a simple rectangular box section so pretty easy to reconstruct, could have done without it though and I'm irked with myself for not spotting it before.

I did wonder if it was historic damage from jacking improperly or something, before I realised the cause.

Image

That damage lines up absolutely perfectly with the centre of the dent in the nearside door and the slight kink in the exhaust. Was clearly caused by the telehandler fork when the car was picked up (though it's obvious the area was weak before so would have needed work sooner than later anyway).

It's just never nice when you find structural bits that have turned crunchy.

Also noticed while changing the oil...I suspect I may need to come up with something more durable than duct tape to cover this unused PCV port in the rocker cover.

Image

Though it's clearly been on there a while and is well and truly stuck...guess it's a good demonstration that this engine doesn't have much blow by...

The oil is now looking rather cleaner, to the extent that it's kind of hard to see on the dipstick even after letting the engine run for half an hour or so.

Image

Was really quite surprised how little oil it took, pretty sure including the filter it was just under four litres. Was expecting nearer to five.

I get the impression that a new set of shock absorbers probably wouldn't be a bad idea. They're kind of crusty, though do seem to be working for now at least.

Image

Well nobody had showed up by then so I got the vacuum cleaner and cleaning supplies out and went after the interior.

Image

Image

Image

Image

Pretty sure this must have had a going over when it arrived with the previous keeper as aside from being a bit dusty it really wasn't bad. Though the plastics are basically just drinking the conditioner, which is why the dash top currently looks patchy.

Once the seats and carpets have been shampooed it will pretty much look like new in there I think. Even as it is, for a 44 year old car you can't fault how that's come up.

I really don't understand why car makers insist on making interiors so dull these days, what was wrong with a bit of colour? Is there some unwritten rule which says we can't make an interior look warm and inviting any more?

I did notice today that one of the headlights has previously been used on a higher trim level car at some point as it has a scratch on it from a wiper which this car has never had.

Image

Moving on from there I went and checked the various fluid levels on the rest of the fleet, checked all the tyre pressures, topped up the steering box on the van, and paired all my socks. Still no sign of contractors.

Turned my attention to the recently acquired bike. Main thing it needed was a fresh set of tyres. The ones on it were quite badly perished and were more off road focused than I wanted. An easy change.

Image

That quite predictably made a huge difference in how it rides - the difference in rolling resistance is truly remarkable.

Then gave it a bit of a wipe down, peeled some of the already disintegrating stickers off and replaced the smashed up rear mud guard.

Image

Need to investigate the play in the front fork top bearing and tweak my previous adjustment of the gear shift as I over compensated slightly when I moved the limit screw on the front gear set when I adjusted it last week. I'll also need to put a new rear reflector on, the original would have been totally obscured by the rear mud guard, so I'll swap it out for one on the seat post. I'm not too bothered about lights as I'll never be riding on road save for a couple of hundred yards to the cycleway here or after dark at all. If that changes I'll obviously fit a decent set. It's just something else to break/get nicked otherwise.

At this point the last of the four people who we were expecting actually appeared so I had to down tools - then get a whole day's worth of errands run after they were left in about an hour.
Current fleet:
07 Volvo V70 SE D5, 88 Renault 25 Monaco, 85 Sinclair C5, 84 Trabant 601S, 75 Rover 3500, 73 AC Model 70.
User avatar
Zelandeth
Donor 2024
Posts: 4982
Joined: 17 Nov 2014, 00:36
x 1494

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by Zelandeth »

Today is time for another dose of "occasional distractions" I think.

We have guests staying later in the week, so a lot of effort has been going into getting the house ready for that. By and large the heavy lifting is now done. Aside from another tip run or two and a deep clean throughout we're pretty much done. However this has made me reflect on the absolute disaster area that is my room. It basically looks like an explosion in a vintage computer museum, but slightly less organised. The main workstation now isn't far off how I want it. It's not perfect, but it's decent.

Image

At the weekend I spent a bit of time getting what is intended to be the "working on old computers and electronics" bench unearthed.

Image

You see that Mac SE there? The pile of detritus I moved where those two monitors was of sufficient size that it had been completely buried. It had been there long enough that I'd totally forgotten it was in there too!

Speaking of forgetting it...i'm not entirely sure if I have ever had the cover off it. I really ought to examine it in more detail to make sure there aren't any issues there with leaky RTC batteries or capacitors as I know these are issues that old Mac's can suffer from.

That's one tiny bit of desk though...probably the worst area of this room though is right here.

Image

That box on the top of those shelves dates back to when we first moved in - originally it was a box of miscellaneous cables etc...but has kind of snowballed to the point that I can now barely lift it, and it's a tangled mess of everything from USB cables to ATX power supplies, and I think I can even see a whole motherboard of some sort in there...but getting anything out takes about an hour because you have to unravel all the cables. It needs to be sorted...but I just don't have any proper storage.

We did pick up a cheap bookcase a few years ago...and I'd kind of pictured it going into the corner. However today when I started constructing it it immediately became apparent that it was far too shallow to be useful.

Image

That can go into the garage as I have an endless need of storage in there. Decided to instead carry out a bunch of measuring and throw a bit of money at the problem.

Image

I figured out that I can actually fit 18 IKEA Kallax cubes worth of storage in here. Two columns of six against the wall to the left in the photo above, and another six over by the door between the office and bedroom parts of the room (I may actually put that in the corner and shuffle the chest of drawers to the left).

This is going to be a bit of a game changer in here as the room has always been a disaster area. This has always been quite a barrier to actually getting anything done, so hoping having a place for things will help. Not spending 3/4 of an hour looking for the Windows 3.11 install discs would be a good start.

A box of things a friend had kindly passed my way was picked up today. This is mostly BBC related and will be staying in the box for now because the room is in pieces. One thing seemed worthy of immediate investigation though.

Image

Any guesses what might be inside?

Image

There we go, a 30Mb MFM hard drive on a hard card.

Image

Believe it or not, this is actually the first MFM drive I've had. I've confirmed that it spins up and does some sort of seek activity when fed power, but further testing will need to wait until the room is reconstructed. Imagine the old Compaq will be fine for testing this - I don't actually have any AT class machines with a full size ISA slot as all my 8086/8088 machines are laptops!

I'm not convinced it sounds exactly happy, but we will have to wait and see. Spindle motor seems happy though, it's far quieter than several other drives a good ten years younger than it (especially those made by Conner!) so hopefully it will come good.



One item in the box that will warrant further investigation is one of the ubiquitous Cumana 5.25" floppy drive for the BBC. I want to take a closer look at this as the Apple II "Super 5" definitely looked to be one of these sans the power supply with a seemingly clever ULA based adaptor providing the translation...I'd like to take a closer look to confirm this. If that is the case it would make diagnostics of that drive far easier if I could just hook it up to a PC, as I've rather more useful software available on there.

That will need to wait though as I need to finish disassemble most of the room next...let's see how much worse this gets before it improves.
Current fleet:
07 Volvo V70 SE D5, 88 Renault 25 Monaco, 85 Sinclair C5, 84 Trabant 601S, 75 Rover 3500, 73 AC Model 70.
User avatar
mickthemaverick
(Donor 2025)
Posts: 15934
Joined: 11 May 2019, 17:56
x 6771

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by mickthemaverick »

Zel, I have started clearing out my storage unit and am finding many things, One thing is a brand new sealed 25W D-D parallel computer cable which is of no use to me or worth trying to sell so its on the dump pile at the moment unless you have a use for it? :-D
Own work
Own work
Own work
Own work
Own work
Own work
I used to be indecisive, now I'm not so sure!
I used to ride on two wheels, but now I need all four!
User avatar
SwissTony
Posts: 55
Joined: 08 Jan 2022, 15:45
x 29

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by SwissTony »

I'm enjoying reading through your blog very much, especially the Cavalier. But, pray tell, what is more durable than duct tape? I'm not sure such exists ;)
2011 C3 Picasso in black - The love wagon.
2016 BMW F800R - the throbber between my legs.
User avatar
Zelandeth
Donor 2024
Posts: 4982
Joined: 17 Nov 2014, 00:36
x 1494

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by Zelandeth »

mickthemaverick wrote: 31 Aug 2022, 14:32 Zel, I have started clearing out my storage unit and am finding many things, One thing is a brand new sealed 25W D-D parallel computer cable which is of no use to me or worth trying to sell so its on the dump pile at the moment unless you have a use for it? :-D

Image

Image

Image
Not something I've ever needed before, but as I'm getting more and more into older systems it could be useful.

Today we waved goodbye to the BX.

Image

Don't worry, it's gone into the hands of another enthusiast and should have a bright future ahead. My plan with that car had always been to ensure it was safe when the prior owner lost their storage, and to make some improvements. If it had been an easy run to an MOT that would have been nice, but I was never wanting to get into dropping subframes to rerun major hydraulic lines.

The new owner already has some beige PSA metal on the driveway so the BX will be in good company.

The "let's make the room be less of a disaster" project has officially begun.

Before:

Image

After:

Image

Think that's making a bit more efficient use of the space. Especially as it now has given me somewhere to put the really awkward and annoying things like these.

Image

Being able to slot a 12" CRT into a shelf in here is a nice bonus, I was fully expecting that to be relegated to the loft. Having somewhere to put the steering wheel and pedals is also great as that has to be *the* most annoyingly shaped thing in the history of the universe to try to store if there's not a big enough slot somewhere for it.

The drawers which have been categorised so far are:

[] Power supplies and power cables.
[] Internal computer cabling and similar. Also small internal items like fans, drive bay adapters etc.
[] Flat computer parts - so expansion cards, motherboards, the bag of memory etc.
[] External computer, audio, video cables and adapters.
[] Computer peripherals and similar small items.

The rest is just assorted misc so far. It will be properly sorted once we're done with the destruction and construction phases.

On the other side of the room we had a similar scene of chaos to start with.

Image

Which now looks like this.

Image

There's another two cubes to go on there yet to take it mostly up to the ceiling as in the first corner. That requires me to truncate the existing shelf above there. That's a job for another day. I've just thrown things back in there pretty much at random too as I wanted to gain access to the bedroom again. The car magazines for one will be going.  I think every issue of Practical Classics and Top Gear from mid 2014 to the current day is in there.  Just taking up way, way too much room.  I'd far rather use the two cubes they're taking up for computer things!  This set I'm planning to be the main media storage, I don't have a massive amount of software on CD/DVD, but some (which I can never usually find) and a metric tonne of floppy discs, so having an actual home for those will be nice.  Especially as I can actually have a separate area for software, OS etc and blanks.  Luxury! I would like to move the hard drive stash over there too rather than having the precarious pile over the main desk that I can't really properly reach.

The shelf above the fish tank I may well replace with a similar unit hung from the wall (using suitable hangers!) rather than the random bit of board offcut that's currently up there.  That is mostly just stuff for the fish (aside from the fridge with is full of film), but it could be made a lot tidier.

May well do the same over the main workstation too...this place has never not been a mishmash of random cheap bits of shelving, offcuts and whatever I had laying around...the idea of it actually not looking like absolute rubbish is actually kind of appealing now there's starting to be a little order to some areas.
Current fleet:
07 Volvo V70 SE D5, 88 Renault 25 Monaco, 85 Sinclair C5, 84 Trabant 601S, 75 Rover 3500, 73 AC Model 70.
User avatar
mickthemaverick
(Donor 2025)
Posts: 15934
Joined: 11 May 2019, 17:56
x 6771

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by mickthemaverick »

In that case I'll start a new box for 'Zel's Stuff' and put it in there. Anything else I find, which I will, can be added and then I can drop the box off when next in MK area. Could be a couple of month's time but it's better than sending good stuff to the dump! :-D
I used to be indecisive, now I'm not so sure!
I used to ride on two wheels, but now I need all four!
User avatar
Zelandeth
Donor 2024
Posts: 4982
Joined: 17 Nov 2014, 00:36
x 1494

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by Zelandeth »

Unsurprisingly not been much going on over the weekend between initially having guests arrive then immediately being plunged into isolation when one of them tested positive for COVID on the first evening here. Not really the weekend we'd planned.

This afternoon I escaped outside for an hour though determined to do...well...anything useful.

So targeted the fuel system on the Cavalier. The main tank to front line on this is nylon and is in fine condition so I see absolutely no reason to disturb that. The rubber line from the tank to that nylon line has already been changed (it was leaking back when the car was at it's previous home), however the front end lines haven't been touched any time recently. The one that goes to the carb was way too long as well and would get in the way of the (missing) warm air duct from the manifold. This car has worn a plethora of carbs when a historic running issue was fought with so that may well explain why the routing seemed odd.

A quick careful reshape of the steel line and a shorter length of hose made things far tidier on that side.

Image

The other side of the engine is a little more awkward as the fuel pump from the engine bay is totally hidden by the alternator - access from underneath is fine though.

Image

I've replaced the inlet side hose there, outlet will have to wait as I don't have any more fuel hose clips the right size and don't want to reuse those jubilee style ones.

I added an inline fuel filter as well as there was no evidence of one having been fitted anywhere before.

Image

The suction side lines that came off are branded GM. Makes me wonder if these might even be original.

Image

I'd have expected fabric covered lines probably given the age, so reckon they're replacements off a later car - quite prepared to be proven wrong though. Not in terrible shape but they were just starting to go.

Managed to get the traditional oily handprint somewhere.

Image

Very much looking forward to getting the engine bay in this car...getting fed up with getting covered in grime every time I touch it.
Current fleet:
07 Volvo V70 SE D5, 88 Renault 25 Monaco, 85 Sinclair C5, 84 Trabant 601S, 75 Rover 3500, 73 AC Model 70.
User avatar
Zelandeth
Donor 2024
Posts: 4982
Joined: 17 Nov 2014, 00:36
x 1494

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by Zelandeth »

It's been a little while since I've had time to do an update so time for a bit of a catch up.

Giving the engine bay a bit of a clean up had been very much on the wishlist since the day the Cavalier arrived. It really wasn't bad given the age of the car, but nevertheless was grubby enough that whenever you touched anything in there you got covered in gunk. It needed a clean.

Image

Especially down here.

Image

The underneath of the bonnet was pretty unpleasant too.

Image

A not insignificant amount of degreaser was deployed and left to soak for a bit while the pressure washer was dug out and set up.

Image

After 20 or 30 minutes things looked quite a bit better.

Image

Image

Image

It's not perfect but has got rid of most of the major grime and will make working on the car a lot less unpleasant. I was really surprised that I didn't even need to crack out the WD40 to get it started after the cleaning, it just started up as though nothing had happened.

I did give the rest of the car a once over while I had the pressure washer out. Difference isn't that dramatic from a distance.

Image

Image

However if you looked up close before and after the amount of moss, lichen and general gunk that was blown out from the gutters, around badges, under trim etc was quite impressive.

The amount of surface grime that was blown off the paintwork was also actually visible.

Image

Will still need some major attention with the polisher before it's actually shiny, but at least it's vaguely clean now.

Other paintwork issues included this blue overspray on the nearside rear quarter.

Image

I wanted to see whether this would just buff off with some cutting paste. Turns out the answer is yes, which also gives us a glimpse of the actual colour the car will be once cleaned up.

Image

I would have liked to finish that panel but it decided to start raining then which meant I had to abandon it right after that photo was taken.

For a normal family car from the closing years of the 1970s there is a surprisingly large amount of brightwork on this thing, all of which is quite dull. Unfortunately there are dents in both the front and rear bumpers, but the chrome work itself seems in good condition. I hit one little spot on the rear with some Autosol polish to see how it would clean up, the results are encouraging.

Image

Getting that all polished up will make quite a big difference to the car I think. Yes by the way, that did actually happen before the cleaning at the start of this post, hence all the gunge you can see under the trim on the rear quarter.

Work on the braking system has now commenced. Before I could do much I needed to confirm exactly what type of calipers I had fitted. Knowing they both need attention (or replacement) I figured pulling one off the car for inspection was a good starting point.

Based on prior experience on other cars I was expecting this to be quite a war, likely involving several hours of me smacking myself in the face with breaker bars and swearing at the car. The caliper to hub mounting bolts are (for good reason) generally very tight, and given the low mileage of this car quite likely have never been removed before.

I was thrown a bit of help on this one though as I have enough room to get the impact gun in there.

Image

This rattled the bolts off in a few seconds each, so I had the caliper off the car and in my hands in about ten minutes, including jacking the car up.

Image

Image

Image

The inboard piston retracted quite readily (thankfully as there's quite a lip on the discs so I'd not have got it off otherwise), the outboard one however is quite firmly stuck. I know the discs are shot which is why new ones are already in the boot.

I need to have a look around and find out whether these calipers are readily available for sane money or whether I need to look at rebuilding these ones (or getting a professional to do it for me). I'd probably opt for replacement as my first choice as it gives me a good "it should just work" solution without me needing to buy any more equipment I don't already own. I do already have new wheel cylinders for the rears in stock, though I'm giving those the chance to work before I condemn them as I've generally had pretty good luck with them before and this car has not been sitting *that* long in the grand scheme of things. I'd rather not wind up having to replace all the rear axle hard lines (which from memory look to be in good shape) if I don't need to because I'd tried to remove a wheel cylinder that turned out to work just fine.

Once the brakes are sorted the main thing between it and a careful barely above walking pace trundle round our estate will be getting this previous welding repair that has failed sorted. Given the proximity to the subframe mounting I'm not willing to drive the car until that's been sorted.

Image

The other two sides of that box section feel fine and access is decent with the wheel off so I'm hoping this won't be the worst repair to do. As far as I'm currently aware this is the worst bit of rust on the car, and it's not a surprising one as it's a very common place for these cars to go from what I've read. The other welding needs doing before the car is used in anger, but it's nothing which concerns me for a sub 20mph trundle on very quiet roads, that bit though is firmly under the "it ain't going nowhere unless it's on a trailer/transporter until that's fixed" category.

Which brings us up to date I think.
Current fleet:
07 Volvo V70 SE D5, 88 Renault 25 Monaco, 85 Sinclair C5, 84 Trabant 601S, 75 Rover 3500, 73 AC Model 70.
User avatar
CitroJim
A very naughty boy
Posts: 52784
Joined: 30 Apr 2005, 23:33
x 7241

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by CitroJim »

Excellent 😀 Loving reading all about the Cavalier restoration project Zel... Keep up the great work 😉

Sorry to see your BX go but happy it's to a good home...
Jim

Runner, cyclist, duathlete, Citroen AX fan and the CCC Citroenian 'From A to Z' Columnist...
User avatar
Zelandeth
Donor 2024
Posts: 4982
Joined: 17 Nov 2014, 00:36
x 1494

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by Zelandeth »

After a certain amount of patience, brute force, swearing and assistance from compressed air (seriously, how did I function without having compressed air on tap in the garage?) we have had some success getting movement out of the caliper I've taken off the Cavalier.

Image

That piston is moving relatively freely. I reckon once it's cleaned up it will probably be okay. The other piston is moving pretty readily for a few millimetres, but nothing beyond that. Most likely because there's a rust ridge we need to get past. I ran out of time when I was working on it on this occasion but we'll get back to it soon.

TPA has been out and about again doing normal car things. Realising that as we're getting further on in the year probably won't be all that long until she's tucked up for the winter. So taking advantage of the decent weather to get her out for a good run.

Image

Figured as it's been absolutely forever it feels like since I really did a proper inspection of the drive system it was about time I did.

I finally seem to have pretty much got the knack of installing and removing this cover.

Image

Usual slight misting of oil from the gearbox output shaft but it doesn't seem to have got any worse. The level has never dropped between me checking and changing the oil so I'm not worried about it. It only takes a tiny amount of something as sticky as EP90 to look horrendous.

So let's take a closer look.

Image

Belt looks to be holding up just fine. This will have probably somewhere in the ballpark of 3,500 miles on now I think. I'll need to look up the logbook to confirm the exact number. Definitely is a bit of wear there but nothing which alarms me.

Image

Pulley surfaces are looking fine.

Primary:

Image

Secondary:

Image

There was some slight surface tarnish on that when it went on, doesn't look any worse now.

What I did find however was that the bolt on the primary had backed off slightly. There was no actual movement in the pulley itself (it's a very snug fit on the gearbox output shaft), but that washer behind the bolt was free to rattle around. I was able to get maybe 3/4 of a turn out of it.

Image

Used an extension bar to lock the pulley in place.

Image

Given that the slightly metallic rattling noise at low speed that I've had for as long as I can remember now seems to have gone away I reckon this may have been slightly loose for a long time. I think I will look at making up a locking tab for that bolt as that coming properly loose at speed Would Be Bad. Though I think you would get plenty of warning as before it could come out the bolt would hit the inside of the service hatch I think, so would make all the noise ever.

In the meantime it's been done up Quite Tight, and a decent blob of Loctite has been applied.

Image

This is a good example of why preventative maintenance is a good thing. I have checked on the belt visually from the engine bay regularly, but it's well worth getting right in here now and then to check on things.

Also found a ball joint where the metal clip holding the dust cap on has rusted away. Otherwise seems fine still so will just replace the clip if I can find one the right size. Failing that I do have a full set of replacement ball joints in stock if necessary.

Something I want to try is a little bit of experimentation with drive pulley spacing. The only thing I've noted with the HP2020 belt versus the standard one is that it drops into "overdrive" slightly earlier than the book says it should. Given the dimensions are essentially identical I'm guessing the difference there is in the actual weight of the belt. It's a very low priority task and is only really noticeable when accelerating from a standing start on a gradient, but now it's stopped being a million degrees outside I might be more inclined to try tweaking it a little. My guess is that we need a fraction more tension on the belt.
Current fleet:
07 Volvo V70 SE D5, 88 Renault 25 Monaco, 85 Sinclair C5, 84 Trabant 601S, 75 Rover 3500, 73 AC Model 70.
User avatar
Zelandeth
Donor 2024
Posts: 4982
Joined: 17 Nov 2014, 00:36
x 1494

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by Zelandeth »

That piston cleaned up not too bad. Some surface tarnish, but nothing too dire.

Image

This piston moves easily and smoothly by hand, so I'm not going to pop it out for now. That would simply ensure that I absolutely definitely would need to change the piston seal. I've given it a dose of rubber grease, refitted the (cleaned) rubber boot and am leaving it be.

The other piston however is still refusing to move fully out. I'm struggling to get any real force on it and can't really apply heat because I'm having to hand hold the caliper while working on it. This really is one of those jobs which would be a thousand times easier if I had a workbench with a vice handy.

Given that I'm struggling with this one piston already and I know the driver's side caliper is even worse (it had to be split and the pads removed to get the car rolling originally I'm told), I think that I'm going to hand this job off to a professional outfit. Once I've got both calipers off I think they'll be getting sent off to Bigg Red Brakes to be refurbished. I know a few folks who have used them, and have had nothing but praise. That's good enough for me. I'd personally trust a set of professionally rebuilt calipers than some random no-name set from goodness knows where that eBay claims will fit...

Rears at least are simple as the cylinders were readily available for something silly like £6 each for good branded ones (which I already have). Those I'm giving the opportunity to work before I pull stuff apart - I've had pretty good luck with drums before, so we'll see.
Current fleet:
07 Volvo V70 SE D5, 88 Renault 25 Monaco, 85 Sinclair C5, 84 Trabant 601S, 75 Rover 3500, 73 AC Model 70.
User avatar
mickthemaverick
(Donor 2025)
Posts: 15934
Joined: 11 May 2019, 17:56
x 6771

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by mickthemaverick »

One of the last things I am about to chuck out of the workshop is an old workmate and clamp on vice. Any use to you Zel? I' ready to bring up your crate and Jim's book once we can sort a day you are both around.
I used to be indecisive, now I'm not so sure!
I used to ride on two wheels, but now I need all four!
User avatar
bobins
(Donor 2025)
Posts: 6400
Joined: 05 Jul 2012, 18:07
x 3304

Re: Zel's Fleet Blog - BX, Jag XJ-S, Sinclair C5, Mercedes 208D & 230TE, AC Model 70.

Unread post by bobins »

I've seen a grease nipple fitted to the brake pipe hole and a grease gun used to wind up enough pressure to force out a stuck piston - but frightening amounts of force were needed :shock: