Ol' Rusty - FB/EK Sedan

Post photos of your pride and joy, or updates on your rebuild!

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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Been a minute. Tinkering away but not much going on. Just making stuff shiny with a new bench top polisher that I got to complemnt/replace the angle polisher set up I made which was pretty loud when running.
Bought some stainless coach bolts to replace the chrome ones in the bumpers. Getting imperial in stainless is next to impossible from where I have searched on the internet, so metric it is. M8 and M10 for the rears.
First polish - straight out of the packet at the bottom and polished holding the bolt precariously by hand
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Second Attempt. Got smart and put the bolt in a drill. Results and pretty good, initial polish on the left, drill on the right. Take a couple of minutes per bolt.
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Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
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Errol62
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Re: Ol' Rusty - FB/EK Sedan

Post by Errol62 »

You’re a clever bugger Scott!


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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Errol62 wrote: Fri Aug 16, 2024 8:22 am You’re a clever bugger Scott!

Not when it comes to storing pool fencing :roll:
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Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
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Errol62
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Re: Ol' Rusty - FB/EK Sedan

Post by Errol62 »

Nothing broken? Clever. Otherwise, unlucky…….


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Blacky
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Re: Ol' Rusty - FB/EK Sedan

Post by Blacky »

Errol62 wrote: Fri Aug 16, 2024 7:08 pm Nothing broken?


:crazy: :crazy: :crazy: :crazy: :lol: :lol: :lol: :lol:
I started with nothing and still have most of it left.


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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Errol62 wrote: Fri Aug 16, 2024 7:08 pm Nothing broken? Clever. Otherwise, unlucky…….
Too true!

Discovered the hard way that a tiny slope, gravity and roughly 400kg of glass strapped down with the help of 3D printed brackets is not the ideal way to store it.

Lasted 8 week in wind and rain then decided to fall over on a calm afternoon. Maybe my regular shaking to make sure everything was still tight was not the smartest idea. :lol:

On the plus side - the cost of glass has dropped (pun intended) over the last 14 years so it is relatively cheap to replace.

Just need to get this deck done then back onto the car.... been a slow winter.
Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

So back in May the plan was to reco my EH steering box using a rares kit.
Ordered an adjustable hand reamer (23 - 27.5mm) and asked my old man to source a large tap to assist the bushing removal. (4 month later and I’m still waiting on that tap.)
Rares kit arrives and after comparing it to what I pulled from the HR box I am now thinking I don’t need the kit. The bearings and races are in really good condition, and the bushes in the EH box are not sloppy with the HR sector shaft roughly fitted.
Only one way to find out and that will be to rebuild the EH box with the HR internals and see how it feels on the car for play. Won’t be able to test it in anything other than the vice for now but curious to know.

The ends of the splines on the shaft have been mashed a bit and are preventing the my pitman arm from fitting very well.
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So out with the file for a quick chamfer.
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Used a flat bladed screwdriver to tap out the HR bearing cup. These two recesses in the steering box are your friend when removing.
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Everything into an ultrasonic kero bath. Monitored temperature so as not to let it get too hot (google says flash point of kero is between 37-65C). I stop when it gets to 35 C. Clearly not a risk taker!
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Initial fitting of the bearing cup into EH box.
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In my ‘lathe’ I turned a washer down to the OD of the bearing cup.
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Final fitment with bolt/washer/socket combo pulling the bearing cup into place.
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Result
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Then it was just a matter of greasing everything and fitting. No photos as this was all dirty work.
Putting all the balls back in the nut was not as hard as I thought it was going to be.
Left the bearing cup in the HR adjusting nut and swapped it for my EH one.
There was minimal slop between the HR sector shaft and EH bushes, and the shaft moved freely so for now I’m going to leave it at that. Got the overhaul kit for future Scott if he needs it.
Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
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funkyscooter
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Re: Ol' Rusty - FB/EK Sedan

Post by funkyscooter »

Next is a seal for the top of the box to the steering shaft. At the moment the seal is for the selector shaft.
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I cut one down and my first thought was to fit o-rings between the steering and selector shaft segment to seal the gap and have the selector shaft turn with the steering wheel. But that feels a little hokey and I don't think the o-ring is up to the task. So I have been looking for a seal to fit the dimensions of steering box ID 33.4/ steering shaft OD 17.4mm/ seal width 6.35mm. Closest so far is 33/18/7 which is too loose in the housing, but fits nicely on the shaft.
What have others done to their modified steering box to seal them up?
Scott
(Not so rusty) Ol' Rusty - FB/EK Sedan
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