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Post by R2S on Nov 14, 2015 22:02:12 GMT
Thought it did but wasn't sure as Ive removed ABS so no sensor cable. Thanks
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Post by john on Dec 5, 2015 18:12:36 GMT
How's it going R2S ? Just been removing my abs sensors and remembered your post. Need any pics or anything mine is a mk2 that had abs and now my chassis off but its still all together.
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Post by R2S on Dec 6, 2015 3:46:10 GMT
How's it going R2S ? Just been removing my abs sensors and remembered your post. Need any pics or anything mine is a mk2 that had abs and now my chassis off but its still all together. Thanks John, things have ground to a halt again as work and family commitments mean I have no time to work on the car. This is made worse by the fact that my workshop is 8 miles away, has no lighting and I have to carry all my tools back and forth so when I do get the odd hour at home where I could do the odd bit of work its not really long enough to load up the car and make the trip. Rest assured when work picks up I will take you up on offer of photos.
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Post by john on Dec 7, 2015 12:34:15 GMT
Ahh yeah its a busy time of year I manage to just keep stealing an hour here and there but thankfully garage is small but at home.
I'll take some pics as I'm currently thinking about brake line and fittings etc
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Post by R2S on Dec 7, 2015 15:25:40 GMT
Was thinking about Kunifer for brake lines but read somewhere it can be difficult to work. Already have the braded lines that fit into callipers.
In terms of work so far I have taken everything (and I mean everything) to pieces to either refurb or renew.
Brake Servo and master cylinder swapped for one from non abs car, unit serviced and painted (servo had external paint damage from previous brake fluid leak but was cosmetic only).
Callipers completely stripped, including the weird hand brake system, new piston on one of rears, all new sliders on rears and two new callipers (complete) at front all four painted with yellow brake enamel.
Last piece of the brake jigsaw is handbrake cables; I had to cut one off and am not keen on replacing only one so next purchase will be two handbrake cables.
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Post by R2S on Jan 18, 2016 8:43:07 GMT
May be a naive question but in the absence of a shearing machine whats best way to cut the supplied floor piece in half to get best finish? What have others done? Also has anyone used Teroson Terotape Seam Sealer?
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Post by stevednorris on Jan 18, 2016 15:47:11 GMT
I just used a jigsaw, cut it really well, just took a quick run over with a file to finish it off.
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Post by R2S on Jan 18, 2016 17:19:57 GMT
Having measured everything it will have to be a jig saw or something suitably thin (cut width that is) as supplied sheet is only 1250 and each piece should ideally be 630mm, if I am to have the 75mm side extension suggested in build manual. Did you use brush on seam sealer?
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Post by marmot0 on Jan 18, 2016 18:08:37 GMT
I used tigger seal on all the Ali to chassis joints
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Post by john on Jan 18, 2016 18:42:01 GMT
I used a nibbler on a drill did the job but jigsaw maybe better for such long lengths.
I used just a thin bead of sikaflex mainly to act as a cushion more than anything else between the panels.
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Post by R2S on Jan 19, 2016 21:15:07 GMT
Thanks guys, I need some more 16mm rivets which Screwfix stock so it looks like I'll pick up some sikaflex too (no local supplier of tiger seal) I' d like to get floor sorted this week in order to lift onto subframes next week.
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Post by john on Jan 20, 2016 20:48:06 GMT
What are the 16mm rivets for mate I think the floor ones I used were 20mm ones as I had to go and buy some more, my local tool places didn't have of the extra wide ones so ordered some online.
Agree about the floor the sheet it is just big enough , its a good day getting the floor on. Drilling 200 holes and 100 rivets was time consuming though but with air tools your probably going to sail through that bit.
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Post by R2S on Jan 20, 2016 22:31:18 GMT
The 16mm rivets are for the floor (Stuart suggested these ~ www.screwfix.com/p/flange-head-rivets-4-8-x-16mm-pack-of-250/76744). Yep air tools will be getting a good day out, saw, grinder, drill and rivet gun. Plan with floor, once cut and tidied, is to set all four corners using temporary fasteners and then blitz away at the holes before removing sheet, seam sealing, then back on and in with the permanent fixings, I expect it to take most of the day (assuming no problems ~ power cut last time I used workshop!).
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Post by R2S on Jan 21, 2016 16:24:51 GMT
As usual things didnt go quite as planned and only a couple of hours on the build today.
I needn't have worried about the dimension of the floor sheet as it turns out the frame is a different size on each side (no idea why I assumed it would be identical) and the pneumatic saw made short work of the cutting.
Was also surprised to find the cross rails for the seats on the passenger side aren't parallel to the end rails so good job I checked everything before drilling, drivers side floor now done with clecos holding in place until i can seam seal and then rivet.
Passenger side should be a quick job over weekend.
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Post by john on Jan 22, 2016 23:49:38 GMT
Glad to hear saw made short work, I didn't compare my floors left to right just marked it out and cut good luck over weekend and take your camera
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