I slept from 4.30am to 9.30am this morning so still a bit seedy but once I woke up I wanted to get straight into the car and did so with gusto. I didn't rush it however, I'm not retarded. I did everything right and made a nice job, if I say so myself. I took progress pics all the way along and a few shots once it was finished. It is as clean as the day it was made except for the usual varnishing on the exhaust manifold that comes from castor oil in the fuel.
LOCTITE THREADLOCKER - SUPER NUT LOCK - I used loctite nut locker on the screws for the new pull starter and on the exhaust manifold so they won't rattle loose in a hurry. It is great stuff and I took a pic of the bottle so you guys can go find it. You can buy it from engineering supply shops such as blackwoods and paykels and maybe at bearing shops such as saeco etc. Maybe from repco or supercheap auto but not sure on them. Anyway, it only works where you're screwing into metal, not plastic, and also works great on nuts-n-bolts. It sets anaerobically: meaning where no air is present, so doesn't go hard until the screw is tightened in place then it sets solid. You can still get the screws out later though so don't worry if you think it's in there forever - you can still uno it. Cost is about $16 a bottle and you only use 1 drop on most little screws.
You can see in the pics I have used the largest spacers for the springs making them rock hard, perfect for hard-nuts racing. No-good for off-road but I intend to stay firmly on the tarmac anyway so it's just what I wanted. There is no droop at all - when I put the car down it stays up on the shocks and doesn't sink down to halfway down the travel.The back end is sitting 16mm front the ground to the underside of the chassis plate and the front 18mm (measured at the front end of the radio box and before the bend in the nose of the chassis). I think they rally tyres contribute about 1 or 2mm to the height so once I get road tyres it should be a fraction lower. I'm not worried about slamming it to the ground at this point, maybe later if I pump the shocks with 100 weight shock oil or upgrade them completely.
The front right-side shock is slowing a hint of weepage so it needs a bit of attention. As I had stated earlier, it had some air in it so I think the dome-shaped oilcap inside it might need replacing. I'll have a look at that late one night - at this stage it's not a major issue but I'm pretty fussy and like everything to be as damn near perfect as I can get them. Of course, it helps that I don't have a wife to bytch and grizzle about the time I spend on the car so once I get home from work each night I can spend as much time as I want on it and don't have to rush things.
Ok, I wanted to throw in a tip for you good men. Sometimes when you spin the drivetrain by hand (with wheels off the ground) you might feel the occasional bump or "stiff" spot. You shouldn't get these and need to sort it before it ends up costing you bucks. Usually it will be caused by a piece of grit or gravel lodged in somewhere and getting compacted each time the drivetrain rotates. A good place to start checking is in the spur gear as a piece of gravel lodged in there can damage the clutch bell and eventually require either the spur gear or the bell, or both, to be replaced. I had a tiny piece stuck in mine, causing a "bump" and used a small blade screwdriver to dig it out. Unfortunately, it has damaged the bell a smidgeon so I know I will need to replace both parts at some stage but for now they're not tooo bad and I wouldn't replace one without doing the other at this stage. It's a different story when a spur gear has just stripped because of driver abuse or mis-alignment of the engine and gearbox - in that case you can safely replace just the spur gear and make the necessary adjustments; alignment or attitude as required ;o)
I still need the end piece for the tailpipe but that's a quick swapover, and the grub-screw that holds the front end of that piece is missing so hopefully the new bit will have one in the pack. Other than that and checking that front shock, the car is fully rebuilt after a total strip-down and clean, with a new pull starter and manifold gasket all firmly inplace. Today's effort took about 3 and a half hours to do the reassembly including setting up the servos and giving the body shell a wash out with detergent and a streak-free dry-out in the sun. The tyre that had peeled off the rim has been put back on but I need to get some glue to re-stick it. I'm not overly bothered about that though as I want to switch to road tyres pretty much straight-away so for now that one is on the back and I just won't run the car ;o) ...you believe me right?? lol Anyway, I'm happy with the overall job I've done - the car is near new and once I get the tailpipe, leaky shock and road tyres sorted it will technically be better-than-new so I'm fairly pleased with the whole business.
Enjoy the pics :o)


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