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Slippery slope skier
 
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Quote:
Originally Posted by jjeffries View Post
Great stuff. That oil line fix is so cool/clever; I'd read the original version and neat to see others duplicate the process.
This might be a stupid question: how could the stub axle assembly get so cockeyed on the McPherson strut tube without having dented the tube, even if just minimally? Is there enough of a gap between the OD of the strut tube and the ID of the stub axle assembly/ring to allow for that to happen without physically deforming either?
Best regards, John/CT
Hi John.
I must add, that this oil line fix was extremely gratifying. It is almost surreal how the dent gradually disappears before your eyes as you circle the torch around it!

Iv been pondering on your questions about strut tube and stub axle.
It is possible that there is a localized dent in the tube.
It is also possible the stub axle press fit over the tube has stretched ever so slightly.
In fact, we had to press the stub axle 0.5deg past the intended final position to account for that amount of spring back once the pressure was released in the press.

Perhaps Iv been over eager to see this issue resolved.
In order to avoid any future doubts, I’ll recheck the straightness of the strut tube.
I’m thinking of placing it between centers and reinspecting it for any runout.
If the tube is rotating true ( ie it’s not bent) then everything is fine, right?

Any localized small dent is negligible since it doesn’t affect the sliding fit of the damper insert inside the strut, right?

And the addition of “RSR STYLE” gussets will ensure that the stub axle stays securely in its correct place, even if the press fit collar is slightly more loose than originally intended.
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Costa P
'85 930 Grand Prix White ...the oil leak rebuild which mutated into MoTeC EFI+twinscroll GT35R+twinplug+ ...

930 rebuild – The revival of my mothballed project
Old 09-21-2018, 02:59 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #101 (permalink)
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The strut tubes aren’t particularly thick, or tough. I’ve come across stock, non race vehicles which showed signs of spindle defection on the tube. Your gussets should do the trick.

Good thread!
Old 09-22-2018, 02:40 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #102 (permalink)
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Quote:
Originally Posted by Jim2 View Post
The strut tubes aren’t particularly thick, or tough. I’ve come across stock, non race vehicles which showed signs of spindle defection on the tube. Your gussets should do the trick.

Good thread!
Thank you Jim
Old 09-23-2018, 09:55 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #103 (permalink)
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Quote:
Originally Posted by Costa P View Post
Hi John.
I must add, that this oil line fix was extremely gratifying. It is almost surreal how the dent gradually disappears before your eyes as you circle the torch around it!

Iv been pondering on your questions about strut tube and stub axle.
It is possible that there is a localized dent in the tube.
It is also possible the stub axle press fit over the tube has stretched ever so slightly.
In fact, we had to press the stub axle 0.5deg past the intended final position to account for that amount of spring back once the pressure was released in the press.

Perhaps Iv been over eager to see this issue resolved.
In order to avoid any future doubts, I’ll recheck the straightness of the strut tube.
I’m thinking of placing it between centers and reinspecting it for any runout.
If the tube is rotating true ( ie it’s not bent) then everything is fine, right?

Any localized small dent is negligible since it doesn’t affect the sliding fit of the damper insert inside the strut, right?

And the addition of “RSR STYLE” gussets will ensure that the stub axle stays securely in its correct place, even if the press fit collar is slightly more loose than originally intended.

So, I setup each strut in a makeshift arrangement “between centres” and placed the dial gauge with magnetic base to crudely inspect and compare any runout in the LH and RH strut tubes;



  • This (albeit crude) arrangement provided surprisingly stable/repeatable results.
    On the LH strut (the good one) I measured a runout of 0.5mm
    On the RH strut (the repaired one) I measured a runout of 1mm

  • Contrary to what one would assume, the mounting hole for the lower ball joint is not concentric with the strut!
    The "wobble", as indicated by the red centreline, was clearly visible as I rotated the struts.



All in all, I’m quite happy with the repair and happy that the strut tube isn’t bent.
Next step, to add the “RSR style” gussets
__________________
Costa P
'85 930 Grand Prix White ...the oil leak rebuild which mutated into MoTeC EFI+twinscroll GT35R+twinplug+ ...

930 rebuild – The revival of my mothballed project
Old 09-27-2018, 10:08 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #104 (permalink)
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Good stuff.
Old 09-27-2018, 05:08 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #105 (permalink)
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Nice work matey!!
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1993 (MY92) 964 Turbo 3.3 - Horizon Blue - Follow my 964 Turbo project here... http://forums.pelicanparts.com/911-engine-rebuilding-forum/626572-964-3-3-turbo-efi-conversion-using-syvecs-life-racing-engine-management.html
On Instagram (along with other stuff) as @spenny_.b #spennybengineproject
Old 09-29-2018, 02:24 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #106 (permalink)
 
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Quote:
Originally Posted by jjeffries View Post
Good stuff.
Thank you John

Quote:
Originally Posted by Spenny_b View Post
Nice work matey!!
Thank you Spencer
Old 10-02-2018, 10:01 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #107 (permalink)
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External Oil Thermostat Housing (continued)

Quote:
Originally Posted by Costa P View Post
Hey Spencer, I have a hell of a lot of catching up to do!
I’m too scared to take my foot off the throttle now

Sneak peak into tonight’s progress;



I borrowed the friction spanner from my mate Fred. It worked like a charm to loosen the 50mm cover. I’m preparing a special tool for the removal of the 38mm cover.

Did one or two other tasks as well , but I’ll wait before I write about those. Want to have a bit more considerable progress before I share
So i've been trying to loosen the 38mm cover. My mate Brenton helped me out by turning a "coin" for me to the exact sizes required (Dia 37mm x 3.8mm Thk):





I thought mild steel should be more than strong enough....after all, it is indexing into an Alu slot!

Take 1:




hmmm....I halted before causing damage to the Alu slot.

Take 2:
Subsequently, Take 2 was repeated with assistance from my father in-law.
He applied the torque on the wrench after I applied heat to the housing via Mapp gas torch + a few healthy smacks to the coin with a hammer.
Equal fail....hence the frustration and omission to take more photos.

Busy rethinking the approach...to be continued!
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Costa P
'85 930 Grand Prix White ...the oil leak rebuild which mutated into MoTeC EFI+twinscroll GT35R+twinplug+ ...

930 rebuild – The revival of my mothballed project
Old 10-02-2018, 10:28 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #108 (permalink)
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TIG Welding Practice Practice Practice

Quote:
Originally Posted by Costa P View Post
.....
All in all, I’m quite happy with the repair and happy that the strut tube isn’t bent.
Next step, to add the “RSR style” gussets
In preparation for welding the “RSR style” gussets, I need to practice running some beads on 3mm plate. (I am leaning towards using 3mm plate for the gussets)
This is also an opportunity to try out my new welding helmet with jumbo viewing lens



Dremel setup with diamond wheel used to grind my tungsten



1st and 2nd weld that I put down (both @ 130amps).
Far from #weldporn but pretty ok for amateur DIY!
In hind sight, I omitted to brush the scale off the plates before welding.
This caused some splatter contamination on the surface of the welds.
Otherwise, the penetration and heat affected area looks ok.



Pic of the back of the plate, showing a nice and narrow heat affected area.



Need more practice practice practice...
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Costa P
'85 930 Grand Prix White ...the oil leak rebuild which mutated into MoTeC EFI+twinscroll GT35R+twinplug+ ...

930 rebuild – The revival of my mothballed project
Old 10-02-2018, 10:59 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #109 (permalink)
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Spring Plate Disassembly

Quote:
Originally Posted by Costa P View Post
...


The 930 is in good company at Café 9 Automotive
Full suspension refresh has been initiated and new parts from our host are on the way.

Feeling quite satisfied that the spell has been broken and I’m getting excited to see some progress again
Here is another pic of the work in progress on the 930...in good company with the Cafe 9 Automotive 935



Well…while I’m in there, might as well do some cosmetic freshening ups!

Spring plate disassembly - Take 1:




Nothing kills your enthusiasm (and ego) as quickly as a complete failure on executing what you initially considered to be a trivial exercise!
My failed attempt to disassemble the spring plate clamping bolt and adjustment bolt left feeling quite “humble”. My pneumatic impact driver made ZERO progress.

Spring plate disassembly - Take 2:
Take 2 was repeated with assistance from my father in-law.
He held the spanner on the bolt head while I applied heat to the nut via the Mapp gas torch.
Once hot enough (boiling spit test), I attacked it again with the impact driver.
Still ZERO progress. Darn, I didn’t even need to restrain the bolt head, it didn’t even come close to rotating.

Time to retreat and read up on the subject in order to plan the next step.


Spring plate disassembly - Take 3:

After a quick pelican search on the topic, I learnt that these bolts are torqued at approx. 250Nm.
I also gathered that they you need a hefty power bar and you need to put your weight into it to break them loose.
My mate Brenton came to the rescue and lent me a power bar and some more hex sockets (24 & 36).

(...Oh, Brenton also lent me his Ingersoll Rand impact wrench as a backup (more about that in a moment)

This time I didn’t have a second pair of hands. So, I set everything up in the vice for a solo attempt.
The spring plates were placed on the bench with the nuts inboard and the bolt heads outboard.

The power bar was placed on the nut (inner side). I supported the socket with a make shift “v-block”, to keep the engagement nice and square on the nut, while I tug on the end.

My T-handle with power bar extension was placed on the bolt head (outer side).

Long story short – I tugged on the power bar and nothing. I added another pipe/extension for more leverage and tugged again….still nothing , but after witnessing the amount of flex on the power bar I aborted that approach.

Spring plate disassembly - Take 4 (The One with the Big Guns):

Time to call the Big (impact) Guns. My hopes turned to Brenton’s IR impact wrench.

For future reference, the vital Technical Specifications of the Ingersoll Rand 2135PTiMAX Series Impact Wrench - Nut-Busting Torque (1100 FT-LBS / 1490 NM) !!!





WOW WOW WOW. This impact wrench is a BEAST! #peaceofcake #doesnt_bat_an_eyelid
It is difficult to explain it in words, you need to witness it working to understand.
Just the knocking sound it makes (compared to my mickey-mouse impact wrench) means business!
Old 10-07-2018, 09:17 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #110 (permalink)
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Spring Plate Disassembly




There you have it folks......not all impact wrenches are made the same.
You get what you pay for!


Old 10-07-2018, 09:25 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #111 (permalink)
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Preparation of Suspension Parts for Replating

Well…while I’m in there, might as well do some cosmetic freshening ups!

After the application of a variety of power tools with steel brushes ...voila!














Making good progress to get everything prepared and ready for replating.
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'85 930 Grand Prix White ...the oil leak rebuild which mutated into MoTeC EFI+twinscroll GT35R+twinplug+ ...

930 rebuild – The revival of my mothballed project
Old 10-07-2018, 09:46 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #112 (permalink)
 
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Costa, I will renovate my SC suspension this coming winter and keep thinking this would be a cool bit of mission-creep:

Modding Factory Spring Plates

One could of course just buy Elephant's elegant solution but clearly you have the skills and gear to do this all by yourself. Best, John
Old 10-08-2018, 06:55 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #113 (permalink)
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Quote:
Originally Posted by jjeffries View Post
Costa, I will renovate my SC suspension this coming winter and keep thinking this would be a cool bit of mission-creep:

Modding Factory Spring Plates

One could of course just buy Elephant's elegant solution but clearly you have the skills and gear to do this all by yourself. Best, John
MUST. RESIST.
😂
John! Stop encouraging my urge, to dive head first, down the slippery slope!
Old 10-09-2018, 11:13 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #114 (permalink)
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Quote:
Originally Posted by Costa P View Post
So i've been trying to loosen the 38mm cover. My mate Brenton helped me out by turning a "coin" for me to the exact sizes required (Dia 37mm x 3.8mm Thk):





I thought mild steel should be more than strong enough....after all, it is indexing into an Alu slot!

Take 1:




hmmm....I halted before causing damage to the Alu slot.

Take 2:
Subsequently, Take 2 was repeated with assistance from my father in-law.
He applied the torque on the wrench after I applied heat to the housing via Mapp gas torch + a few healthy smacks to the coin with a hammer.
Equal fail....hence the frustration and omission to take more photos.

Busy rethinking the approach...to be continued!
Take 3 - succeeded!
Iv documented the successful tool here:
DIY tool for external oil thermostat cap
__________________
Costa P
'85 930 Grand Prix White ...the oil leak rebuild which mutated into MoTeC EFI+twinscroll GT35R+twinplug+ ...

930 rebuild – The revival of my mothballed project
Old 10-17-2018, 01:44 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #115 (permalink)
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Suspension parts refresh and Zinc plating (continued)

Quote:
Originally Posted by Costa P View Post
Well…while I’m in there, might as well do some cosmetic freshening ups!

After the application of a variety of power tools with steel brushes ...voila!


.
.
.



Making good progress to get everything prepared and ready for replating.
It has been a while since my last update. In the meantime, I’ve slowly been completing various tasks and the results are coming to fruition.







Iv posted a detailed writup with lots of pics in the 911 Technical Forum
Suspension parts refresh and Zinc plating (continued)
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Costa P
'85 930 Grand Prix White ...the oil leak rebuild which mutated into MoTeC EFI+twinscroll GT35R+twinplug+ ...

930 rebuild – The revival of my mothballed project
Old 11-10-2018, 11:46 AM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #116 (permalink)
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DIY fabrication of RSR style gussets for Bilstein struts

Quote:
Originally Posted by Costa P View Post
So, I setup each strut in a makeshift arrangement “between centres” and placed the dial gauge with magnetic base to crudely inspect and compare any runout in the LH and RH strut tubes;



  • This (albeit crude) arrangement provided surprisingly stable/repeatable results.
    On the LH strut (the good one) I measured a runout of 0.5mm
    On the RH strut (the repaired one) I measured a runout of 1mm

  • Contrary to what one would assume, the mounting hole for the lower ball joint is not concentric with the strut!
    The "wobble", as indicated by the red centreline, was clearly visible as I rotated the struts.



All in all, I’m quite happy with the repair and happy that the strut tube isn’t bent.
Next step, to add the “RSR style” gussets

Spoiler alert!
The RSR style gussets turned out awesome

[/QUOTE]

I submitted a detailed write up with pictures in the 911 Technical Forum
DIY fabrication of RSR style gussets for Bilstein struts
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Costa P
'85 930 Grand Prix White ...the oil leak rebuild which mutated into MoTeC EFI+twinscroll GT35R+twinplug+ ...

930 rebuild – The revival of my mothballed project
Old 11-10-2018, 01:12 PM
  Pelican Parts Catalog | Tech Articles | Promos & Specials    Reply With Quote #117 (permalink)
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