Rebel
Part of things
Posts: 343
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Bled the brakes and the pedal seemed to be a bit spongy after bleeding, also noticed that the brake lights were on permanently. Checked the brake light switch under the dash and the brake pedal was sitting too low and not making contact with the switch. The new master cylinder has an adjustable pushrod, adjusted the length of the pushrod to lift the brake pedal enough to make contact with the brake light switch. Bled the brakes again and got a load more air out of the system. Checked the brake lights and they were coming on with the brakes applied and going off when you took your foot off the pedal. With the brakes sorted, I went to put the wheels on, only to find that they no longer fit!
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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Its the peanut oil that does the business. You don't need a much of it, used it for a while now. No smell, don't smother the plastic in it, you're not making a sandwich, lol. Just a small amount and polish it off, no adverse effects and black plastic stays black
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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Have you acquired a merc now?
Peanut butter ( smooth, not crunchy ) is excellent for keeping black plastic looking good. Just a small amount works wonders
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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Having got the disc and hub assembly fitted and bolted to the spindles, next up was the new brake calipers, However, when trying to slip the calipers over the disc to bolt up to the caliper bracket, this is what happened, The caliper bracket looked as though it was too far away from where the disc was sitting. After actually reading the instructions properly, it turned out that I'd bolted the discs to the hubs the wrong way round! So, take the disc and hub assembly off again. Take the disc off and turn it round and reattach it to the hub. This time, the calipers fitted perfectly and looked like this on the car With all the brake lines connected up and ready to go, it was brake bleeding time.
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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Sept 3, 2017 22:50:24 GMT
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... looks like the spindles need a LIGHT cleaning with emery cloth (or brands probably available ) first , then use the nut to ease the bearings home ... Exactly, both spindles were given a light clean and the hub assembly was mounted again without the front bearings. This allowed enough thread to show so that the hub nut could be used to ease them a little further onto the spindle. Hub nut removed, the front bearings were then fitted and the hub nut reinstated and tightened to the correct spec, not forgetting to add a new split pin as well
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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And this is how the master cylinder looks fully installed with the lid bolted on Once the brake pipes, master cylinder and proportion valve were fully fitted, I could make a start on fitting the brake discs and calipers. A seemingly easy task which provided plenty of problems. Anyhoo, it started with the opening of many boxes, The discs and hubs in the kit are a two piece item which needs bolting together before installing on the spindles ( stub axles ) of the car. This is how they looked when the boxes were opened, And, this is they look when the discs are attached to the hubs, Having got the hubs and discs assembled, I added the bearings and went to put them on the spindles only to find that the large hub nut that keeps the bearings in place now wouldn't fit. There was no threads showing at all at the end of the spindle! Further investigation revealed that the new hub / bearings didn't go all the way to the end of the spindle, as can be seen below, No matter how hard I pushed at the hubs, they just didn't want to go any further. Taking the hub back off the spindle left me with this The bearings were stuck on the spindle. With a little help from the very gentle use of a puller, I managed to get the bearings off the spindle without causing any damage. After checking with a couple of people in the know, I was advised to try again but this time use the hub nut to help with pushing the hub assembly all the way home.
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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All the pipes are new, including the flexi's. However, the rear wheel cylinders are not new, but are in excellent condition so didn't need replacing. The system was previously using DOT 3 fluid and there was probably still a residual amount in the cylinders, so, I used DOT 4 fluid because of the possibility of any issues caused by the remaining DOT 3 mixing with the new DOT 5
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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Having got the pipework and unions sorted out, I trial fitted the new master cylinder, Due to it originally being a drum brakes all round car, changing to disc brake front / drum rear means it needs a brake proportioning valve adding in to the rear brake pipe. Some people fit these in the rear pipe under the floor, sometimes the brake pipe is fed through the floor so that the proportioning valve can be fitted inside the car. I didn't really want to put any holes in the floor and had decided that I'd just mount the valve under the floor. Then, after bending the huge 12ft length of pipe to run from front to back under the car, I fitted it and realised afterwards that I'd forgot to put the proportioning valve in the pipe! Not really wanting to take the pipe off again, I had a look online and found some pictures of cars in the states with the valve attached to the master cylinder, the bulkhead and even under the master cylinder. After checking the available space around the master cylinder, I decided to make a bracket and attach the valve to the side of the master cylinder. I had a bit of stainless steel lying around and using the tried and trusted CAD ( cardboard aided design ), made a template, transferred it to the stainless steel and cut it out. The bracket needed 7 holes drilling in it, which wasn't easy, but I managed and once bent into shape, it was a perfect fit. Once the bracket was all bolted up and had the proportioning valve bolted to it, it looked like this When all the brake pipes were fitted, it looked a bit steam punkish but as a first attempt at replacing an entire brake system, I'm happy with it. In case you're wondering, the colour matching towel is there to protect the paintwork from any spilt brake fluid and only temporary.
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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Back in June of this year ( where's the year gone, nearly September already! ). I had the geometry pretty much sorted on the Charger, well, as sorted as it could be until the drum to disc conversion was completed and the wheels were back on the car. The last time the Charger was MOT'd, I had an advisory on one rear brake pipe. Knowing that I was replacing most of the brake system and thinking that if one pipe was a bit iffy, the rest probably weren't far behind it. I decided to replace all the brake pipes as well. I have one of these, But, it's awkward to use. Either I'm not very good with it or it's not a very good bit of kit. So, I started looking for a hydraulic brake pipe flarer and discovered that I couldn't afford one! However, I did manage to find this, Which works really well. I found a few videos on you tube that showed how to use it correctly and it's a lot easier to handle than the other type. It only comes with a 3/16 former, but as that's the very size pipe I'm using, it's all good. its very easy to use and produces nicely formed single and double flares every time. I also bought a couple of reels of copper brake pipe and some brake pipe unions in preparation. I figured that two reels of pipe would be a good idea, especially as the longest pipe on the car, from the distribution block at the front to the "Y" shaped adaptor just above the rear axle, is 12ft long! Then the fun started, The first pipe I made up looked great, but didn't fit. The brake pipe unions that I had were too big, checking all the unions used on the car showed that there was three different sizes used throughout the entire car! The original master cylinder and one of the unions on the distribution block used a 9/16 union, two more unions on the distribution block, the rear wheel cylinders and the front calipers were 7/16 unions and the final two unions on the distribution block were 5/16. My local motor factors couldn't help with a supply of the correct sizes. Posting a question on the MMA ( Mopar Muscle Association ) forum resulted in being pointed in the direction of automec.co.uk I can't recommend Automec highly enough, a quick phone call and I was given an email address, took a couple of photos of the unions that I needed and sent them by email. A return phone call resulted in Automec sending me one union to see if it would fit. When it got here and fitted, I quickly called them again and placed my order.
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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Aug 14, 2017 14:47:06 GMT
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Like that, nice project and looks cool
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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It's still ongoing, progressing a little slower than previously, mainly due to it being car show season and I'm busy at weekends. Then there's all the weeknight cruises and I've been working on the Charger as it's so close to being on the road again. Anywho, I've started to get it bolted down, once that's done I can line the doors up properly and start insulating it
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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Loving the car, you can't beat '60s muscle ( not that I'm biased at all ). The rubbing from the back wheel and tyre combo that you can't find could be the tyres rubbing on the inside of the wing, just above the wheel arch lip. If that makes sense. The rear tyres on my Charger rub in the same place going over bumps when there's four people in it. Bookmarked.
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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They do like their narrow lanes down there. Used to go to the North Wales Coastal Cruisers show in Rhuddlan, Rhyl, every year. Ain't nuthin' as scary as flying round a narrow bend in a big old American pick up and meeting an equally large tractor coming the other way. Keeps you on your toes, lol
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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I seem to recall from my deepest, haziest memory that parabolic (and possibly ordianry) springs for Series Landies are different N/S and O/S. Something to do with the driver and the fuel tank being on the O/S. If you put them on the wrong sides it can cause them to lean over. I might be wrong, it's a long time since I last tinkered with one... you are right, the UK drivers side springs have about half inch more free camber (arch) but the actual spring rates and leaf thicknesses are all the same. so on the ground the truck should still be level (ish) Thanks guys, something else to check when I get that far.
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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Jul 20, 2017 17:00:56 GMT
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Loving this, I have two Hilux Surfs, ( basically a pick up with a full length roof and back seats, lol ) looking forward to further updates and progress reports
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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11 leaf front, 11 leaf rear for diesel 88 (9 leaf front 11 leaf rear for petrol 88) i agree with the previous comment that the long shackle will be to correct a sagging spring / vehicle lean. perfectly ok if its a land rover military shackle, but yours doesn't look like it (millitary shackles have a horizontal strengthening tube halfway down running between the two bars) the rear windows look like generic boat windows (think along the lines of 1970s norfolk broads cruiser ) more interesting, to me at least, is the horizontally split "stable door" style rear end. this is not a standard land rover item, although it does look like its modified from land rover parts. they usually have a cat flap setup (think along the lines of range rover, with a tailgate that drops and a tailgate that flips up) or traditional full height safari door like a defender, or half tailgate and canvas tilt. have you got any better pictures with it open in stages ? It's definitely not a military shackle, we'll see what happens when I get it changed for the correct item. know exactly what you mean about the rear windows, close inspection suggests that they're either factory fitted or one of the previous owners has converted them very well. no pictures of the rear door open I'm afraid
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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Jul 15, 2017 14:10:26 GMT
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Loving the Austin, in the interest of possible modifications. I'd be tempted to remove the front sidelight / indicator unit, putting the siudelights in the headlights and if possible movving the indicators into the headlights as well ( in the same way as found on some VW Beetles ). Would clean the front end up and with the possible addition of a chrome tube grille should look good. Obviously just a thought, lol
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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Didn't realise they were parabolic springs, we'll see what happens when I get the shackle changed over. You'll immediately tell if they only have 2-3 leaves, standard is 7 leaf petrol and 11-leaf for diesel, that's SWB, for info LWB might be different. Ah, that explains it. I was wondering why it only seemed to have 2 or 3 leafs when all the pics I've seen have 7 or more. Thanjs
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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Sadly the original centre shaft isn't in great condition. I'll have to use the new centre shaft
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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Rebel
Part of things
Posts: 343
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Hi George, I really like your escort, especially the work you did on the roof rack. Glad you like the truck, stay tuned it's bound to get interesting. Updates might be a little slow due to four other cars and a shed to finish, but it'll get there
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1968 Dodge Charger 1985 Chevrolet Camaro 1993 Toyota Hilux Surf 2001 Ford Mondeo
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