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  #21  
Old 10th April 2021, 05:54 PM
Audifan Audifan is offline
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Quote:
Originally Posted by MikkiJayne View Post
The suspension turret brace is cracked at the top so fell off as soon as I removed the lower bolt



The rest of it is still in the top plate. I have spares of these so no matter.

What is the purpose of this turret brace that you speak of? And why is it poorly designed?
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2001 S8 Brilliant black with Recaro black interior.
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  #22  
Old 10th April 2021, 07:39 PM
MikkiJayne MikkiJayne is offline
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It ties the top of the suspension to the chassis leg. Logically it will stiffen up the front end, but interestingly the workshop manual says it doesn't need to be refitted. I did think it was to stop the front of the suspension turret tearing apart, but I've seen that happen even with the brace fitted. I fit it anyway since anything that reduces flex in the front end is a good thing.
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  #23  
Old 10th April 2021, 08:55 PM
MikkiJayne MikkiJayne is offline
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More on the upright. Cut the tie rod end off so I could get some heat on the bolt without settng the rubber boot on fire.



I hit this with the mapp torch and the bolt came out with a bit of persuasion



On to the wheel bearing



The old bearing came out easily enough.



I have a good spare hub and bearing



Bit of a mess on the chassis leg



The power steering fluid is the wrong colour



The return hose is a bit mashed, but this can be repaired.



This is the remains of the power steering brackets. Whoever attempted to repair the pressure hose couldn't get the brackets off, so just mashed them.



The rack boot was damaged at the same time.



Trying to crimp the replacement boot right in here is a bit of a 'mare with the engine in. Luckily, much easier with the suspension and PS hoses removed though. The rope is to help pull the PS hoses back in btw.



Pulled the bumper off. Bizarrely the headlight washer pump is disconnected. I'm sure it'll be interesting to find out why...



Bumper and nsf wing removed





The bumper is trashed



As are the radiator and condenser



One of the wing bolts snapped This is not going to be fun to solve.

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  #24  
Old 10th April 2021, 09:11 PM
Audifan Audifan is offline
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Quote:
Originally Posted by MikkiJayne View Post
It ties the top of the suspension to the chassis leg. Logically it will stiffen up the front end, but interestingly the workshop manual says it doesn't need to be refitted. I did think it was to stop the front of the suspension turret tearing apart, but I've seen that happen even with the brace fitted. I fit it anyway since anything that reduces flex in the front end is a good thing.
Interesting. The reason why I asked "And why is it poorly designed?" if this is suppose to stiffen up the front end, then why isn't this brace made from a solid piece metal? Having the brace with the large section cut out making it a weak link in the brace.
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2001 S8 Brilliant black with Recaro black interior.
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My mods: LED interior lights, D3 ignition coils, new window tint
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  #25  
Old 10th April 2021, 09:56 PM
HPsauce HPsauce is offline
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I'm guessing it's a "tension" piece, the hole is to give room for a tool to fix it and the remaining metal is more than adequate?
It looks like it could be cast rather than pressed which might be odd?
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Last edited by HPsauce; 10th April 2021 at 10:00 PM.
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  #26  
Old 10th April 2021, 10:28 PM
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RICKY D RICKY D is offline
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Quote:
Originally Posted by MikkiJayne View Post
The bumper is trashed

Are these ďmeantĒ to separate where this has? Iíve always wondered if the bumpers can separate for repairs etc. Are there two separate part numbers for upper and lower bumper?

Canít say Iíve ever seen one section for sale without the other
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  #27  
Old 11th April 2021, 07:25 AM
MikkiJayne MikkiJayne is offline
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Yes, it is two separate pieces and they can be split if one is determined enough, although it isn't easy. The two parts could be bought separately, and indeed new lowers were still available from Tradition, when they would ship here.

This bumper is completely trashed as the upper is scratched and damaged, and the lower has actually split along the flange where it attached to the upper. My donor bumper has the same problem but I have a few spares so I'm hoping I have a good one in the pile.

In accordance with all things D2, the bumper is a very complicated assembly so it is probably a full day's work to strip down three bumpers and make one good one from the remains! (parking sensors and foglights from the original, upper from the donor, lower from something else).
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  #28  
Old 11th April 2021, 08:26 PM
MikkiJayne MikkiJayne is offline
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The snapped wing bolt wasn't such a big deal in the end. I drilled a pilot hole down the middle of it, then a 5mm down an M6x1.0 thread and all the little bits of broken bolt just fell out.



Cleaned all of them up with a tap and they're fine again



A slightly odd extension cable on the external temperature sensor. I've never seen this before but it looks factory, although not perhaps factory for this model.



The air intake is missing a few screws



I cleaned up the chassis leg and ABS pump area while the wing was off since it was properly nasty in here



Replacement wing on and looking much better



Since I made a radiator pressure tester a while back I thought I'd pressure test a spare radiator before putting it in. I'm glad I did as it blew up like a balloon! Scrap bin for this one then.



Finished refurbishing the PS pipes



The blue rope is used to pull the return hose through this barrow gap in the pipework



Pipes back in place with a replacement bracket



Now I can put the suspension back on. I've got a good used arm in here at this stage as all the others are ok. It may get a full set later on but now I just want it to get through an MoT so I can drive it about.



On the left is a metal bushing which is used to locate the upper suspension mount. There should be two of these - one each on the front and rear studs, but both are missing on this one (possibly also on the other side but I haven't looked). These are unobtanium, I don't have many spares, and they're very fiddly to make on the lathe so I just printed some instead.



They fit on the studs like this



There's no load on them - they simply locate the upper mount in place until you put the nuts on, so plastic is perfectly functional.



The rest of the suspension will go on tomorrow.
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  #29  
Old 11th April 2021, 10:37 PM
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The chassis legs before and after are night and day different

Seems like the radiator pressure tester used for the green beast is proving very useful

Is this still going to be a slow burn project or have things changed now that Bert has relinquished his ownership?
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  #30  
Old 12th April 2021, 08:32 AM
MikkiJayne MikkiJayne is offline
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I'm getting as much as I can done to it in the couple of weeks I have between projects, using parts I already have and not spending much any money on it. The aim is to get an MoT on it and just drive it about, then I can assess all its foibles and deal with them on a slower timescale, in between other jobs. The longer it stays with me, the better it gets. At some point it will get a machine polish, engine-out service, subframe refurbs, etc.

20 hours on it so far.

Parts used:

PS hoses (refurb)
PS hose brackets (used)
NSF upper rear arm (used)
NSF lower rear arm (used)
NSF wheel bearing (used)
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