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  #1  
Old 25th June 2022, 07:55 PM
MikkiJayne MikkiJayne is offline
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Default WITW - quickies

I have a bunch of small jobs over the next month or two so I thought I'd stick them all together in one thread for general shenanigans.

This weekend Marcel is here with his 2.8 so we can replace the rear subframe



We wasted no time stripping the rear end and removing the subframe



The old one is crusty but recoverable so this now gives me a rolling spare again after using my spare on the FE.



Reasonable condition underneath. The heat shields had been smushed and attached with tekscrews at some point, and the tank straps are pretty crusty



Marcel had already prepared a replacement subframe, blasting then powdercoating, then painting, then internal waxing. This will probably outlast the rest of the car now



One of apparently only three sets of Lemforder D3 bushes ever produced After I bought two sets and Marcel bought one they became out of stock everywhere and Lemforder aren't making any more. Very odd.



Heat shields all fixed, with rivnuts to replace the broken studs as usual



Fabricated stainless steel tank straps



Brake pipes cleaned up and repainted while we had good access to them



Bugger.

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  #2  
Old 26th June 2022, 08:45 AM
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steamship steamship is offline
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Quote:
Originally Posted by MikkiJayne View Post
Bugger.

Someone doesn't know their own strength.

Out of curiosity, how old was it before it gave up?
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2001 A8 D2 FL 3.7 Q - LPG Conversion, Engine: AKC, Gearbox:FBB, Colour:LY5X Aqua Blue pearl effect, Interior:WJ light beige/dark beige valcona leather with burr walnut inserts

My DIY jobs - Replaced alarm horn, Replaced Coolant Temp sensor, Updated RNS-D firmware, Installed Reversing Camera and Digital TV, Dashcam Installation, Retrofitted Rear Blinds, Auto-Dimming Rear View Mirror, Chrome Boot Struts

Sold! 2008 S8 D3 5.2 V10 - Engine: BSM, Gearbox:KLW, Colour:LY7F Suzuka Grey Pearl Effect, Interior:Black/Black with Silver/Black valcona leather with carbon atlas inserts, Bang & Olufsen, Heated windscreen, Soft-close doors, TV, DAB, AMI, Quad Zone, Auto Boot, Auto dim Mirrors, Keyless entry, PDC with rearview camera, AFS II Headlights

My DIY jobs - Fan Jet Windscreen Washers, Retrofitted Electric Side Blinds
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Old 26th June 2022, 12:41 PM
MikkiJayne MikkiJayne is offline
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7-8 years. It was one of the first things I installed in the workshop. It was getting a bit worn anyway so its not catastrophic, just very bad timing as I had to go and get another one this morning to finish the job.
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Old 26th June 2022, 05:02 PM
HPsauce HPsauce is offline
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Quote:
Originally Posted by MikkiJayne View Post
Fabricated stainless steel tank straps
Is this going to become a standard item in the D2 Doctor Service Catalogue?

And how were they made, by you or externally?
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2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!)
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
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Old 26th June 2022, 06:55 PM
MikkiJayne MikkiJayne is offline
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They are a one-off, made by Marcel and his brother. They are a lot of work to produce as stainless is very hard to work with, so are not economically viable to offer as a product. I do powder coated originals instead
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  #6  
Old 26th June 2022, 07:17 PM
HPsauce HPsauce is offline
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Quote:
Originally Posted by MikkiJayne View Post
not economically viable to offer as a product.
About as economically viable as owning and running a D2? So, how much?
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2003 D2 FL S8. Irish Green Pearl/Beige. Solar sunroof, auto-dim mirrors, electric rear seat functions, ski hatch retrofit; extended leather. Aftermarket DVB-T, reversing camera and full XCarlink (Bluetooth etc.).
2016 Volvo V40 T5 Cross Country (4WD) with ALL the toys including adaptive cruise etc. etc. Osmium Grey with Blonde/Charcoal leather interior. Polestar performance "optimisation". (A much rarer model than a D2 S8 by the way!)
Finally: gone, but not forgotten.....
1998 D2 PF S8. AgateGrey/Platinum. Every option (I think) except electric rear seats, tiptronic steering wheel, ski hatch, towbar & dimming door mirrors.
e.g. Cruise control, NavPlus/TV, Bose, GSM, Xenons, Solar roof, Parking sensors, Alcantara/leather everywhere of course. (internal dimming mirror added later)
1998 (very early) Ford Focus 1.8 Zetec; ABS/TCS, Heated screen/mirrors, Aircon, Auto-dim mirror, Leather, Trip computer, Cruise control, OEM Ford SatNav with CD changer.
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Old 26th June 2022, 08:26 PM
MikkiJayne MikkiJayne is offline
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Not chronologically viable to develop in to a product either tbh, while I have more pressing things to work on like heater valves and wiper linkages It can go on the list for the future though.

Today's progress:

Broken rear springs



New replacement from Tradition



Subframe reassembled



Back in the car



The right gearbox seal is leaking. I've been meaning to make a tool to refit those for ages so today is the day.



Its quite tight in here to hammer a seal in!



The flange is held in with a single bolt



With the flange out the seal can be easily removed



A piece of threaded bar is screwed in to the diff, and then the tool can be tightened up to push the new seal in place to the proper depth.



New seal fitted



Replaced the CV boot while the shaft was out as it was perished and would fail soon



All done in time for a wheel alignment in the morning

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  #8  
Old 27th June 2022, 09:59 AM
ainarssems ainarssems is offline
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Quote:
Originally Posted by MikkiJayne View Post

Bugger.


I had one fail in similar fashion long time ago when I was young and broke and back in Latvia. Getting new one was out of the question and while searching for used might have been an option I tried to repair it. Cast iron is hard to weld especially considering that in vice it would have soaked up grease and oil over time. There are some methods and materials for cast iron welding but availability and cost at that time was not realistic for me. I have heard before about a DIY trick for cast iron welding so I gave it a go as I had nothing to loose anyway. I used regular arc welder with the coated steel welding rods but wound a copper wire around the welding rods so it was kind of hybrid between welding and brazing and it worked a treat. Used same vice for several years after that.
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  #9  
Old 27th June 2022, 07:21 PM
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The car is home now and after driving around 115 miles it has been totally transformed and I have new found confidence in it.
MJ is such a hard worker I had a hard time keeping up with her
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  #10  
Old 20th July 2022, 07:03 PM
MikkiJayne MikkiJayne is offline
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A new little project - a 5HP19FL freshen-up and swap out for a 2.8 FWD PF.

Standard 2.8 anti-corrosion treatment



Cleaned up and tipped on its side to drain the diff





Valve body



No valve body



Valve body in bits in prep for an upgraded pressure valve which doesn't fit

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