Bognor Lean-to Project

[Mazza]

OH !!!!!

What a dopey TW@ I am !!!!

Not sure where it starts but it goes through the trailing arm and may connect to a filter??????? Dont know, but definitely not on the 1.9lt.

 

[Althulas]

You must have a charcoal filter box like on my ///M, the breather tube takes that route. If you have a look on Millers zed shed build you can see it on there.

 

[Mazza]

Its not the same as an ///M, as there is no additional strap, but thinking about what you said, I had a look at RealOem, and there is this on a 2.8
A charcoal filter

No 3 is a vent pipe, so it may be that. cant get underneath to look at the moment, but if it is just a vent pipe then it should be possible just to unclip it and move it out the way. (I hope)

 

[Mazza]

After a couple a days tidying the garden, and finding better storage for all the bits I have removed so far, I got back on with the task in hand... the sills.
So a second clean off with a thing that looked like a pan scourer on my angle grinder, gave both sills the FE-123 treatment. This goes on white which makes it easy to see whats been covered, unlike some of the clear versions.

I jacked up the front end just to give me a bit more wriggle room.
Just used a 1/2 inch brush

Once both side were done had to leave it to dry off, so pulled every thing that I had dumped into the boot to have a good inspection......

As you can see ....no leaking and in good condition. i can see a bit of minor surface rust down in the battery well, but dont want to disconnect the battery yet as I will need to put the roof up and down when I have to get to the rear shocks.
In fact after a wipe over with a damp cloth...( I bet @andyglym will be impressed ) the rear end looks to be in reasonable condition.......until you look underneath!!!!

Removed the spare wheel....

I think this is destined for a skip !! As Lee would say......a bit on the crusty side !!!
The plastic carrier will clean up on, but the support cage is too far gone, and will have to be persuaded off with an angle grinder. ( when its in the air ...as cant easily get to it at the moment). So better start getting a shopping list together.

The rest looks ‘ weatherbeaten’ but seems solid enough, but will definitely require a Zedshed powder coating ....along with all the rest of the bits.

Once its dropped out I will be able to clean and treat all the underside.
I think I better start spraying all the underside bolts now and every day for the next week, if I want any chance of getting them undone.

After about an hour of playing around with the stuff at the back, the sills were dry and all the rust had gone black.
So a quick overpaint with some red oxide, and then leave it for 24 hours.

Probably give them a coat of primer and then a top coat of something like a black stone chip.

 

[andyglym]

After a couple a days tidying the garden, and finding better storage for all the bits I have removed so far, I got back on with the task in hand... the sills.
So a second clean off with a thing that looked like a pan scourer on my angle grinder, gave both sills the FE-123 treatment. This goes on white which makes it easy to see whats been covered, unlike some of the clear versions.
View attachment 176869

I jacked up the front end just to give me a bit more wriggle room.
Just used a 1/2 inch brush
View attachment 176871
View attachment 176873

Once both side were done had to leave it to dry off, so pulled every thing that I had dumped into the boot to have a good inspection......
View attachment 176877

As you can see ....no leaking and in good condition. i can see a bit of minor surface rust down in the battery well, but dont want to disconnect the battery yet as I will need to put the roof up and down when I have to get to the rear shocks.
In fact after a wipe over with a damp cloth...( I bet @andyglym will be impressed ) the rear end looks to be in reasonable condition.......until you look underneath!!!!


View attachment 176903


Removed the spare wheel....
View attachment 176879

View attachment 176881

I think this is destined for a skip !! As Lee would say......a bit on the crusty side !!!
The plastic carrier will clean up on, but the support cage is too far gone, and will have to be persuaded off with an angle grinder. ( when its in the air ...as cant easily get to it at the moment). So better start getting a shopping list together.

The rest looks ‘ weatherbeaten’ but seems solid enough, but will definitely require a Zedshed powder coating ....along with all the rest of the bits.
View attachment 176883

View attachment 176885
Once its dropped out I will be able to clean and treat all the underside.
I think I better start spraying all the underside bolts now and every day for the next week, if I want any chance of getting them undone.

After about an hour of playing around with the stuff at the back, the sills were dry and all the rust had gone black.
So a quick overpaint with some red oxide, and then leave it for 24 hours.

View attachment 176887
View attachment 176889
View attachment 176891
View attachment 176895
View attachment 176897
View attachment 176899

Probably give them a coat of primer and then a top coat of something like a black stone chip.View attachment 176903

 

[t-tony]

If you find yourself needing the long bolt for the spare wheel carrier Malc I have one, I know sometimes they get cut off.

Tony.

 

[Mazza]

Will definitely need one ...mine will have to be cut in two to get it out..

 

[t-tony]

Will definitely need one ...mine will have to be cut in two to get it out..

PM me your address mate and I'll send you it.

Tony.

 

[ktnez99]

What an interesting thread! Great work @Mazza and an interesting project. I’m looking forward to reading more*
*in your own time, naturally

 

[Mazza]

Was hoping to get the sills painted today.....but.....
on opening the doors found there was a bit of rust round the body nuts

( plus a couple of other bits that would benefit from a bit of rust treatment)

So first remove the bodynuts..
A screw, a piece of MDF ( after all don't want to damage this pristine heap of junk) and a clawhamer

Easy ...just popped out....
Then paint over with the FE-123

Have to leave it now for an hour or so, then red oxide it all. So hopefully painting tomorrow.
I did notice that there were some plastic clips still in some of the holes, so I went round and pulled them all out .....going to have to replace loads of them, so I might spnd the afternoon looking through RealOem to get all the part numbers.

A minor delay in the scheme of things and as Dawn says...’ in your own time’
If I was working in Zedshed HQ helping @Lee , ..........by the time I had finished just one task, he would be all grown up and wearing long trousers

 

[Althulas]

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[Mazza]

Right....after a bit of speeddialing to my local guru....tomorrow wont be painting, as that can wait.... I have found out I hate painting just as much as cleaning !!!!

So tomorrow......I need to go to Tesco first.... before I die of starvation, ......but I will endeavour to drop the back end......
Now I think @Lee ’s time is just over the hour........so.......thats the target..........( but even by Sunday........will be a Personal Best )


At least then I can sit back and watch Lee do all the difficult stuff and sort out what needs replacing!!!,

I can honestly say.....without the support of ALL the people that are on this forum, ( and most I haven’t yet met) , there is no way I would have ever taken this on.
So thanks to you all ..............for getting me into this mess

 

[t-tony]

That’s another fine mess you’ve gotten me into Stanley By the way I posted you that bolt this afternoon mate, postage was only 96p so forget that and the bolt comes courtesy of ole Grumps, as it came off Reggie. I cleaned and oiled it so that’s one job less Malc.

Tony.

 

[Mazza]

I thought that was it for the day...but no !!!
I had a call from @Lee ( in his capacity of help the aged ), and it seemed to spark me back into life again

So when I went out to bring the wheelie bin in, I couldn’t resist, ( with my new found information) in getting the car in the air..

And who doesnt like using a Nugga Nugga gun.......so now all ready to drop the back end stuff.

A couple of things to note....the locking nuts and adapter are shot so will need new ones, and three of the bolts on the front O/S wheel must have been done up by a Lorry Mechanic!!!! Had to use a breaker bar to get them moving and my Nugga gun is rated as 500Nm !

Oh, and the garage is nice and bright as I (like many on the forum ) have changed the old fluorescents to LED’s and
It make such a difference.

 

[Lee]

OH !!!!!

What a dopey TW@ I am !!!!

View attachment 176645

Not sure where it starts but it goes through the trailing arm and may connect to a filter??????? Dont know, but definitely not on the 1.9lt.

Just a breather vent hose. Clips onto the side of tank. I tend to remove the lower jubilee type clamp and wiggle it off.

 

[Mazza]

So GOOD FRIDAY.......no it bloody wasn’t

Was in Tesco at 6.15am.....just to get it out of the way....packed with staff doing the shopping for lazy online shoppers
Everything put away, thermos of tea done.....so out to the garage at 8am.......wish I hadn’t bothered,,,,

If it could go wrong it did........
First thing to do was to remove the spare wheel cage.....cut the bolt.....but then spent the next half an hour trying to get the two halves out and drop the cage.....finally it did succumb to a bit of persuasion....
Cage will need replacing!!!!!

Next was to get the exhaust out of the way.......
Undo the nuts from the down pipes.....what nuts?????

Plus the exhaust was in one long and welded system...

The cat..was falling apart...

So just cut the back end off. ( yellow arrow)

The red arrow happened later when trying to separate the brake line.....tube just collapsed.....by this time I was passed caring so it got snapped off!!!!

Wanted to have a better look and get the the front nuts so thought it wols be a good idea to remove the cross brace......
NO.....a bolt sheared and it stuck in the front cross beam.....

By this stage .......not a happy bunny ........so decided to see how may of the rear end nuts and bolts would actually undo.....
Apart from the constant getting up and down to tighten and release the handbrake....All the drive shaft and propshaft bolts and nuts loosened off..... First bit of good fortune.

The beam nuts....did start to undo....but I’m not sure if its the nut undoing or the whole pin undoing????
Couldn’t shift the diff bush bolt.....so left it!!!!
Generally the underside is pretty poor condition.....and I am not convinced that the beam is salvageable....

I did get the diff nuts undone so drained the oil

Then....the big one ......’the screws of doom’ All four totally F***ed, so I now have no idea how to get them out, unless I cut the side plates so the beam can be dropped to give me access to drill out or some other method......

So at that point ...enough was enough.......and wondering whether to give Andy ( spurs) a ring ..........

 

[Bazza]

Great work Malc, keep it going mate.

 

[Lee]

Good effort Malc, the majority of zeds that visit us are in this condition. Just tackle each problem at a time, the only mildly difficult job is those side bolts.

At this stage I would just cut them off so you can get the beam down and out the way. This then makes life easier, what I do next is put a slit in the head and get my big boy hammer and chisel. I had one round on me on the coupe yesterday and did the hammer and chisel method. Failing that a dremel or disc cutter very gently side loading the disc to remove the bolt head.

 

[Althulas]

As Lee said one job at a time mate. Certainly do test us I had a pig of a time taking my Catalytic converter off last weekend with the same bolts a combination of heat, WD40, plenty of well and a hope that the car didn’t collapse on me. I found these tools useful for a stud and nuts. Your most welcome to borrow them. I had some of the front splash guard studs shear off and one of the rear deflector duct studs as well when I came to drill them out they popped back into a cavity so was only tacked or interference fitted. Easily sorted with some 5mm rivnuts.

 

[Mazza]

Thank you for the offer of the tools

I am going to have the long weekend off......and then look at each problem and work out how to sort it....and as Lee said ........One at a time.......
A bit overwhelmed today with the amount of things that went crap on me......just goes to show how good a condition my 1.9 is.....didn’t have a problem with any of the nuts and bolts when I stripped that one down.

I think I will try to get the exhaust off first......removing whats left of the nuts.......do the studs on the manifold flange push out. ( ie smack them with a bloody great hammer!!!!!) or would they need to be drilled out.