What's in the workshop this week, Pelikanblau edition

[27litres]

I love your methodical approach MJ - you put a lot of mechanics to shame!

[Ameiseuk]

Fascinating work as always!
I watch these posts with so much interest

[Spanker]

Originally Posted by Ameiseuk

Fascinating work as always!
I watch these posts with so much interest

I know how you feel.
I'm actually getting withdrawal symptoms and feeling quite jealous that Vera is now getting all that mechanical love lavished on her D2.

If only MJ would open up an "MJ's D2 Surgery" in the Midlands and make a business of it

[MikkiJayne]

Last night's update this morning since I finished quite late. Time is getting rather tight now with the two new challenges.

Did the CV boot. Caught it just in time - there was hardly any grease left in it, but no dirt and the joint is fine.



New boot



I was not expecting to be removing blue paint this week Cleaned up the area to be welded and chased out the crack with the dremel.



Clamped it down ready for welding



The engine is patiently waiting to go back in



Tackled the leaky power steering hose. Since this is a LHD-specific part there's no way we were getting a replacement in time so I'm repairing it instead. Its leaking from the joint as the crimped joints are loose - a standard D2 failure mode



Carefully cut the old crimps off with the dremel and clean up the joiner and hose ends



Re-crimp the hoses with O-crimps



Cover with adhesive-lined heatshrink for protection and neatness



One of plugs from the old engine. The ash on the tip tells me its burning the oil, but the lack of petrol smell in the sump does reinforce the blow-by through the crankcase vent theory.



Welding commences in about half an hour hopefully...

[David's8]

phew! thought we'd missed the daily update there MJ!
Keep up the good work

[moltuae]

That cracked weld is a bit worrying. I wonder if it's a common problem. Can the weld joint be seen/inspected without major disassembly?

[MikkiJayne]

I've not seen it before, but its mostly hidden by the header tank and the plastic strut cover. You could see it by removing the cover.

[David's8]

Originally Posted by moltuae

That cracked weld is a bit worrying. I wonder if it's a common problem. Can the weld joint be seen/inspected without major disassembly?

Given that MJ believes the usual cause to be "potholing" then I wouldnt be surprised if its a common problem given the state of the roads. My Indy garage reckons that he sees a big increase in suspension/wheel damage over the past few years as the roads deteriorate.

[pete-p]

Originally Posted by David's8

Given that MJ believes the usual cause to be "potholing" then I wouldnt be surprised if its a common problem given the state of the roads. My Indy garage reckons that he sees a big increase in suspension/wheel damage over the past few years as the roads deteriorate.

Originally Posted by MJ

... I believe this is from hitting a pothole and bottoming out...

If it is a case that the suspension bottomed out, would it not be more likely to happen if the car has been lowered or the suspension stiffened? Or if it was a particularly big hole!

[moltuae]

Originally Posted by David's8

Given that MJ believes the usual cause to be "potholing" then I wouldnt be surprised if its a common problem given the state of the roads. My Indy garage reckons that he sees a big increase in suspension/wheel damage over the past few years as the roads deteriorate.

That's what I was thinking. The roads around here are in terrible condition too. I had every every single bush, ball-joint and arm on my S8's suspension replaced a couple of years ago (with OEM parts) and already there's knocking and signs of suspension wear again. It's infuriating considering the amount we pay in taxes. I might give those weld seams a check ...