In the post today...

Received replacement poly bushes for Rimmer Bros today!

Two working days not bad, just a shame I was required to send both parts back.

Jiffy bag & postage – £3.95

Turret clean up...

Before re-installing the front suspension I needed to remove the remaining under seal from the off side turret which allowed me to examine the rusty areas that need some welding.

2 hrs

Spot the difference...

Assembling all the parts to refit the font suspension I discovered that the spacer tube for the new inner track arm poly bush is 5mm short.

The front/rear suspension poly bush kit was purchased a few months ago from Rimmer Bros, I called the returns department and was told I needed to the return the bush and a replacement would be sent out by return.

Now I know why some rebuilds can take so long! 

30 mins

Ball joints in...

After a quick ring around I dropped off the ball joints and track arms to a local garage (Meadvale, Redhill) which used a press to fit them, at a minimum charge it was cheaper then hiring the tools.

1 hr

Lower steering shaft...

With the steering rack off. I removed the lower steering shaft, after a clean-up and a coat of paint it's ready for fitting.

The bulkhead bush looks ok, not worn or cracked.

1 hr

Steering rack ready to turn...

With replacement track rod ends supplied from Robsport (great service and shipping - thanks) I cleaned off all old grease and then re-greased the rack main inner shaft and track rod ball joints, refitted the cleaned gaiters. After wire brushing the threads I fitted the new track rod ends. Just need get some wire clips for the gaiters.

Also have new ball joints to fit the track arms, I had a quick try at fitting one, but going need the right tools or pop down the local garage for help.

1 hr

Ball joints out...

I planned to see if I could borrow a press to remove the ball joints, but no luck so I used a large hammer and vice.

I had soaked the ball joints for a couple of days with DW-40. Then placing the track arm end in the jaws of the vice centering on the ball joint, a couple of good hits they started to move – several hits later the ball joint dropped out.

30 mins

Front end down under...

Made a start this afternoon on looking at the work to be done to the front end body. There is some surface rust but not major. The two corner areas under the bonnet and the front of the inner wings at the bottom.

The lower front panel which is behind the spoiler has a couple of small rust holes which will need patching.

I've pull out the front lights/flasher wiring from the top headlamp panel and back through the wing in the engine bay near the battery area.

Paint job...

Over the past couple weeks while doing some the other jobs I've been cleaning and painting the front suspension parts for refitting when replacement ball joints and track rod ends are ordered.

Other parts like disks, dampers, springs, bump stops and gaiters will be bought later due financial pressured, It's hard to justified spending money on the car - food on the table comings first.

10 hrs

Drivers' seat trim removal...

The drivers' seat requires some repairs to the front vinyl side panel. By un-clipping the material at the base of the back allows you to run you hand up and around the break the gluing of the foam to the frame, with a few more clips and pulling out the headrest the cover slips off.

Ever since a bought the car the drivers seemed to rock back and forward a little – examining the base frame I spotted it had cracked – small welding job.

The question I need to ask is:

1. find someone to repair the cover so the red check matches on both seats

2. depending costs of above, find a second replacement seat and hope it matches

3. find replacement cover for both seats including foam (haven't seen red check covers for sale)

4. worries about it later and put the cover back on.

1 hr

Nice turn...

Now free of the track rods ends I started stripping and cleaning the steering rack – removing the rubber gaiters, rust from the centre tube part and shafts. Then polishing the alloy mounting points it looks like new – finished with a coat of black paint.

3 hrs

Cut off...

With the track rod end soaking overnight, I tried and failed to move it – out came the angle grinder! I cut off the end and cut a groove along the shaft until I could just see the thread.

Using a small hacksaw I cut along the groove, then with a large screwdriver and hammer I hit the open end to break the joint which allow me to unscrew the remain piece.

1 hr