Sunday 28 March 2010

Step 4 of 80

Judging by the number of steps completed, we are now 5% of the way there. Or, we would be if we'd fully completed steps 1 (drill all the panels - on hold for now until we get three replacement panels), 3 (drill holes for securing the wiring loom, fuel lines, brake pipes - mostly done but on hold until I can get clarification of part of the diagram which I can't figure out). So, maybe 3% complete.

Today's job, after cleaning up all the aluminium swarf from panel drilling, was pressing in bushes. The rubber bushes went in pretty easily with the aid of some washing up liquid and a G-clamp:


Rubber bushes pressed in to a front wishbone

Unfortunately the metalastic bushes were considerably tougher to get in, defeating even that most versatile of tools, the large hammer. I managed to borrow a vice (thanks Pete) but that wasn't much use either, as I wasn't able to press the bushes in exactly straight. Eventually I made a simple press tool:


Press for metalastic bushes: nut, socket, wishbone, bush, socket, nut. Sockets are so that it pushes evenly on the correct bit of the bush / wishbone.

This made life pretty straightforward, although still fairly hard work to press the bush in... 15 times. Still, 23 bushes now pressed in today. This means that now I can start building up the suspension, at which point it will start looking a little more like a car. A little.


Metalastic bushes for the rear suspension.

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3 comments:

  1. Unknown30 March 2010 at 12:57

    Some of those bushes can be a pain to get it.

    Hope your hammer use didn't spread the bush housing much.

    Don't forget the copper paste on those bolts, it may avoid a future annoying squeak :)

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  2. dave30 March 2010 at 17:00

    Actually the hammer was never really a serious attempt - gave it a few light taps but it was clearly never going to work, so no damage done there. Once I'd figured out to use the press device it was pretty simple, just tiring.

    Haven't put the bolts in as I can't get them to fit right - fortunately Peter is coming round to drop some bits off on Thurs, so can advise in person then. Pretty good customer service :-)

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  3. Unknown31 March 2010 at 08:41

    seem to remember a bit of a jiggle needed, the odd hammer tap and ensure slippy surface on rubber bush edge where it is close to the metal.
    The customer service is a real plus for GKD builder/buyers, a few items taken a bit to get right for me being the build before manual and so early on, but the feedback hhas gone into quite a few adjustments that should make everyone elses build much smoother.

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