Q91CMV - Dutton Legerra ZS Series 2

[Adrian Southgate]

So, MOT sorted by the skin of its teeth, loads to do before tomorrow morning, panic has set it due to a little mishap with the pedal box...

How many of you fitted metal spreader plates between the pedal box and the bulkhead? Here is something for those of you with pinto engines to think about.

I didn't see this coming 8 years ago when I re built it... The holes are supposed to be there... the crack around the edge is not.

Seems the proximity to the manifold has weakened the fibreglass of the tub a little

Well a lot actually :)

A metal spreader plate on the inside would have eased the load on the area and this may not have been quite so severe. This is going to be a fun evening..

[Adrian Southgate]

Another observation.

The bolt holes in the maxi ball joint are 9mm, obviously meant for an imperial bolt of some description. 

The tubes on my stub axles are 10mm ID and have little bits of weld on the lower edge which stop an M10 nut and washer sitting flat, i noticed when they were bolted to the bench upside down. Now I know I have no choice but to fix it. Do I drill the ball joint to M10 and upsize the bolts or sleeve the inside of the tube with thin metal and hope it lasts?

[Adrian Southgate]

I deleted that entry as the photo's won't load from my tablet.

SO... progress so far. One set of calipers, discs and stubs refurbed and ready to be test fitted back on the car. (both sides are done but the n/s is still on the bench mount.

[Adrian Southgate]

By the way, anyone here live near enough to didcot in oxfordshire to collect some ebay items for me?  Auction ends before 8pm tonight and its personal collection only, 3 apple boxes full of capri instrument clusters, about 15 or 16 in total, happy to come to some arrangement regarding parts swaps in return?

[Adrian Southgate]

They do the right bolts in a suitable length for vented discs @ £15.99 for four including washers...

The green must have a mk2 rack as it takes mk2 trackrod ends, therefore it must have mk2 stubs or the taper on the steering arms would be wrong or so I would hope...

[Adrian Southgate]

I would be happier with the right size bolts, not sure if the green ones stubs are mk1 or mk2 so may be possible to use the metric bolts and just not change the stub axles. I'll see at the weekend when I get it up on axle stands.

[Steve Kerswell]

so are the imperial bolts to short to use? Plus, will the disc and bearings match the stub axle? Seems I may have been lucky with the Sierra using Capri struts.

[Adrian Southgate]

I haven't finished the painting yet however this is a pair of calipers I was set to exchange for new ones in desperation. Fitted with new pistons and seals from Brakes International (£43) and a spacer kit (£32) to wrap round the new vented discs (£29). 

Anyway, very pretty but... went to dry run them back onto the stub axles with the new bolts purchased especially to fit my strut bottoms ... There may be an issue with these bolts I think.

I assume the old (fatter) bolt is off a mk1 escort strut, hence the slight discrepancy in diameter and thread pitch. This changes the whole game plan for fitting a refurbished stub axle assembly to each side of the green leggie as I now don't have 'spare' stub axles that fit

[Adrian Southgate]

Update. Been out playing in the garage for the last few days, ended up with a before and after shot for your amusement.

[Steve Kerswell]

I know, but I will claim the tax back through my business, so thats .40p........yipee

[Steve Kerswell]

Its only money Ade, I had to spend £2 on the Sierra today, never before have I had to buy nuts, steering rack ends are M14 and I never had any. Wife reckons I doubled its value :-)