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]

The shock on the bottom is the one I took off, the one at the top is the replacement before I cleaned it up.

and these are the springs, there seems to be quite a difference that I just didn't see until I took the old one apart.

[Adrian Southgate]

I don't have access to a lathe, would save so much time and hassle if I did. Next major purchase maybe?

The small triumph size poly bushes are the right diameter just too long, easy enough to shorten with a very sharp knife and the hole inside will expand by 1mm, the difference in the size of the tubes. I have one old bush tube spare that i'm going to cut in half to get a temporary fix in place.

[Dave Adams]

no mischief intended it is actually a subject i have been doing a bit of research on myself.....funnily enough for some shockers i have that have knackered bushes.... 

[Dave Adams]

i have just noticed the supplier address of the casting resin........very good for you Ade...

[Dave Adams]

polyurethane rod

this company sells the rods to turn your own up...........easy peasy.

[Dave Adams]

really useful link on subject

this is a post on a forum that might help..

[Dave Adams]

pollyurethane

this is an old link to an ebay seller who sold some stuff to cast your own bushes.....

[Dave Adams]

i have heard of polly bushes being turned down on a lathe. you have access to a lathe have you tried.....?

[Adrian Southgate]

 There is an image in front of this comment that describes this situation and works on so many levels.

On to the car. Rose joints arrived (from Aberdeen) and will work, top hat fittings may not be required other than to sleeve the ball down to 12mm for the HT socket cap bolts which didnt arrive (from Wigan)  :(  The top hats are in fact misalignment spacers which allow the ball to rotate to its limits if you are using a standard hex head M12. I'm using socket caps so it will rotate to it's limits anyway. Don't know if I'm going to get a boot over it as they look a little bulbous, might have to create my own using isoflex or something similar.

Cleaned and painted the replacement shocks, the lower bushes are shot so adapting poly bushes to fit, need slightly longer sleeves to fit the larger bush shoulder. I tried finding some on ebay, then the spax and dampertech sites all with no definite 'yes that will fit' results, seems if the bush goes you are supposed to replace the shock absorber DOH... Seems that a two part tube may be a very temporary solution until I get the new adjustables from Dampertech. 

Bought a 'cheap' imperial tap and die set to help rethread the bolts. 

[Steve Kerswell]

Dare I mention the slipped disc ?