Ayresys Workshop Thread :)

[gemsdad]

And it's all off

Axles and engine have been washed to get rid if all the crud to make for a cleaner rebuild, ill probably wax oil everything when I'm done

All the crap and rust that fell of it haha

put all that crud on ebay,sell it as chassis filler.someone will buy it.

 

[flat]

wow how does it get into that state? Did they park it in a salt water bath every night or something??

Eek!

Ed

 

[200tdi ayre]

put all that crud on ebay,sell it as chassis filler.someone will buy it.

Not a bad plan 1 chassis, slight assembly required ...

 

[200tdi ayre]

wow how does it get into that state? Did they park it in a salt water bath every night or something??

Eek!

Ed

That doesn't include the slabs that came off when I removed the crossmember

 

[gemsdad]

Not a bad plan 1 chassis, slight assembly required ...

no,just mash it up in a tin,then add some glue.mix together and sell as chassis hole filler.jobs a good un.

 

[200tdi ayre]

Stripped the suspension and radius arms off this morning and swaped all the bushes

It's alot easier when you've got a massive press

Then stripped the a frame and replaced the ballpoint and shotblasted the arms to get rid of all the rust, sprayed them up.

Then the rest of the bushes and all the other bits arrived

Then started to fit it all back together

And we have a rolling chassis again

 

[nrgserv]

Flintstones would be in a better condition

I didn't have to undo the rear exhaust bracket it came off in my hand

has that tyre been regrooved?
is it a farmers motor by any chance?
nice pics, cheers

 

[200tdi ayre]

has that tyre been regrooved?
is it a farmers motor by any chance?
nice pics, cheers

Not that I know of, no it's not a farmers one do you think a farmer would spend 3 grand rebuilding one ?

No worries

 

[200tdi ayre]

Engine, fuel tank and steering components reconnected

Sorted out some wiring and then worked out how to thread the wiring through the chassis rails

First got a nice long length of welding wire and straightened it out to make it flow better and wiggled it through the chassis

Then put a loop in one end and tied the rope to the wire

Then pulled it through and tied it off job done

 

[200tdi ayre]

Body is back on, wiring is re connected, most things are done just got a few tidying up and fixing jobs and putting the front end back on and she's done .

Then my mate called and apparently his gearbox has blown up (200tdi tuned in a series) so I had to go rescue him

 

[200tdi ayre]

Services the handbrake on my mates D3 today, the tidiest D3 I've ever seen but I didn't expect any less from him they have the cleanest vehicles you'll see

Definately a gloves, seat covers and no power tools job

 

[Thomson]

I now see why my problem with my td5 is easy..... Compared to this, top man.

 

[v8landyman]

Panel gap at top of rear door looks tight on that disco.

 

[200tdi ayre]

Panel gap at top of rear door looks tight on that disco.

I think it's just the picture angle I didn't notice it

 

[200tdi ayre]

Wings are back on

Suspension is done
Brakes are almost done
Wiring is all done
Steering is all done apart from tracking
Exhaust is refitted and sealed
Fuel is done

Just a few more tidying jobs fitting small bits and the radiator etc and a tiny patch on the bulkhead to do and she's done

 

[200tdi ayre]

The red 90 is done, a few little teething problems like little leaks of water in the rain and the 7 pin plug being slightly out :doh: so onto the next ones

First one mate brought this beast for mot

Awesome Mach 5 bead locks

And I'm doing alot of work on another mates 90 which passed mot with an advisory for slight corrosion on the outrigger ......

Some mot stations are ****

And this

And the rear shock bushes are knackered, and there was a hole in a front chassis leg and it's leaking Oil inside the handbrake drum from the rear seal and the drop arm ball joint has craploads of play

Yeah real reputable garage :doh:

 

[200tdi ayre]

Doing a drop arm ball joint on a 90 today. I do a couple a month so I've made a tool for getting the top cup out more easily

I've ground down an old ball so it just fits within the chamfer on top but catches on the upper cup, I put it in the wrong way w
Round so you tighten the nut at the bottom with plenty of big washers so the ball can pull through. Came out easy as grease

Mabie not as much use for you guys who do alot fewer than me but it makes it alot easier to get out.

If it still pulls through the cup you can very carefully weld on the inside of the cup to
1. Give more grip on the ball
2. Contracts the cup to make it easier to remove

 

[Headtester]

Cracking thread this, proper spannering!

 

[200tdi ayre]

Another Pressbrake rear crossmember to fit

 

[Dan_Trials]

Excellent keep the pics coming!