Silverbullets' resto: Engine, gearbox, suspension

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TOONGA
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Post by TOONGA » Fri Jun 17, 2016 7:17 pm

Alternator looks good I take it you are going to put a V pulley on it ... unless I missed the section where you have a ribbed section on your crank pulley.

Just did a search on line for MY power steering hoses ... no luck.

TOONGA
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Silverbullet
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Post by Silverbullet » Fri Jun 17, 2016 9:26 pm

TOONGA wrote:Alternator looks good I take it you are going to put a V pulley on it ...
TOONGA
Yes ;)

If I ever see an incomplete P/S set at a wreckers (it does happen) I will nab the hoses, doesn't matter what condition they're in just as long as the fittings at each end are ok.
Will it ever end!?
-EA81 TWIN CARB!!!!
-L series 5 speed
-Custom paint job
-2" lift
-Full custom re-wire
-L series front end
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Silverbullet
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Post by Silverbullet » Sat Jun 18, 2016 6:50 pm

Power steering system is complete :) All hooked up ready to go, just need some fluid now. I haven't found a solution to the steering knuckle/uni extension yet, once that is sorted I'll be able to test the system. I haven't got my A/C/alt bracket back from the sand blasters yet, hopefully next weekend though I can install the alt and A/C compressor for the last time :rolleyes: Feels like things are coming together now, not much more work to do under the hood! :D

Also got my compressor working again, installing that motor was a pretty fiddly job.

P/S hoses re-made, better than new!
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Will it ever end!?
-EA81 TWIN CARB!!!!
-L series 5 speed
-Custom paint job
-2" lift
-Full custom re-wire
-L series front end
Image

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AusTas75
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Post by AusTas75 » Tue Jun 21, 2016 6:27 am

looking good

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Silverbullet
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Post by Silverbullet » Sat Jun 25, 2016 7:26 pm

Today was a cold day so the paint on my A/C/alternator bracket didn't dry fast enough, but that will all be going on tomorrow.

So today with the help of the indispensable rivnuts I found a neat little spot for this ;)

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Drove the work van the other week with a DIY cruise kit in it and decided I had to have this on the wagon :cool: Was surprised how well it worked, and how it kept correct speed up hills etc. Someone I know just happened to be offering an old kit of theirs (used) for free so that's all the reason I needed.
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Will it ever end!?
-EA81 TWIN CARB!!!!
-L series 5 speed
-Custom paint job
-2" lift
-Full custom re-wire
-L series front end
Image

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TOONGA
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Post by TOONGA » Sat Jun 25, 2016 7:41 pm

Sam I'm using one of these knuckles in my brumby

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I believe it is an outback Knuckle I'm pretty sure it would work in your wagon as well.

Excuse the really good anti rust paint job on the chassis rail and subframe ... and everything else :)

TOONGA
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PJ Gone but not forgotten
JETCAR AKA the sandwedge Rusted in pieces

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El_Freddo
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Post by El_Freddo » Sun Jun 26, 2016 12:10 am

I was about to say nice spray job Jules!

Sam, what brand is that cruise control unit? More importantly have you worked out where you're going to mount the control pad/stalk?

The way the cruise holds speed up hills depends on two main factors:
1/ How the system is tuned/setup for that vehicle
2/ engine performance and gear selection for hills etc.

I can cruise around town in 5th at 60km/h in Ruby Scoo on cruise no worries, put a hill in that mix and I have to intervene...

You'll love it once you've got it set up properly ;)

One tip: create a bar off the back of the gearbox to mount the speed pickup sensor then fit the magnets to the tail shaft. It's a good idea to measure and mark the tail shaft to get the two magnets exactly 180 degrees apart.

I'm surprised to hear you're not painting in the lounge room - it's far too cold to be painting else where!

Cheers

Bennie
"The lounge room is not a workshop..."
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Silverbullet
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Post by Silverbullet » Sun Jun 26, 2016 6:51 pm

Thanks for the tip Jules, Phizinza also has a similar knuckle in his Brumby. Now I will definitely be on the lookout for an Outback at the wreckers. One question though, is it a bad thing to not have the rubber disc in there any more? As for the tip top paint job, looks like someone sneezed in your engine bay :mrgreen:

Bennie, the brand is Equus (American made) model 9000-B or something like that. It is quite old, funky retro looking control panel for inside :cool: It only has the control pad and the vacuum can, no other black box to mount anywhere (all the brains are inside the vacuum servo) Think I've found a good spot for the controls under that little storage bin thingy on the right hand side of the steering wheel, below the vent. If everything still works as it should it has a few adjustments that can be made with dip switches etc to suit different cars. Can run the magnet/sensor OR hook up to negative side of the ignition coil for speed sensing and prevent over-revving. If I can get my twin coil pack with it's two negative sides combined to one negative then that option will work instead of the magnet. Also the assumption is I will only use the cruise control when on longer open roads in top gear only.

Here's todays progress shot, can confirm VG30E Maxima alternator is a direct fit for the MY with no mods required, very nice :) Charging system is all done now, next time I start the engine I should be able to see 14 volts at the battery. Once I get all the right belts that is, haven't looked for them yet hoping they're all still easily obtainable. A/C compressor is in for the last time too, just need to make some mounts for the condenser and I can seal the system up.

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Will it ever end!?
-EA81 TWIN CARB!!!!
-L series 5 speed
-Custom paint job
-2" lift
-Full custom re-wire
-L series front end
Image

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Bantum
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Post by Bantum » Mon Jun 27, 2016 4:37 pm

Awesome work Sam ... :)

One query - What type of plug did you end up going with on the back of alternator ?

Cheers, Bantum ...

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TOONGA
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Post by TOONGA » Mon Jun 27, 2016 4:44 pm

Looking really good Sam ... as for the rubber it stops vibration through the steering column I don't get vibrations in this vehicle but in my last brumby I did. I never got around to putting the rubber plate back in.

If you look around the forester knuckle has a rubber disc in it, so does the later model impreza. It is just a matter of finding the right length knuckle.

The paint was applied with a WD40 nozzle, a layer of kill rust grey then a layer of cheap white paint it took 2 days to dry. I did it when I was waiting for a replacement gearbox to show up. it was still tacky when the box went in :)

TOONGA
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Silverbullet
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Post by Silverbullet » Mon Jun 27, 2016 8:07 pm

Bantum wrote:Awesome work Sam ... :)

One query - What type of plug did you end up going with on the back of alternator ?

Cheers, Bantum ...
Just bare spade terminals for the moment, have one of these on the way - hoping it is the right connector, it looks right from the photo at least. Also a nice big copper cable lug crimped properly for the main power connection.

Jules, I'm not sure if all of these different models of differing years use the same splines as the MY? If I can get one like in your pic I'll see how it goes, maybe I won't need a rubber disc. Would power steering in general resist vibration more than a manual rack? Same as power steering doesn't follow the troughs and holes in the road like my manual rack does.
Will it ever end!?
-EA81 TWIN CARB!!!!
-L series 5 speed
-Custom paint job
-2" lift
-Full custom re-wire
-L series front end
Image

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AusTas75
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Post by AusTas75 » Mon Jun 27, 2016 8:50 pm

That must be the best EA81 engine I have ever seen nice very nice

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Bantum
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Post by Bantum » Mon Jun 27, 2016 9:52 pm

Jeepers, nearly 20 bucks for one small plug ... :(

My touring wagon has power steering - can't recall if it had the rubber disc though ... :rolleyes:

The disc usually takes all the smaller bumps out of the system - so it wouldn't hurt if left out, you'd just feel all rattles in your system more though ... :)

Cheers, Bantum ...

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Proton mouse
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Post by Proton mouse » Tue Jun 28, 2016 12:48 am

Getting so so close now to being on the road!!
My 84 wagon ran power steering for 12 years without any rubber between the uni joints and had no discernible vibration.

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Silverbullet
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Post by Silverbullet » Sat Jul 02, 2016 10:22 pm

Another little progress report for this week; the alternator plug arrived and was the right one, hooray! :) $16 for one plug may be a bit steep to some but for one-off's like this to make everything plug and play, I don't mind. Same story with the connector for my Audi crank angle sensor. The plug came with two wires already in it, I got them out and put my own wiring in the plug for that factory finish.

Also got the two little brake lines that go on the RX rear discs copied in stainless braided this week, which allowed me to complete and seal up the brake system for the first time. Might put some fluid in it next week and attempt to bleed the system...maybe...:???:

Also slightly un-related but in the coming week I might hopefully be getting my hands on that new welder I've been after for some time, dedicated TIG machine with AC capability so I can weld ally amongst other things :) Can't wait to hack up that pair of old cylinder heads I've got for some experimenting :twisted:

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Will it ever end!?
-EA81 TWIN CARB!!!!
-L series 5 speed
-Custom paint job
-2" lift
-Full custom re-wire
-L series front end
Image

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El_Freddo
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Post by El_Freddo » Sat Jul 02, 2016 11:02 pm

Very nice work and once again close attention to detail. Outstanding work SB!

Cheers

Bennie
"The lounge room is not a workshop..."
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Silverbullet
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Post by Silverbullet » Sat Jul 09, 2016 8:12 pm

Steering knuckle is sorted :) I pulled it out of a Liberty sedan, perfect length and perfect fit.

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Will it ever end!?
-EA81 TWIN CARB!!!!
-L series 5 speed
-Custom paint job
-2" lift
-Full custom re-wire
-L series front end
Image

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El_Freddo
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Post by El_Freddo » Sun Jul 10, 2016 2:01 pm

Nice one mate.

I think you'll have to paint it :p

Cheers

Bennie
"The lounge room is not a workshop..."
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El Freddo's Pics - El_Freddo's youtube

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Silverbullet
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Post by Silverbullet » Sat Jul 16, 2016 7:32 pm

A little more progress today - I took the rad out for the mods to the top mounting holes so while it was out I decided to fit up the A/C condenser. My car didn't have the 2 little angled brackets on the bottom support for the locating pins on the bottom of the condenser. The Brumby has these brackets, I find it strange that the wagon didn't have them (never had A/C from factory) when every other hole and bracket for the A/C system is present throughout the body. Anyway I made up 2 little brackets and attached them with rivnuts (no welding on the painted body!) I'll remove the whole lot again to paint the brackets and get the condenser tested for leaks, once it's all back together those brackets will never be removed again :)

I'll be taking the rad to work to use the AC tig welder there, since the first shipment of new machines (one of which I had my name down for) were sold out before they even landed :( Now have to wait till August for the next lot.

Yes the condenser is touching the center light assembly, will have to space the bottom of the light bracket out a few mm to get some clearance.
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Will it ever end!?
-EA81 TWIN CARB!!!!
-L series 5 speed
-Custom paint job
-2" lift
-Full custom re-wire
-L series front end
Image

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Silverbullet
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Post by Silverbullet » Sat Jul 30, 2016 6:53 pm

Belts! :)

All my drive belts arrived this week (bought 2 of each for spares) so I put them on today, looks like spaghetti junction in there now! Also welded the ignition trigger ring on the crank pulley properly and painted it. Removed all the rest of my custom brackets for painting too, now they are done and I know they don't need any more work. Still need to get a plug made for the dizzy hole and think of a way to hold it in there.

Also now thinking about how to make one good (twin carb) air cleaner box out of 2. The original twin carb air cleaner box is all beat up and has big holes in it, and I have 2 regular air boxes in perfect condition. Will cut the center part out of the beat up one and weld it into the center of a good one while still using the twin carb air box lid. I'll need a special cutting tool to cut these out neatly.

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Will it ever end!?
-EA81 TWIN CARB!!!!
-L series 5 speed
-Custom paint job
-2" lift
-Full custom re-wire
-L series front end
Image

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