Warwicks Split

[Warwick-Lowlight]

I still cant believe that there is not a similar kinda rubber anywhere in our sunny land to replace the shot ones on the kings and links
So having a thought that the profile is somewhat similar to a hydrolic piston rubber as those are also flared on the outer lips
Made it my mission to find something better to use than the current solution

By lowlightwarwick at 2012-08-30
Od 50 and Id 40 with a 5-7 flare - has to be something out there less than 50 zar !!!!

The mechanical mission continues
Stripping down the kings and links
Need to make a puller to get the king pin out
Then will get out all the bushes for samples for my mate that he can get a replcement "kit" going

By lowlightwarwick at 2012-08-30

Generally the settup looks good -was still grease in all the moving parts
Link pin needle bearings seem good and snug in the bushes - a little bit of play on the lower king pin bush
Will have to wait for the puller to see whats happening in there

Got the brake master and slaves back yesterday - just one front slave needs attention as the bleed nipple does not engage properly so going to drill it out to 6mm and then put an 8 mm tap and nipple in
Got a lession from the GS Master yesterday on the cleaning of the release bearing - so that is also on the cards
Thankyou again Grand Master

Sand blaster will also be put to work on the backing plates so I can finish them off and fill that brain fade gap


Allot planned here will hope to get a few hours in this weekend
One day I hope to swop places with Sean and get just 1 full 12 hr stint

[Warwick-Lowlight]

Seems I have found a replacement rubber seal 10 Zar
Just need to get the kings out
So made a puller
Seems more soaking is needed as that thing is tight

By lowlightwarwick at 2012-08-31
Here is the Sand Pit

By lowlightwarwick at 2012-08-31

Also started taking off some of the rusted bits to see whats cooking behind



By lowlightwarwick at 2012-08-31


By lowlightwarwick at 2012-08-31


By lowlightwarwick at 2012-08-31


By lowlightwarwick at 2012-08-31


By lowlightwarwick at 2012-08-31

[jolas]

Ouch ! A fair bit of work, care of the tin worm. Really interested in what you're up to with the king and link pins there Warwick

[Warwick-Lowlight]

Stuggling a bit with them Paul
Seems i need to modify my puller - not pulling straight
Interesting - the grease nipples all had a section of wire spring in them
Lets see if the soak and the puller modifications will help get that thing apart

[Warwick-Lowlight]

Well this was challenging but I have overcome

Tools required
21 and 19 sockets
Home made puller
Gas
cut off section of pipe or as I used a big old plug spanner
Hammer
Small drift

Had to upgrade the puller as I kept on bending the pin
Drilled hole bigger to fit the Link pin
Then the 17 mm threaded rod snapped
So went up to a 20 mm bolt
Welded bolt in place and started pulling
No go
Then a bright idea - use some head and heat
Heated the top section first still nothing
Whole lot is still under tension
Heated bottom section for about 10 seconds and bang - nothing better than that sound of something givving in
A wee spray of penetrating fluid and the rest just turned out easy
To get the bushes out
Link pin bushes -21 mm socket and pipe extention and just press out with a vise
King pin bush same procedure just use the 19 mm socket
Just remember to push out the dust cap at the bottom of the arm
Used a small metal drift
Cleaned up and ready to go off to the engeneers to take down all the measurements and get get some pricing sorted out
All bushes are good except a little play on the bottom king bush

This was a real fun mission
Hopefully the other side will go a bit easier with what was learned
Main point is put the whole lot under tension and heat the bottom knuckle

Some before and after play in sand pit

By lowlightwarwick at 2012-08-31

Straightning the puller - did not help as that treaded number broke

By lowlightwarwick at 2012-08-31

Link pin for bottom piece of puller

By lowlightwarwick at 2012-08-31
Used a step bit to drill out - did not have a 20mm bit
Nearly did a kung foo move when the bugger bit !!

10mm bar not good enough

By lowlightwarwick at 2012-08-31

Pushing the bush out started with the 21 and 36

By lowlightwarwick at 2012-08-31
Then made this

By lowlightwarwick at 2012-08-31


Can see the little gap starting

By lowlightwarwick at 2012-08-31

All washed

By lowlightwarwick at 2012-08-31

This job is definately not as bad as all make out - a bit of patience and it will come apart
Going to be fun pushing the whole lot back together - might have to fasion a press of sorts

[jolas]

I smell Jeyes Fluid in that last photo !

Good stuff Warwick, thanks for all the detailed photos

[retrovan]

Hi Warwick,

Get a heat gun, and heat the knuckle before you press in the bushes, Makes it much easer, I heated mine with plumbers blow torch and pressed them in with the vice, just slipped in......

Great job so far.

Herman

[Warwick-Lowlight]

Thanks Herman for the tip
Will remeber that
Now off to take the right side apart

[Warwick-Lowlight]

[quote="Warwick-Lowlight"]Now off to take the right side apart

To quote myself
if only it was that easy !
6 hrs later - many more repairs to puller an still only got him to move like 2 mm
Retired beaten lunch time yesterday
Gave it another attempt last night and some shoddy welding gave way on the puller
Soak overnight

This morning repair the puller - made sure all the bits were nice and square
Oiled the thread on the puller and turned away
To my suprise she gave in and came right apart without even a sqeek of resistance

Washed all the bits
Seems the only thing abit buggered -apart from the bottom king bush - bottom needle bearing seems a bit rusted

By lowlightwarwick at 2012-09-03


By lowlightwarwick at 2012-09-03

[Warwick-Lowlight]

Well have not been busy here for a bit
Gave in and will get the front parts from over the sea - uncle owes me a favour
till then play with the Manx
Finished off the backing plates
Maybe get the back axle together again

By lowlightwarwick at 2012-09-14

[Warwick-Lowlight]

Got these the other day from a "Donar"
With the sand blaster ready after doing the Manx drums got to taking out the old rubbers
First with a screwdriver then after nearly stabbing myself - used head and cut them out with a carpet knife
Still cant believe that these popouts are in such a good shape considering what the rest of the bus looked like



The ones from my bus are smoked and the bus not in too bad a shape -





Will have to cut one corner from mine the short side to replace some internal rust - will see what the look like after a sand job

Also got my colour swab from one of the inside popouts -



Enjoy the heritage day
And for those of you doing the Braai day - braai like champions

Im "working"

[Stütz]

What you're doing here is amazing Warwick! Very impressive.

[splitbusahollic]

Braai'd like a champ yesterday.....bus duty today !
looking great Warwick !
i need to start seeing some green patches on that bus of yours......

[Warwick-Lowlight]

Jacques heard on the grapevine the other day that the bus boys want to add a new colour to the vw colour pallette

Code - 041

For international users - +2741

Gerson Green


Even Madiba wants some for his 100th birthday shirt

[Warwick-Lowlight]

The good
The bad
and
the
Ugly




Sand blasted
Rubbed with that wonder plastic wheel

Now just for some etch primer paint and some rubbers