Day 40 – 11/6/11 - Success is as fickle as the days weather

First job today was the putting the drive shaft back into the differential.  And two hours later I gave up. I can’t get the end of the shaft passed the circlip and I’m concerned about damaging either the shaft/diff splines or the circlip.  I suspect I need some advice.  Part of the problem is applying the pressure to slip through the circlip.  Eventually I ran out of other ideas so the only option left is to put in on the car so all the parts are secure and I have better control when applying pressure or until I get the advice and try again.

I switched to the steering column. I cut the hole out no problem a quick pilot hole then the new hole saw.  I pulled out the steering column and put it in the hole then grabbed the column/pedal box bracket.  Now if I’m honest something about this bracket bugged me. It had since the Kit Car show.  The problem was the fixing holes.  I mounted the steering column to the bracket and put it up to the underside of the Tub “dashboard”.  The Clutch pedal is already mounted and I was able to slide the bracket over the top of it and then the niggling in the back of my mind became clear. The fixing hole for the front of the clutch pedal bracket didn’t line up, and it wasn’t a millimetre or two out it was far more.  I grabbed the brake pedal and looked at the fixing points and compared them to the bracket holes.  Nope they were nowhere near.

I took the bracket out and removed the column.  Turning the bracket over I tried to put it in place again.  The pedal mount holes aligned no problem but the rest of the bracket wasn’t going to fit.  I’m going to take a guess that when the plate was drilled it was done upside down so when it was welded into place on to the bracket the holes are ass about face.  I went back to the donor car and it confirmed my suspicions.  The holes are the wrong way round.  I took a few photos to send to the lads at MCS and see what they recommend.

Right, back to the rear of the car.  This time it is the rear shock mounts.  The three fixings holes are marked on the tub there are two options A or B. I held the mount up to the tub I would need B.  There is also a centre hole 75mm diameter.  I double checked all the measurements with the donor car and set about drilling pilot holes and then the full 3x8mm.  I measured repeatedly to find the centre between the three points and then drilled 1x75mm.  It took a little playing to ease the 8mm holes before the top fitted close to flush. I still need to do some finishing touches but it looked right.