5 GT Turbo R5 GT Turbo - Complete strip down and re-build #1

[Russyh]

If they are the same brake clips as fitted to 182 brake hard to flexy lines, then they are the same as the BMW ones here:

Pardon our interruption...

Hope that helps

 

[Chris74#]

Spot on cheers mate. Im in Redcar, where are you based?

Burton upon Trent mate.

 

[Chris74#]

If they are the same brake clips as fitted to 182 brake hard to flexy lines, then they are the same as the BMW ones here:

Pardon our interruption...

Hope that helps

Thanks @Russyh just ordered 4

 

[Turbell]

I'm absolutely resisting saying I want that extra beam for Camprust , because I'm absolutely not going to do anything with it.
I have in no way had a tape measure out today on the 225 and looked at how the engine would fit.

 

[clarky_gtt]

Any chance you have the sizes for the rear axle to body nuts and bolts? Only ones I didn't get new as nla

 

[Chris74#]

Any chance you have the sizes for the rear axle to body nuts and bolts? Only ones I didn't get new as nla

Hi @clarky_gtt - 2x M12x170mm & 2x M12x 140mm - Both 10.9 Grade with M12 Flanged Nylocs - I went for A2 Grade Stainless Steel just because of where they sit! Slight difference with these is the bolt head size, Mine are a 19mm head as opposed to the original being a 17mm head. I just have to file out the clip bracket that goes over the top of them.

 

[Chris74#]

I'm absolutely resisting saying I want that extra beam for Camprust , because I'm absolutely not going to do anything with it.
I have in no way had a tape measure out today on the 225 and looked at how the engine would fit.

If you want the beam, come and get it, I have a campus beam I can put on to roll the van off to the scrappers!!

 

[Chris74#]

Got out there today, and whilst reading @clarky_gtt 's thread yesterday and his most recent game with the fuel sender unit, I realised that I hadn't got a plug at my sender unit!! Bugger!!! I got under the car and pulled the cables down......after I had dropped the fuel pump & filter!

I messed around for a while, delaying the inevitable tank drop, which I really didn't want to do! I eventually gave in and first released the bolts along the back of the tank! I tried to feed the cable up around the back, in the end I got a piece of cable and managed to feed it through, and down the back of the tank, I then taped the sender unit plug to it and gently pulled it all back up through the sender unit inspection hole! phase 1 complete!


Now I have to get the other cable for the pump on the reserve tank back across the top of the fuel tank to the rear of the car! For this I used a metal coat hanger and fed it in from next to the filler spout towards the sender unit hole!

I then taped the pump plug to the hanger and gently worked it through until it popped out at the back of the car. I did have to ease the bolts of in the tank, just enough to lower it slightly!

Job done, Now to put the fuel pump & filter back together although I have ordered the correct clamp for the pump as I have the wrong one on it currently!


Then on to what I intended to do today! Thanks again to Mr @Duncan Grier for advising me on the route of the handbrake cables - through the beam! a bit fiddly, but coming from the front of the car backwards is the way to get them in!



The I started to have a clean up in the garage, and got the brake compensator valve cover into the wash and gave it a scrub!

Then put it through the sand blaster and got some paint on it! Tidy it up a bit!



That looks a lot better! In between painting I decided to make a start on the passenger side rear discs! Got the new disc out and pressed the bearing in!


Again I used an old bearing to drive the new one in....

and its in!

Then in with the snap ring, I got it half way in there and then used the old bearing again and gently tapped it home!

Then off with the old disc!


I gave it all a wipe down in there as there was loads of dust and crap! Then on with the new disc!

Then the new calliper and shock absorber with new stainless bolts!


Then on with the pads!

Gave the clips and retaining bar a wipe down and got the pads in!



I then got another wheel down from the loft and got it on, along with a new brake line clip!




I then got the new compensator valve out and got the freshly painted guard off the washing line!!

I then roughly fitted the vale in position, but this can wait til next week.



Really happy with this weeks progress and with the way it all looks! Thanks for reading guys!

 

[Big Steve - Raider]

Simply stunning @Chris74# !!

 

[Chris74#]

Simply stunning @Chris74# !!

Thanks @Big Steve - Raider means a lot coming from you!!

 

[Turbell]

If you want the beam, come and get it, I have a campus beam I can put on to roll the van off to the scrappers!!

I'm starting nights today, so I'll be zombie-fied in the day for a bit, but yes, I'm interested in the beam, sort of forming a plan for Camprust if it stays, but I'm not shouting about it yet as I really don't have the mojo ATM.
If you want shut quick , like in a few days, or someone else steps up, crack on, but I'll send you my number on a PM, see what I can sort, I'm only an hour away.
Thanks.

 

[DaveL485]

with new stainless bolts!

Don't use stainless on load bearing suspension, it's not the right tensile strength, you need 10.9's.

Is it me or have nuts and bolts gone mental in price lately? I save a bit by buying in bulk for most, but the bigger stuff, M12 upwards is crazy money all of a sudden.

 

[Duncan Grier]

@DaveL485 looking at the post @Chris74# has used 10.9's just in stainless flavour - as not a stretch bolt application what is difference? Genuinely never looked so could be talking out my butt maybe different carbon content and other properties change sheer point?

@DaveL485 cant remember the name of the place/guys but one at bottom of humber road in Stoke by the bridge, used to be my no.1 place to go - was fantastic....think they might have moved upto a unit by Canley/Tile Hill if still trading?

But yeah shocking costs now, and sheet steel rocketing

 

[DaveL485]

@DaveL485 cant remember the name of the place/guys but one at bottom of humber road in Stoke by the bridge, used to be my no.1 place to go - was fantastic....think they might have moved upto a unit by Canley/Tile Hill if still trading?

Kebrell's, yes used them for ages, yes they moved and from lockdown 1 they stopped dealing with public/over the counter wasn't very please about that I can tell you.

 

[DaveL485]

@DaveL485 looking at the post @Chris74# has used 10.9's just in stainless flavour

The materials used to make steel stainless inherantly make it weaker, It's basically down to tensile strength where fasteners are under load. You'll see the markings on the bolt heads.

8.8 (carbon steel) 828 N/mm²
10.9 (carbon steel) 1035 N/mm²
Carbon steel being an iron/carbon alloy.

A2-70 (stainless) 700 N/mm²
A4-80 (stainless) 800 N/mm²
Stainless is a carbon steel with additional alloys, such as chromium, nickel, molybdenum etc.

Tensile strength is "the point at which it snaps". As you see above, even the higher grade stainless is weaker than 8.8 carbon steel. The bolt will deform before it snaps, but to be fair you dont want either to happen.

Deforming takes even less stress, you have the 0.2% yield which is "the point at which it permenantly deforms by 0.2% of it's original size" - you dont want this to happen in suspension components.

8.8 635 N/mm²
10.9 897 N/mm²

A2-70 450 N/mm²
A4-80 600 N/mm²

Obviously there are a metric shit-ton of variations of stainless alloys with varying properties but the above is based on what an average joe like me and you can access easily.

(I confess I did have to google the N/mm² values - it's about 25 years since I was doing this at Uni!)

 

[DaveL485]

...saying all that it looks like its a plated 10.9 anyway when I zoomed in (does that say 10.9?), so I think it's OK. Just remember kids, dont use stainless fasteners on load bearing components

 

[Chris74#]

...saying all that it looks like its a plated 10.9 anyway when I zoomed in (does that say 10.9?), so I think it's OK. Just remember kids, dont use stainless fasteners on load bearing components

View attachment 208222

So, just checked the invoice from Westfield fasteners, the longer M12 bolts are BZP 10.9

 

[Chris74#]

Todays update! firstly unwrapped my new pressie! was really struggling to get the car high enough to get the axle stands underneath with some decent height! I need the extra space!

Some other bits turned up during the week too! thanks to @Russyh for the tip on the brake saddle clips!
I carried on with the rear brake pipes! I checked the destruction manual first! that was a waste of time! Some I got under the van to see how the valve is plumbed in!

That helped, so I marked up the drawing in the manual!


Then got on with pipes!


I made a template and bent a new pipe to match, ran it across to the valve and then noticed that there are different size holes in the valve! WTF?

I am assuming that the bigger holes are for the feed from the front of the car??? any info on this would be appreciated! Anyway the pipe had the wrong size union on it and so was scrap! Started again and got all the pipes bent and on, Had to have a dig through my bucket of bits to find a brake clip for the rear!




Then posty turned up with the new fuel bracket!

Then I started to look at the handbrake! I sorted through the bits and had to get cleaning & plating as it is seized!


Gave it a good dose of WD40 and wiggled it around until it was free! The I stripped it down and got the bits in to some hydrochloric acid!




I made a neoprene gasket for the handbrake!



I then plated the bits once I had cleaned them up!

I got the handbrake outside and plasti-coated the handle as it was a bit rough!




I got the rear arch on and dropped the car back down! Thats it for today, thanks for reading guys!

 

[Chris74#]

Forgot to add this one!!!

 

[Big Steve - Raider]

Take the plastic fella off, I believe it’s a gauge to help you set the correct tension.

Otherwise the spring won’t spring.