The aim today is to get the rear suspension stripped down and all components separated and ball joints removed ready for the metal parts to be cleaned and re-finished.
The standard rear suspension and brake set up is pretty straightforward with floating brembo caliper acting on a vented disc, top and ottom wishbones with an aluminium upright connected to the wishbones with a ball joint. An adjustable tie bar connected between the lower upright and inner rear wishbone mounting keeps everything pointing in the right direction.
Handbrake cable off first, then 2 bolts holding caliper. Loosen the flexible brake hose and the caliper can be unscrewed off the hose. The disc can then be lifted off and chucked. The Koni spring damper unit is next off and that goes straight in the bin too. 2 bolts holding the upper plinth to the upright loosened next followed by the 4 bolts holding the lower plinth in place came out pretty easily (see photo). Screwdriver between the CV joint and gearbox casing frees the inner CV and drive shaft. 6 Bolts can then be taken out and the whole upright with driveshaft removed.
A quick trip to the vice to split the plinths from the ball joint and it was out with the Eliseparts bj removal tool and they were quickly removed and dispatched to the bin to join the brake disc and spring damper.
Then repeat the whole thing on the other side. All went ok, everything came out pretty easily with no seized bolts. Only whoopsie really was that I slightly damaged the gearbox oil seal carrier when I pryed the driveshaft out on the n/s. Doen't look like the seal itself is damaged so I might have got away with it. Not that it's a problem anyway cos there is a new close ratio box going in. Just don't like damaging anything but will probaly sell it some point later.
So, only eleven o'clock and all the rear suspension is out. Had a coffee then demolished the last of the mince pies I had sneaked out of the house and it was on with removing the old exhaust. Not too long before it was out although I did have to cut the flexy pipe between the cat and the manifold as the nuts securing the cat were just a rusty blob with no discernable flats to even attempt getting a socket on. The silencer was soon out and joined the other bits in the bin. Next to come off was the rear subframe which was easy enough giving access to the engine which I am planning to remove tomorow, day 6.
Access to th engine and gearbox is excellent with the rear subframe out of the way. The plan is to take the standard K16 out and fit the VVC. Not sure yet what I am doing about a rebuild on the VVC and some trick bits. Junks assured me that it was out of a low mileage car and should be good for a while in std. spec. Will think about that and maybe have a chat with Dave Andrews and see what he recommends. Plenty of time for that as there is quite a bit of work in the engine bay to do to tidy things up and fit some nimbus to the bulkhead.
Got to pick up an engine hoist from work in the morning, I think I have got some straps somewhere which should do the job.
With everything I had planned to do at the rear finished it was then on to the front end. First to come off was the steering rack which is missing a steering arm, Phil did know about it and promised to let me have a recon unit he has.
The pedal box also came out complete with brake and clutch master cylinders, both of which I will be replacing. You can just see it to the left of the rack in the photo. Pedals have already been modified to help heel & toeing. but I will have a look at the bushings before it goes back in and replace any that are worn.
Then it was the turn of the radiator having first drained everything down (by pulling off the hoses and some careful placing of a bucket). The rad doesnt seem too bad tbh but I will replace it with pro alloy jobbie and new fan and keep the other as an emergency track spare.
With the rad out I could have a good look around the front structure. I tucked the loom back into the the footwell to gmake it easier to work in the area. The wiring look to be in a bit of a state and I am not looking forward to sorting it out, there is even a suspoicion of a small fire having melted the cable sheathing. I will come back to that in a few months time when I am feeling brave!
Apart from a good clean, there wasn't much needed doing. Next to take out was the heater and fan, I say take out, it pretty much fell apart. Good job I am leaving it out to save weight. The whole area around the heater was filthy and full of years worth of muck and leaves. Took a while to clean out but after I had spent a good few hours wiping down the ally and front crash structure with WD40 it started looking distinctly improved.
In summary a good day with lots done although with so many bits taken off so far, the garage is laready starting to look cluttered. Mmmm, I wonder if my gf Emma will notice if I store them in the house...... I will let you know in the next post. Finally last photo of the day gives you an idea of how it now looks and I am reminded that there is still much to do and a very long way still to go before I can start putting bits back on.
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