Formerly Green BB9

[Scott560]

Some epic work there - now if only i had somewhere to install a lift!

Glad to see you went for some of the red strongflex bushes in the most critical parts - i have yellow all round and wish I went red.

Out of interest, how did you galvanise the bolts?

[Brozilla]

That is my good friend's lift. Lifts to be exact, he has two, I don't have one of my own unfortunately.

Yes, I went for the more soft setup because I've driven in an all yellow setup and if I had kidney stones they would shatter

There is a place nearby that galvanizes anything magnetic. They steam the parts to clean them, then put them in sulfuric acid, then steam again and finally galvanization.

[wurlycorner]

Wow.
That is really epic work. Looks SOOOO nice.
Well done and I can't wait to see more of how it turns out!

[DocQaz]

Totally amazing!!! I've had my BB8 resprayed and arches sorted out.

Now looking to get the bushings totally revamped with Poly's too and the whole underside properly de-rusted undersealed.

I was wondering if you could help me out with the anti roll bar bush size? Mine's a 1998 with 4WS and strong flex want to know the so,e of the front and back ant roll bar bushes, which I'm not certain on I'd really appreciate if you could help me out. The US forums will likely have different sizes to us.

One other thing I'm struggling to find is replacement ball joints. If you could let me know where you got yours that would be awesome because getting them separate to the whole are is almost impossible unless you get from US and pay extortionate import charges.

Thanks!!

[Brozilla]

Sure, no problem. Basically 2.0 models had 25.4mm front anti-roll bars, and 2.2 had 27.2mm. For the rear bar I remember only a single option: 23mm.

I have a friend that works in auto parts who supplies me with parts that cannot be acquired as OEM. He has the part number for ball joints, I will let you know tomorrow.

EDIT: here you go:
Part number: 825003810, make: FAG, 4 needed
Part number: BJ-499, make: japanparts, 2 needed
Part number: H-213, make: teknorot, 2 needed

[DocQaz]

Wow, such a quick response. Greatly appreciated!!

[sol-lude]

Holy jobby balls thats epic work love the dedication.

[bennyboy]

Fantastic commitment! Nice one.

[Brozilla]

Some updates:

Engine had some major setbacks unfortunately and never lived to be turned on. Luckily I detected something was wrong with the work that builder did and had it opened. These were the results:

ARP headstuds were torqued into block, not hand tightened, causing the block to crack
Some threads in the block were damaged
Head was scratched and had to get remilled
Main bearings were chosen and placed in wrong order
Piston ring gaps weren't adjusted, just placed in the engine as is.
Cylinder walls were bored to wrong spec, they were too tight

Considering the cost to repair all the damage, I trashed the block and got another one. This time I personally drove all the parts to be machined and had the machine shop measure it in front of me. Needles to say, another builder did the second block, under close supervision. He did great work and engine started without a hiccup. Hope to get it on the road by the end of the week.







Finally in the chassis. Bolts that got paint on them got cleaned up, galvanised and reintstalled meanwhile.




Creative mess while figuring wiring and vacuum routes. All water and vacuum hoses were replaced with silicone in the process. I will update the state of the engine bay when I tidy it up.
Battery was also relocated to trunk.


Charge pipes, still need to do the upper part:







Braided brake lines and ATR front calipers:




Finally on its own wheels after months on the lift:

[vanzep]

Just brilliant