FFR Refurb

Decided to move the FFR tables out of the way today, they've been cluttering up the workshop since I got them from Corowa. They needed fixing and I just hadn't got round to it.

They were all slightly damaged, one had the spotwelds torn apart and was in two parts. The others were bent and had one or two spotwelds broken.

https://www.aulro.com/afvb/images/im...013/05/230.jpgDSCN2390 by Colin Radley, on Flickr


I'd asked a couple of customers that had spot welders and they weren't keen on welding aluminium for some reason. Instead I dug out some aircraft aluminium rivets that I aquired about 30 years ago when I worked at Stanstead Airport in the UK. It took a while to locate them but it was straightforward from there....
Drill a 4mm hole, countersink, insert rivet and peen over the back. Wherever practical I put the rivet into the depression left from the original spot weld.

https://www.aulro.com/afvb/images/im...013/05/231.jpgDSCN2388 by Colin Radley, on Flickr


Here are the tables finished and ready to store away. They need cleaning and then a coat of olive drab.

https://www.aulro.com/afvb/images/im...013/05/232.jpgDSCN2393 by Colin Radley, on Flickr


Problem then is that storage space is at a premium so they have been put into the back of the 2a GS temporarily.

https://www.aulro.com/afvb/images/im...013/05/233.jpgDSCN2395 by Colin Radley, on Flickr




Colin

Long weekend so I decided to do something, however small, on the FFR.

When I got it one of the rear shock absorbers was missing in action.
Dolphint offered me a pair and I finally collected them a few months ago.
Painted them and decided to fit them at the weekend. Initial panic because I didn't have the long bolt the goes through the top mount but it turned up in one of the rear lockers.

The missing one was 'fairly' easy to replace. Top mount was OK but with the bottom by the time you assemble the rubbers & cups there is virtually no thread exposed to get the nut started on. I ended up shaving some rubber off the mounts.
The other side had virtually no rubbers left. The free play had allowed the stud at the bottom of the shocker impact against the spring which had damaged the end (must have made a racket when the previous owner drove it). The nut refused to come off.
Ended up levering out what was left of the rubber, making sure the nut was fully undone and then used the shock absorber like a slide hammer to get the nut off.
The replacement went on without shaving the rubbers.

Shocker in place.

https://www.aulro.com/afvb/images/im...13/11/1354.jpgDSCN2779 by Colin Radley, on Flickr

The FFR has a roof over it but the leaves & dust build up inside because the canvas is off (after the roof section was replaced).
I mentioned 'pocket money' and gained some helpers to sweep out the inside.

https://www.aulro.com/afvb/images/im...13/11/1355.jpgDSCN2762 by Colin Radley, on Flickr


It still starts & runs OK then after a while runs like a dog.
Need a few other projects out of the way then I can try and get this one sorted and on the road.

I need to replace the passenger side wing & door plus the bumper & brushbar needs to be straightened. Not sure how I'm going to do the brushbar yet, I don't have an oxy set and I'll have to take the hydraulic press apart to get it in place.....

https://www.aulro.com/afvb/images/im...13/11/1356.jpgDSCN2784 by Colin Radley, on Flickr


Colin

What a pity about Temora, the outer wing would have been much better than that. Apart from the powder blue civvy colour.

I didn't know it was for a FFR.

I even tried to get a regular attendee to take it back to Melbourne. :(

Quote:

---

Originally Posted by Lotz-A-Landies

What a pity about Temora, the outer wing would have been much better than that. Apart from the powder blue civvy colour.

I didn't know it was for a FFR.

I even tried to get a regular attendee to take it back to Melbourne. :(

---

Diana,

The outer wings I'm after are for the SIII C240 powered shorty, I have a complete wing for the FFR but just haven't had time to fit it.



Colin

They're still yours if we can get them down to you.

After refusing to start a couple of times (plenty of fuel, no spark) I decided to investigate.
Points were not the best so new ones fitted & gapped, no change.
Noticed the coil got warm quite quickly so then had to work out whether to fit a resistor or non-resistor coil. Original was non resistor but this failed early on so I'd used one from another motor which was a resistor type. There is a strange item in the feed to the coil, not mentioned on the military wiring diagrams.....resistor or suppressor (capacitor) ?
Put a meter in the feed to the coil and left for some minutes with the ignition on, voltage didn't drop so went with the non-resistor coil.
Started first time, I'll leave it running later today and see if it starts to misfire again.

Fitted a new rotor arm, found one from a VW that fits the Bosch distributor fitted to the FFR. Also found a condensor that should fit with a few modifications (originals difficult to obtain), just have to order it in.


Colin

Managed to replace the wing today.

https://www.aulro.com/afvb/images/im...013/12/127.jpgDSCN2866 by Colin Radley, on Flickr

Not sure about the bumper, might be a quicker option to look for a replacement.

https://www.aulro.com/afvb/images/im...013/12/128.jpgDSCN2863 by Colin Radley, on Flickr

I'll de-skin the door and straighten the frame next then try to get the skin back to shape and re-fit.



Colin

Several other projects have got in the way of the FFR. It gets started & moved occasionally but that's about it.

I had an unexpected day off work today (work car problems) so decided to do a couple of those jobs I keep putting off.

Someone had backed it into something and bent the rear crossmember so I thought I'd have a go at straightening it.
First off with the Jerry can holder. The bolts were very rusty and I don't think they've been removed since it was built.

https://www.aulro.com/afvb/images/im...016/05/899.jpgDSCN3914 by Colin Radley, on Flickr

Here is the view from underneath.

https://www.aulro.com/afvb/images/im...016/05/900.jpgDSCN3915 by Colin Radley, on Flickr

Backed up to a tree stump and used a Come Along then thumped the buckled part with a big hammer.

https://www.aulro.com/afvb/images/im...016/05/901.jpgDSCN3919 by Colin Radley, on Flickr

The Come Along was at it's limit but after chocking the wheels it did the job OK.

https://www.aulro.com/afvb/images/im...016/05/902.jpgDSCN3921 by Colin Radley, on Flickr

I need to remove the corner capping & straighten it out a bit. Difficult to do in situ.

The bumper & brushbar are damaged and I've had no luck finding a replacement bumper so decided to at least straighten it a bit.

https://www.aulro.com/afvb/images/im...016/05/903.jpgDSCN3830 by Colin Radley, on Flickr

Same stump & Come Along.

https://www.aulro.com/afvb/images/im...016/05/904.jpgDSCN3923 by Colin Radley, on Flickr

Plus a Tool I made to bend the top & bottom edges of the bumper.

https://www.aulro.com/afvb/images/im...016/05/905.jpgDSCN3925 by Colin Radley, on Flickr

Then off with the damaged drivers door.
Found a temporary one to fit.

https://www.aulro.com/afvb/images/im...016/05/906.jpgDSCN3927 by Colin Radley, on Flickr

The canvas has been repaired but because the FFR sits in an open sided shed the blue tarp keeps dust & leaves out and stops the birds sitting on the bows & ****ing into the vehicle.


Colin

Jerry can holder repaired between chores today.

https://www.aulro.com/afvb/images/im...016/05/898.jpgDSCN3934 by Colin Radley, on Flickr

Need to get them both shot blasted and re-painted.



Colin

Excellent thread, thanks for all the information.
I'm in Langy and just starting to work on a S3 GS with the 2.6 motor.
Hopefully it wont need as much work