Isuzu C240 powered Series 3

**gromit** · 26th September 2015, 06:09 PM

Managed to dig up & repair the stormwater drain that was causing problems. Looked like it had been crushed soon after being installed so there was a restriction and a crack that roots were getting into.

After cutting the grass, washing cars etc. I found some time for Wallit.

Fitted the front valance. Wrinklearthur kindly sent me the mounting brackets some time ago (a long time ago in fact).

Then decided to chase down the speedo problem.
Pulled the instrument panel and found that the end of the cable that holds it to the speedo had come away. There were some signs of araldite so I found some 5 minute epoxy and about 1/2 hour later took it down the driveway. Still didn't work.

Disconnected the gearbox end and spun it up using a cordless drill, one of the boys confirmed that the speedo was working OK. Investigated the end that fits into the gearbox and the inner was oval rather than square.
Found a new cable in-stock which was slightly longer (pattern parts ?) fitted that and it works now........

Need to get the swivel hub leak fixed and it's nearly there.

As I tidied up I heard some strange noises down the garden as the light levels dropped, turns out the Tawny Frogmouths are back nesting again......

Colin

**debruiser** · 30th September 2015, 09:10 AM

He's looking good! I've never been drawn to that colour before but it's actually pretty nice

**gromit** · 30th September 2015, 07:39 PM

Originally Posted by debruiser

He's looking good! I've never been drawn to that colour before but it's actually pretty nice

It's not a bad colour but I need to decide whether to paint the rest of the panels as only the doors, front panel drivers side wing & valance have been repainted. The rest are showing a patchy darker green.

You'll see the colour on Mini's, Rover cars, P76's etc. Seems to have been a 'Leyland' colour.

Colin

**gromit** · 10th October 2015, 04:43 PM

Looks like I've fixed the leak on the front swivel hub.
I had to helicoil the drain plug thread some time ago and the drain plug didn't seal properly.

Looks like the Tawny Frogmouths have two young this year.

Dad is usually nearby keeping an eye on things.

As it gets dusk he heads off hunting.

Colin

**gromit** · 10th October 2015, 07:43 PM

Decided the other week that I need to make the battery hold-downs from stainless steel.

Surprising how cheap it is, 4mtr of 304 stainless 6mm diameter was under $7. More expensive was a HSS die but the stainless wing nuts were very cheap.
Cut, bent & threaded the hold-downs tonight.

I'm also going to experiment with leather gaiters for the Hi/Lo & handbrake levers. fed up with the poor quality rubbers that disintegrate while you watch.
I'm making a couple of templates to help cut out a washer made from 5mm leather to support the gaiters where they're clamped. The washer will be sewn to the gaiter. Just need to find some time to play around and make one to see what it looks like. It won't be as waterproof as a rubber one but will keep the dust out, mind you if the rubber one has split a leather one would do a better job !

Colin

**gromit** · 24th October 2015, 07:06 AM

Wallit now has a leather handbrake gaiter.

This was a trial fit (only a couple of screws fitted). I'll apply some neatsfoot oil to the leather to waterproof & soften it.

Looks OK and much better that the aftermarket rubbers which break down in a remarkably short time.

Details of making it here http://www.aulro.com/afvb/showthread...11#post2440711

Colin

**gromit** · 16th November 2015, 07:27 PM

Getting close to some test runs.

Just took out fully comp insurance.
$4K agreed value, Club Permit (90 days use per year) insurance $68 for the year.

A couple of minor issues and a few things like replacing the bonnet, painting the roof etc. but they can wait........

Colin

**gromit** · 17th November 2015, 06:48 PM

Took Wallit for a short run tonight.

Starts OK, accelerates OK, gearbox AOK (nice to have full synchro). Usual whine from the axles but there was a distinct knock when hitting a bump in the road or low speed turns.

Went back home and couldn't replicate the knock by jumping on the bumper, pushing wheels sideways etc.etc.

I can remember that one of the axle U-bolts stripped it's threads but I don't remember replacing it so maybe it's letting the leaf spring move. Another option is the front propshaft hitting the sump plug on the motor (they are very close). I'll look for witness marks on the sump plug later in the week and check all the U-bolts.

Checked the speedo with a GPS and it's reading low, I'll have to look at the number on it and work out whether changing the head will fix things.

I'm still nervous about the home-made flywheel so I'll get to the bottom of the knock and then do some more short trips......

Colin

**gromit** · 22nd November 2015, 06:43 PM

Took Wallit for another run.
During the week I found the suspect U-bolt & replaced it and also went over the suspension bolts.
No sign of the front propshaft hitting anything.

Just a couple of Kms down the road I lost all drive ! Turned out the transfer box had dropped into neutral. There is a lot of sound deadening material that restricts the lever movement so I'll put it down to that for the moment.

Still had the knock when turning or hitting bumps !!

The PO had freewheel hubs which I removed, I'm tempted to put them back on and see if the problem goes away.

The Frogmouths are getting ready to leave, most nights the young are getting flying lessons.

Colin

**gromit** · 9th January 2016, 06:51 PM

Managed a few more test runs over the Christmas break.
Each time a horrible knock that seemed to be under my feet as I cornered or hit bumps.
Tightened bolts, stripped off the plate under the guard today to check the steering box.....finally lowered it down on the jack and then pushed on the bumper and there was the knock.

Had the young bloke raising Wallit on the jack, lowering and then pushing on the bumper, eventually tracked it down to a loose bush in the leaf spring on the drivers side ?
Sounded much worse when out on the road but was just the spring moving and hitting the drop plates.

Cure is to fit replacement springs or get the eye re-set. Temporary bodge was to squish the outer case of the bush in a couple of spots so it grips. Also found a polybush and cut the flange off and fitted this so it isn't metal to metal if it moves.

Took it out for a run tonight and noise gone !!

Found that the temperature gauge has stopped working so need to look into that but otherwise it went well, kept up with traffic, wasn't too noisy (except at tickover where the whole car shakes).
Got to an indicated 90kph but need to take the GPS out again and confirm the actual speed.

Lots of little things to finish off but at least I can jump in & drive it now (after completing the logbook of course).

Colin

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