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Dr.Fraud's Private Scrapyard - A truly horrible blog !


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#181 OFFLINE   Sigmund Fraud

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Posted 13 July 2017 - 07:20 PM

No I even like the colour of the wheels lol, I once painted some Viva wheels a similar coppery hue.

 

"Vive la difference !" - I suspect I'll be respraying them silver or anthracite when they come off the car in November to be replaced by winter tyres.

 

 

How decadent. What was wrong with using a 9.525mm²? Last time I measured a 10mm² key, it was around 9.71mm²

 

For reasons only known to Suzuki engineers, a 3/8" ratchet extension looks like a good fit but isn't. The seemingly minute difference is unfortunately enough to maim the drain plug, which then becomes an absolute bastard to remove.

 

 

Or a short length of 10x10 steel bar and an open ended spanner?

 

Fair point, but there's no suppliers of steel offcuts locally. 


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#182 OFFLINE   Eddie Honda

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Posted 14 July 2017 - 12:44 AM

For reasons only known to Suzuki engineers, a 3/8" ratchet extension looks like a good fit but isn't. The seemingly minute difference is unfortunately enough to maim the drain plug, which then becomes an absolute bastard to remove.


Suppose it depends on the quality of the 3/8" square. Rennos aren't fussy about the minute difference IME.

I'm not knocking buying tools BTW, as I have both these:

embout-de-vidange-3-8-carre-male-10-mm-f
Facom D.105-10

facom-d13a-8-x-10mm-square-bit-oil-plug-
Facom D.13A
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#183 OFFLINE   Sigmund Fraud

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Posted 14 July 2017 - 04:19 PM

Mmmm... Facom !!! I'm a huge fan of their stuff, but they're not easy to find in Britain.



#184 OFFLINE   Eddie Honda

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Posted 14 July 2017 - 05:29 PM

I like them too, but I'm poor.

I got the 8/10 wrench because the Pug has 8mm plugs and the Citroen and Volvo have 10s. There's a Beta tools equivalent, but it has both 90deg bends on the same plane, so it'll sit flat on a bench.

Beta 1496C

r22591_click.jpg


The Britool/Draper Expert is bent just like the Facom:


E200202_PF02.jpg


And the Laser 3121 has looser bends:

3121.jpg


I do have half a dozen Facom tappet wrenches for Renaults. I was just looking for a T251, but ended up with a full house (6).
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#185 OFFLINE   Sigmund Fraud

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Posted 15 July 2017 - 11:36 AM

It's worth pointing out that Britool, Expert and Facom are all in the same group, and many of their designs look nearly identical but their quality is definitely not !

 

Of course, Facom is also significantly more expensive, but money spent on quality tools is never wasted !


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#186 OFFLINE   Eddie Honda

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Posted 15 July 2017 - 12:12 PM

It's your fault I spend some of last night drooling over Facom tools.

Reality means a Clarke HD Plus tool cabinet soon.
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#187 OFFLINE   Sigmund Fraud

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Posted 31 July 2017 - 09:33 AM

It's time for your irregularly irregular update from Fraud Towers !

 

LupoSold.jpg

 

The Loopoo is now in the hands of a new, enthusiastic owner who intends to replace the gearbox and use it as a daily hack.

 

I had feared it would end up being broken for spares, so I'm really pleased it will live on !

 

CloudyIbiza.JPG

 

In other VAG news, I recently spent a week behind the wheel of this shitter. It looks sporty, with its "arrow design", rimz and Recaroid interior, but really isn't. The engine feels like an early 1990s VTEC with a spark plug lead removed : gutless below 3000rpm, then slowly waking up to produce its maximum power at a deafening 6000rpm ! One has to frantically change gears all the time to keep the engine within its power band, which annoyed the hell out of me.

 

The car was otherwise no different to the Polo 6Rs I had driven before : competent but dull. I drove it a fair bit on twisty mountain roads, where the brakes seemed to let the rest of the car down. I don't think I was driving too fast, though my passengers were quick to notice the complete absence of "Jesus !" handles from the interior...

 

GL4.jpg

 

Back at Fraud Garages, the parts for the remaining maintenance jobs on the Ignis had arrived.

 

Suzuki recommends a 75W90 GL-4 gear oil, which few companies make nowadays. I considered using a (cheaper) GL-4/GL-5 rated oil or even a (much cheaper) GL-5, but eventually went for the proper stuff.

 

Furry.jpg

 

The old oil didn't look awful but was certainly past its best. The new oil seems to have made the gearchange slicker, and will hopefully prolong the life of the gearbox as well.

 

PlugTime.jpg

 

The last maintenance job that was due was the replacement of the sparkplugs. I had no idea when they were last done, as the previous owners had helpfully lost all of the car's history !.

 

I was expecting a DI cassette to be sitting underneath the spark plug cover, but was surprised to find a pleasantly anachronistic two-coil wasted-spark system ! Who said that modern cars are complicated ?

 

OldPlugs.jpg

 

Another pleasant surprise was what I removed from the engine : nice NGK iridium plugs, evidence that the car had been looked after. They had also been torqued up properly, so replacing them was really easy.

 

I'm too cheap to buy iridium, so the little green thing will have to make do with a set of Denso TT plugs instead.


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#188 OFFLINE   Sigmund Fraud

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Posted 06 August 2017 - 01:41 PM

Every car mechanic, be they a professional or an amateur, can give you a list of jobs they don't particularly like doing on cars. Regular readers will know that gearboxes and exhausts feature prominently on my list.
 
August started brilliantly* for me, with the rear exhaust box of the ScAAB finally succumbing to rust and requiring replacement.
 
Finding a suitable part for a resonable amount of money was the first hurdle, as the local motor factors wanted over £100, with GSF and ECP quoting around £75.
 
Thankfully, EEC only wanted £50 for their clone of the OEM exhaust. So I ordered one through their ebay shop and two days later a chap in a Tuffnells shirt appeared at my doorstep carrying a bloody huge box. The box contained this :
 
HeavyDuty.jpg
 
Massive and heavy, as befits a quality* Swedish* automobile !
 
Unfortunately, removing the old exhaust wasn't as simple as I expected. Trying to undo the clamp with a feeble 3/8" ratchet resulted in this :
 
Krusty.jpg
 
With the clamp off, I realised that corrosion had effectively welded the stubby pipe connecting the rear box to the middle part of the exhaust. Using brute force, I ripped the rest of the rear box off said stubby pipe, which then had to be sliced with a cutting disc and chiselled off.
 
Stub.jpg
 
Bloody hell ! At least, it gave me a chance to try my new 1mm cutting discs - I used to snub those, but after positive reviews by fellow 'shitters decided to give them a try. I now concur that they're excellent !
 
Quiet.jpg
 
With the ScAAB back to its normal, quiet self I decided to address another of its issues.
 
Remember what I wrote back in February about the gearchange ?
 

...an incompetent moron (other than myself !) had been there before and had decided to remove the reverse lockout tab that also acts as the 5th gear selection guide. Great work !

 

Not a difficult part to replace, but it costs £25 which is a bit rich for a flimsy bit of plastic. I'll see if I can make do without it. I give myself a couple of weeks (and a dozen missed gearchanges) before I bite the bullet and pay.

 

Well, the problem irritated me for the best part of six months, but I remained reluctant to pay £25 for the lockout tab.

 

During a recent visit to the scrapyard, I spotted a condemned, manual 9-3 and decided I had to act ! I removed the part, put my best poker face on and asked the (chronically disinterested) yard owner for a price. "Fiver", he mumbled from behind his desk. Within seconds, I had handed him the relevant banknote and run out the door before he changed his mind.

 

I must confess that the phrase "refitting is a reversal of removal" has rarely been more inappropriate for a job... Under 60 seconds to remove the tab, nearly 30 minutes to install and re-align the mechanism so you can actually get 5th and reverse while driving.

 

ReverseLock.jpg

 

With the box finally working as intended, I returned home triumphant, making sure I selected 5th as many times as I could !

 

Unfortunately, bad news were waiting for me at home. Mrs.F reported that something was seriously wrong with her Polo - she knew it was serious as it "whined like a superbike in 5th".

 

A test drive confirmed she was right, and a gear oil top-up made little difference. Yup, it's gearbox replacement time. The Loopoo may be gone, but 085 box karma has still gotten me  ! Bugger !

 

So where do I find a good 085 with a 1400cc differential ratio ? Nothing on ebay, plenty of 6N2s in the local scrapyard but the boxes are £100, you need to remove them yourself and there's no way to tell if they're any good. Argh !

 

A difficult decision, so I decided to go for a walk in the countryside, to clear my mind.

 

Ah, look at the pheasants in that field ! How quaint ! Hey, what's that black thing over there by the hedge ?

 

PoloBreaker.jpg

 

Yep, it's Mrs.F's old Polo that had been festering there for 18 months. It was completely rotten when it was parked up, and time hasn't made it any better. To our amazement, it started straight away with a new battery and extracted itself from the field with no issues. Wow !

 

It was then transported the short distance to Fraud Garages where a dismantling marathon began yesterday morning...

 

OrganDonor.jpg

 

...continued through the day...

 

MissionAccomplished.jpg

 

...and was concluded at dusk, with most useable parts removed from the car and safely stored.

 

Further gearbox shenanigans are planned for next weekend, so stay tuned for more VAGSHITE action !

 


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#189 OFFLINE   Mr_Bo11ox

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Posted 06 August 2017 - 02:29 PM

How come these gearboxes are so shit? What happens to them and can they be fixed??

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#190 OFFLINE   The Moog

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Posted 06 August 2017 - 02:38 PM

Good luck with the box. Hopefully you have topped up the teabags, biscuits and learnt a few new swearwords
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#191 OFFLINE   Sigmund Fraud

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Posted 06 August 2017 - 02:53 PM

How come these gearboxes are so shit? What happens to them and can they be fixed??

 

Well, they're the usual story of a reasonable design that got over-stretched over the years and was built using increasingly cheaper materials.

 

The basic design started in the Mk.I Golf as the 084 four-speeder. They bodged in a 5th gear in the 1980s to make the 085. I say bodged because its housing is separate to the rest of the box (furthest away from the bellhousing), and it sits physically higher than the other gears. This means that when the gear oil level drops, it's the first gear to be starved of oil (which is what probably happened to Mrs.F's car).

 

085-5thGear.png

 

Oil leaks are not uncommon, because the gear selector shaft conveniently comes out of the back of the box, nearly at its lowest point. The seal for said shaft has to withstand radial movement, axial movement plus keep out plenty of debris from the road that invariably ends up on the exposed end of the shaft. Predictably, those seals start leaking gear oil within a few thousand miles of being replaced.

 

085-SelectorShaft.png

 

The third problem is not one of design but of manufacture. The differential bearings on those boxes were always marginal, but post-1997 (IIRC) VW began using cheaper bearings which have made those boxes even more unreliable than previously.

 

The 085 boxes are not particularly complex to take apart and rebuild, but a rebuild will still be time-consuming and a bearing kit is not cheap (considering that a mint 6N1 is still £500 to buy).

 

Having said that, I will soon have two buggered boxes, one with good diff bearings (but a fucked 5th) and one with a good 5th (but fucked bearings) so I am really tempted to make a good one out of the two... 


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#192 OFFLINE   purplebargeken

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Posted 06 August 2017 - 05:42 PM

This isn't a real update thread 'cos it has no variomatic exploits contained within. Phail.


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#193 OFFLINE   Sigmund Fraud

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Posted 06 August 2017 - 06:21 PM

This isn't a real update thread 'cos it has no variomatic exploits contained within. Phail.

 

It's only because my reliable* modern* cars keep falling apart, allowing me no time to look after my proper* classics*...


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#194 OFFLINE   Tamworthbay

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Posted 06 August 2017 - 07:39 PM

Buy Kens nice Ovlov variomatic and you can have the best of both worlds.
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#195 OFFLINE   Sigmund Fraud

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Posted 07 August 2017 - 08:12 AM

Buy Kens nice Ovlov variomatic and you can have the best of both worlds.

 

I sadly don't have space for it...

 

...unless, of course, someone* decides to buy my 66 Kombi  !


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#196 OFFLINE   purplebargeken

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Posted 07 August 2017 - 09:16 AM

Its a nice combi.



#197 OFFLINE   Tamworthbay

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Posted 07 August 2017 - 09:30 AM

It is indeed, sadly a little out of my present car budget :-(

#198 OFFLINE   purplebargeken

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Posted 07 August 2017 - 09:32 AM

Clive, what have you ACTUALLY got now? I've really lost track lol.



#199 OFFLINE   Tamworthbay

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Posted 07 August 2017 - 09:35 AM

Clive, what have you ACTUALLY got now? I've really lost track lol.


The Beemer estate (in for MoT in 26 minutes), the Capri, a Puma and a mini hillclimb project. So only four at the moment.

#200 OFFLINE   purplebargeken

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Posted 07 August 2017 - 09:40 AM

Forgot about the Puma. :)



#201 OFFLINE   Tamworthbay

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Posted 07 August 2017 - 11:34 AM

And me I think :-( the Beemer did ok, just need to tweak the handbrake adjustment and we are good to go for another year.
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#202 OFFLINE   Sigmund Fraud

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Posted 13 August 2017 - 05:04 PM

It's been a VAGSHITE-special weekend, here at Fraud Garages !

 

I was up early on Saturday, and ready for the first task of the weekend : transporting the mortal remains of the organ donor Polo to Richard Noon's yard, where it could be given a fitting* burial...

 

PoshPikey.jpg

 

Just before I left base, Mrs.F urged me to clarify with the scrapman that only the black car was to be crushed... What cheek !

 

I must confess that I did follow her advice when I drove over the weighbridge, though. Just in case...

 

Back to base, the minty Polo was put on axle stands, ready for the gearbox transplant :

 

TheGermanPatient.jpg

 

A few profanity-filled hours later, the old box was out...

 

OutWithTheNew.jpg

 

...and I prepared the replacement box for installation, by giving it a good clean...

 

ReadyToGo.jpg

 

...and replacing the notorious gear selector shaft seal (that I mentioned in a previous post) with a decent SKF part :

 

The7thSeal.jpg

 

A few more hours of swearing, and the new box was in :

 

In.jpg

 

Mrs.F had reported that the starter motor was becoming sticky. It had to come off for the gearbox replacement, so I hit two birds with one stone by replacing it with a rebuilt one I had in stock :

 

NewStarter.jpg

 

Eventually everything was back in place, and the car was ready for a test drive. This confirmed that it was now working as intended :

 

GoneIn60s.jpg

 

Excellent !

 

But what was actually wrong with the old box ? I couldn't resist a quick post-mortem examination, for the benefit of Mr.Bo11s and any other fellow 'shitters who are interested in VW engineering excellence*.

 

So, here's the view with the end cover of the box off, revealing the 5th gear cluster :

 

Postmortem1.jpg

 

The gear oil was mucky and gritty, despite having been replaced recently. On closer inspection, you could see metal fragments the size of grains of sugar everywhere. But what are those bits at the bottom of the housing ?

 

Postmortem2.jpg

 

Oh... Where did those come from ?

 

Postmortem3.jpg

 

Verdict : FUBAR.

 

At least, I now know why those gearboxes are PURE EVIL :

 

PureEvil.jpg

 

Let him who hath understanding, reckon the number of the Beast... For it is a human number VW casting number !


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#203 OFFLINE   worldofceri

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Posted 13 August 2017 - 05:14 PM

Proof that they are indeed cast from the Devil's own knob cheese.

 

(Yes, I too, am a victim of VAG's gearbox engineering excellence.)


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