Watch me make a stupid mistake - Peugeot 504 Break L

[stuboy]

20 minutes ago, meowmeow said:

i hope treats were duly offered

[meowmeow]

1 hour ago, stuboy said:

i hope treats were duly offered

haha no he is fat enough already

did give him a hug though, which was not appreciated

[Noel Tidybeard]

3 hours ago, stuboy said:

i hope treats were duly offered

shouldn't reward stupidity

[meowmeow]

more sacrificing from the old Golf bonnet

hoping it'll provide just enough metal for all the rust repairs except the cills and the boot floor - swear I'm not a cheapskate

patch installed, sealed, painted etc...

from the factory the primer is just lazily sprayed all over the engine bay - tried to replicate this with whatever I had, won't be very noticeable once the engine is back in

Brake and clutch master cylinders re-installed -

 

Cue upgrade for the work-bathroom cabinet. Can't believe it took me so long to be bothered to buy a vice

no more holding stuff to the ground with my feet to keep it still !

new brake lines for the front, also painted the cross-member with more lovely iron fence paint

Unfortunately (yet unsurprisingly) the bolt for the 5-way union snapped, so just drilled it out and popped a longer bolt through it

Keep telling myself I'll re-tap it properly at some point but...

also look carefully and joy of joys there's another rust hole in the other buttress thingy

only a baby one though

 

was busy trying to remove the O/S front caliper when I heard something on the roof:

a creature visits

caliper off, spiders included

brake discs weirdly have no lip whatsoever, and the bearings are good

lazy boy here will clean em up and reuse.

 

short interlude as mother's iron finally tripped the thermal fuse

tis a bit old says made in W.Germany on the side

pistons out - actually don't look too bad

but the same can't be said for the bleeder screw...

tool creation time

which promptly snapped off inside the caliper.

ok, let's try something else then:

which didn't work either, but did set fire to the cloth in this photo.

 

So I got fed up and returned to the only thing I'm good at - painting things with dubious paint the wrong colour:

  

  

 

Back to the task in hand, probably better to just drill the bugger out

what's that Blondie song? gonna get'cha get'cha get'cha get'cha

 

was feeling ok about this till I realised I'd forgotten the springs clips, and that I'd bloody painted them with non-heat-resistant paint

So stripped, repainted (properly this time) and reassembled...

 

So it didn't feel left out I got the Golf a shitty sticker

 

then the clutch cable snapped and I had to walk home

left the only tube of bearing grease I had in the boot so I can't reassemble the hub and refit the caliper on the 504 till next week

 

also i forgot last time to provide chicken tiles update:

  

 

and that back in March I checked insurance quotes for the 504 and got this:

for context the Golf is about £400 for me to insure

guess it pays to buy something weird - when was the last time someone crashed a Peugeot 504 estate?

 

[meowmeow]

On 10/08/2024 at 20:23, meowmeow said:

brake discs weirdly have no lip whatsoever, and the bearings are good

Ok first things first, that was a complete lie as it turns out:

 

Yeah, not supposed to do that is it

So replaced the bearings, re-greased and reassembled, with caliper and hoses:

 

Next, let's have a look at the clutch and pressure plate

 

toast.

Flywheel looked a bit sad as well but it'll clean up:

 

Painted the engine block while I waited for the new clutch disc to arrive in the post:

oil pan has a fat arse dent in the front so will have to come off and be repaired at some point.

also filed off the decades worth of baked on oil leak from the exhaust manifold:

and sorted that small rust hole in the other 'buttress', and painted to match the O/S:

 

PEOGOET ?

New pressure plate and clutch fitted:

something weird had happened to the grease on the pressure plate surface,  (guessing it had been in storage for well over 10 years before I bought it) - took ages to get it all off...

also quite difficult tightening bolts while the engine was swinging from the hoist

 

Had to buy another caliper for the N/S as the one on the car was fucked inside, so same process again

didn't take any pics as it's the same as the O/S one.

Hub was making the most horrendous sound, turns out the disc shield was somehow bent:

Repaired the lip and painted:

And both calipers re-installed:

I have the clip thingy somewhere for the N/S caliper, will refit it at some point

 

Last hole to repair:

fucking stupid location - welding upside down with not enough space between the hoist legs, the floor of the car, the suspension, the wall of the garage, the increased size of my head with the welding mask on...

managed to set fire to the car, a sponge, the carpet, my shirt and my hair (it still smells weird now)

 

 

Anyway, with that out of the way, went to install the N/S front brake hose and was greeted by this weirdness:

That's not standard fit...

So removed it and tried to screw the hose directly into the caliper - doesn't fit !

Somehow the guy who rebuilt the caliper last has converted it to 3/8 pitch threads - on a French car !!!!

Looking at my sad M10 thread brake hose:

Don't fancy buying another hose so will chance it with an adapter and see how we get on...

 

[meowmeow]

On 26/08/2024 at 15:00, meowmeow said:

That's not standard fit...

correct myself again, turns out that is standard fit, but not on my car - apparently some Girling calipers had these weird banjo bolt thingies fitted for a while

quickly figured out why because when i went to attach the hose to the replacement caliper, the angle of the hole was such that without the fitting it would foul on the strut

so it stays.

why it's 3/8 thread though i have no idea...

 

Anyway, time to pop the engine back in

easy enough right?

apparently not.

Not enough space means the engine crane is to the side of the car, making it a right ballache to push the engine back to engage with the splines on the input shaft.

resorted to jacking up the legs one at a time, sliding a greased metal plate under and whacking them with a mallet to shuffle the bloody thing along the floor an inch at a time.

after an unspeakable amount of time however,

and using my phone as a shitty periscope to make sure everything was lined up:

success:

 

cleaned and re-attached the wiring, and clear-coated the n/s of the engine bay:

built the new clutch hydraulic line:

then took the fuel pump off to disassemble and inspect the diaphragm,

   

I actually have a replacement fuel pump which I've fitted for now, but it's horrid and cheap-feeling compared with the original, so will try and find a replacement diaphragm as this one's started cracking.

 

Ok, floor time. Am going to need to make a new accelerator pedal bracket, as there isn't much left of the original.

Can see how much of a bloody rust trap this part of the floor is as well, all the dirt gets wedged behind the bracket and dissolves the floor.

choppy choppy

which is very useful because now I can easily get to the accelerator cable to unhook it:

Would've loved to remove the door for better access but there just isn't enough room in the garage to open it wide enough to get to the hinges.

Fair amount of work behind this point to do:

 

Managed to source a floor panel, according to the sticker it was shipped from Buenos Aires to France, and then to me

For some reason the return on the outside edge was bent upwards rather then down, so that had to be fixed first:

I've roughed it in for now, will finish and tidy up the rough welds next week, once I've waited long enough that the neighbours won't get pissed off with grinder sounds

Repair panel is a bit short, so will need to create a patch to bridge the gap - luckily it's just flat from this point back.

 

Also, further evidence as to why I need a bigger car,

free oven acquired:

 

matches the £1 kitchen quite well I think

 

[Landy Mann]

Nice progress really enjoying this thread

[stuboy]

good pictures, keep it up

[chaseracer]

3 hours ago, meowmeow said:

Managed to source a floor panel, according to the sticker it was shipped from Buenos Aires to France, and then to me

For some reason the return on the outside edge was bent upwards rather then down, so that had to be fixed first:

Happy* memories of replacing the rear-quarter panel on the 2CV racer.  They'd got the radii of the double return bang on, just not in the right order...

[jim89]

5 hours ago, meowmeow said:

correct myself again, turns out that is standard fit, but not on my car - apparently some Girling calipers had these weird banjo bolt thingies fitted for a while

quickly figured out why because when i went to attach the hose to the replacement caliper, the angle of the hole was such that without the fitting it would foul on the strut

so it stays.

why it's 3/8 thread though i have no idea...

 

Anyway, time to pop the engine back in

easy enough right?

apparently not.

Not enough space means the engine crane is to the side of the car, making it a right ballache to push the engine back to engage with the splines on the input shaft.

resorted to jacking up the legs one at a time, sliding a greased metal plate under and whacking them with a mallet to shuffle the bloody thing along the floor an inch at a time.

after an unspeakable amount of time however,

and using my phone as a shitty periscope to make sure everything was lined up:

success:

 

cleaned and re-attached the wiring, and clear-coated the n/s of the engine bay:

built the new clutch hydraulic line:

then took the fuel pump off to disassemble and inspect the diaphragm,

   

I actually have a replacement fuel pump which I've fitted for now, but it's horrid and cheap-feeling compared with the original, so will try and find a replacement diaphragm as this one's started cracking.

 

Ok, floor time. Am going to need to make a new accelerator pedal bracket, as there isn't much left of the original.

Can see how much of a bloody rust trap this part of the floor is as well, all the dirt gets wedged behind the bracket and dissolves the floor.

choppy choppy

which is very useful because now I can easily get to the accelerator cable to unhook it:

Would've loved to remove the door for better access but there just isn't enough room in the garage to open it wide enough to get to the hinges.

Fair amount of work behind this point to do:

 

Managed to source a floor panel, according to the sticker it was shipped from Buenos Aires to France, and then to me

For some reason the return on the outside edge was bent upwards rather then down, so that had to be fixed first:

I've roughed it in for now, will finish and tidy up the rough welds next week, once I've waited long enough that the neighbours won't get pissed off with grinder sounds

Repair panel is a bit short, so will need to create a patch to bridge the gap - luckily it's just flat from this point back.

 

Also, further evidence as to why I need a bigger car,

free oven acquired:

 

matches the £1 kitchen quite well I think

 

Retro o o 👍🏻

[meowmeow]

good news, I quit my job so now I have a lot more time to spend on this

bad news, I quit my job so now I have no money to spend on this

We'll see how I get on

 

All boring welding pics this time sorry

next hole to sort:

 

Near-enough shape made from the bonnet of the Golf again, fits ok:

 

and roughed in:

 

Pedal bracket time:

Had some weird kind of self-tapping philips head screws to connect the pedal to the bracket before - hateful things that completely stripped when I tried to remove them

So have replaced with bolts (no I didn't leave them this long!)

Suitably shoddy work but nobody's gonna see it so I'm sure it's fine (note that before I made the silly decision of buying this car I'd never touched a welding set, so we're not expecting miracles)

The bolt holes are wonky, but weirdly traced exactly from the pedal, so I guess that wasn't straight either?

Welded in place, will clean up later

Irritatingly the channel in the replacement floor goes slightly too far forwards and under where the bracket mounts (not sure if this is a pickup thing, as the pedal isn't hinged from the floor on those so there's no such bracket)

Promise it's not my stupidity, as the pressing lines up exactly with the drain hole and cutout

So I'll be filling that gap with a hell of a lot of seal sealer or something probably...

 

Next are the bottom pieces from the cross member - somehow they rusted to almost exactly the same shape on either side, so I could reuse my card template

More welding:

   

and much the same the other side:

 

Final big floor hole now - old piccy as a reminder

Cut out the floor and found that many other bits were rusty and sad:

Doesn't look too bad at first, but the inner cill, outer cill, and base of where the seatbelt mounts are gone.

Bit more investigation revealed this sadness:

 

 

Which leaves me with a dilemma - any more cutting and this part of the car is going to be very bendy...

Evident in this photo how little is actually left, helpfully right above the B pillar:

 

It's going to all have to be replaced, but would be great to have some advice on how best to go about doing this without causing the car to start folding in half

 

For now I've put the seatbelt bracket back on just to give it some rigidity

 

Oddly enough, the rest of the o/s cill is, for a 70s car, really quite good:

 

[bangernomics]

You can brace up using some box section or angle welded to the corners if they are present.

[High Jetter]

People pay for welding...