Project Polly - 850 AWD

[Dangerous Dave]

Time for an update.

Sometime in January we were on our way back from a meal late at night, when all of a sudden the exhaust came apart and the car started sounding loud (it was pretty awesome). So we limped home as quietly as possible Next morning I made a trip to my mom's (where I keep my ramps), oh the noise was brilliant, pops and burbles hahaha (though it would drive you nuts on cruise). Turns out the clamp bolt had snapped (original bolt) on the joint above the rear axle and the two pipes had worked apart. So an new bolt was found and repair effected.

Then coronavirus happened and I got furloughed from work. This meant lots of time to spend doing things around the house....nah.

Got some good weather so changed the track rod end and the wishbone on the front N/S.

Finally got round to sorting the petrol flap lock motor (got sick of having to go in the boot and pull the little lever to open it as it would lock but not open). It just needed some lubrication, fortunately it is screwed together so easy to fix (compared to the glued together ones).

The rear N/S caliper had seized (found out on the motorway when the carr started to vibrate like mad). Closer inspection found the dust boot had been worn away (by the disc I think, bit of a design flaw or badly sized pattern part discs, the other side had wear in the same place). A new seal kit arrived and I eventually got the piston out due to all the crap that had gathered inside, got it all cleaned up and it's working great now.

Then I needed to replace the bushes on the gear linkage on the gearbox. After looking around for something to fit I opted to make my own. I measured up the linkage, designed a bush on Sketchup and printed some out using some polyurethane 3D printing filament:



I used the brass centre out of the old rubber bushes. They fit nice and snugly:



Currently I am relocating the data display so will post that once it's done.