unimogjohn

Avanti R2, 1963, refresh

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sIt is Sunday, PM.  I must admit, this job kicked my butt.  It is easily a 10/10 for difficult work.  Camaro Steve came over this morning to help me run the brake lines.  We dropped the main gas tank and it easily came down to the point where we could cut out the brake line.  However, installing the new brake line was troublesome.  Lots of bends and cramped spaces.  But we got it done.  Then we tacked the front two brake lines.  OMG what an ordeal getting them fitted plumbed into the ABS unit.  Steve did it and it took him almost three hours, but he got in all five lines into the controller.  I concentrated on the lines from the controller to each wheel.  All the bends put into the lines did not match up with anything.  So I had to do a lot of rebending.  Got it done, but it certainly does not look factory with all the lines tight to the frame, looks more like a humpback whale.  The lines were just too long to lay flat.  Oh well, they are done and are not going to come back out for sure.  The only things left to do on the brakes is to replace the master cylinder and bleed the system.  

 

I decided to buy new Bilstein HD shocks so I pulled the KYB front shocks and have started on the rears.  I ran out of gas so to speak in the late PM so will finish up tomorrow.  

 

 

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Tuesday, early PM.  Up and at it this morning.  All four shocks are off.  The fronts were actually OK, but the rears were shot.  Glad that I am changing them.  The UPS truck just arrived with the four new shocks.  They will go on tomorrow for sure.

 

Pulled the trailer hitch receiver, 8 big bolts held it on, so with a lot of Liquid Wrench they all spun off.  The seven way electric connector is specific to the GM hitch.  It is a twist and turn to lock plug.  The new Curt cover is a bolt on type.  I did not want to buy a new plug, so used the Dremel tool with a little cut off wheel to remove the attachments that held it into the GM base plate.  I was then able to use the remnant of the twist attachment and a little bolt to hold it firmly in place on the new Curt plate. Saved about $25 for the cost of a new connector.

 

Did some clean-up on the rear end cover.  Brushed off all of the bad stuff and then gave it a good coat of Eastwood's Encapsulator paint.

 

Waiting on the brake rotors and pads to arrive.  Hopefully, tomorrow.  Also waiting on the trailer hitch receiver.  

 

 

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Still Tuesday.  Could not stand it.............  Installed the shocks.  Another project done.  

 

 

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Thursday, March 30th.  Dead in the water with the Suburban, waiting for the brake parts and trailer hitch to be dropped at my door.

 

But I did order and assemble a little welding table from Eastwood.  Bought it online a few days ago with one of their free shipping and 10% off deals.  So for $62 how could I go wrong.  Besides Alice has been beating on me not to use her wooden portable table even if it was covered with cardboard.  Well, she got her wish.  The table is well made and is of good fit and finish.  Should last me a long time.  It took about 45 minutes to assemble.  I am slow.  Here are the old and new table.  

 

 

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Still Thursday.  Yahoo!!!!!! The rear brakes from Canada arrived late this afternoon.  I hauled them to the garage and did a quick inspection.  Everything looks great.  It is suppose to rain all day tomorrow.  A good day to spend inside the garage.  It should only take me a hour or so to put them on.  Then I will gravity bleed the system.  

 

 

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It is Friday, March 31st.  OMG, I am bleeding .........  Actually going to bleed the brakes this afternoon.  Finished installing the rear brakes this morning and into the early afternoon.  I really enjoy taking my time with brakes.  Fun.  Here are the pics from today.  And the new trailer hitch should arrive today also.  At 4 AM this morning it was 30 miles away in Winchester, VA.

 

 

 

 

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Still Friday.  Filled up the master cylinder with fluid to start gravity bleeding.  Noticed a few drips under the master so stopped to tighten up lines.  The FedEx truck arrived so decided to stop for the day as it is almost 5 PM.  So hauled the trailer hitch box to the garage and opened it up.  Put the hitch behind the truck.  Looks like all new bolts came with it also.  The sides are much longer than the factory unit.  

 

I think I will put my little Mighty Vac unit on the passenger side rear brake caliper, and see if I can pull the brake fluid through the system.  That will have to be Sunday as the boys are all going to a farm and construction equipment auction tomorrow.  

 

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John,  You should try a Motive brake bleeder.  Much easier then a MyTVac. All you have to do is change the top for different vehicles.

 

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Edited by Bill Stoneberg (see edit history)

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Bill, I actually have one of those, bought it many years ago.  Will try it tomorrow as could not get any fluid to pass to the rear caliper.  I do not know if I have a leak somewhere.  

 

But I did get the trailer hitch installed and torqued to the proper specs.  Used the little Kubota tractor to lift it into position.  Had to drill two holes in the frame to fit the furthest bolt.  I have the electric connector installed, but not permanently.  Using tie wraps for now.  Don't know if I am going to keep this bracket or not.

 

 

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Tonight Alice and I took the Jaguar out for pizza.  Halfway to our destination, about 30 miles away, we started seeing green rain drops on the windshield.  What is up with that?  And of course we smelled anti-freeze, and the temp gauge was rising rapidly.  Only a mile to our restaurant with Camaro Steve leading the way.  We made it.  

 

Let the car cool down for about an hour and then did an inspection.  The top hose to the radiator from the engine had pulled almost off.  The clamp had no more threads to get it tighter.  So pushed it back on as far as it would go.  Refilled the radiator and left the cap on loosely.  Did not want to build pressure to push it off again. 

 

We made it back home and the engine ran cool all the way.  Tomorrow I am going to put on a new hose and clamp.  I have all new hoses so am going to change them all as soon as I get the Suburban back on the road.  

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It is Sunday, April 2nd.  No work on the Suburban today as we have events that we have to attend.  But I did get in an hour with the Jaguar.

 

I found my spare coolant hoses that I bought last year.  One was just the top hose, and the other was a complete kit.  The one top hose was hand made in England so that is the one I am using today.  The other kit hoses will go on when I get the Suburban done and back on the road.  I did have to cut down the hose a bit, maybe half an inch on one end.  I used the chop saw for the cut.  Stinky as the rubber heats up, but it makes for a very fine cut.  Fits great.  And the new hose is thicker than the one I took off, which is age cracked but still pliable, so I am able to reuse the Cheney clamps.  Refilled the radiator and let the "cat'' run until the engine was heated up.

 

While cleaning up the coolant and with the engine running I noticed that the oil filter is leaking badly.  It has always seeped, but it looks like the big bolt's fiber gasket that goes thru the housing and holds on the filter cannister has given up.  So that is also on my project list for next week.  The bolt does not clear the intake manifold so I have to take off the assembly from the engine to install the round fiber gasket.  Not a big job, but what should be a simple job, just got a bit harder.  I do have new gaskets on hand so will not have to wait for anything.  And I can change the oil also, a once a year job.

 

 

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Here are a couple of pics of the offending, leaking bolt on the oil filter housing.  Now at least you can see what I am talking about.

 

 

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It is Wednesday, April 5th.  Yesterday I planned to continue to work on the Suburban, but Alice reminded me that it was time to pay "the man".   So she handed me all the house and farm receipts for the year and locked me in my room until the taxes were done.  At least I got lunch.

 

So today I headed to the garage to see if the old/new Motive bleeder would hook up to the master cylinder.  Nope.  So I did a bit of research and found the correct cap.  So with the help of Mr. Amazon it is on the way.  It should be here on Friday.   

 

Since the master cylinder looked as if it needed a replacement (leaking around the plunger end) I decided to pull it.  I did remove all the old fluid with a turkey baster.  My oh my, look what I found.  Lots of crud.  Glad that I decided to replace it and bought one last week.  Tomorrow I will bench bleed it and install it back into position.  

 

I know that Roger will tell me again about preventive maintenance.  I am ready for it.  I deserve all the criticism he can dish out.  I deserve it.

 

I did find one of the lines going to the ABS controller seeping, so gave that another little tug with the wrench.  

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I hope for you that the ABS module has not to much contaminated brake fluid...which, according to most manufacturers, should be replaced each 2 years!

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It is Thursday, early PM.  Lots of rain and thunder.  Big storm, but so far no high winds like the south and mid-west have been receiving.

 

I spent some time bleeding the master cylinder for the Suburban.  Mounted it in my big vice, plumbed the bleeding kit I had, filled the reservoir, and bled the system.  Now there is no air in the master.  This afternoon I will mount it back into the truck.  Have to be really careful as the master is aluminum and the brake line connections are steel.  I do not want to strip the master's threads at this point.  I am going to start the lines with the master not mounted and will see if that is easier to make sure that everything lines up and threads in easily.

 

I then opened up the Eastwood blaster that I got last week.  Will start putting it together in the next day or so.  Special black silica sand is available at our local Tractor Supply store for $7 a 50 lb bag.  Greg likes playground sand from Home Depot at about half the price.  

 

 

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It is Friday, am.  We did have a big storm pass by in the afternoon.  So much lightning and thunder, and a couple of inches of rain.  Wind was howling.  So I stayed inside and did not venture out into the metal garage.  Seemed like the right thing to do.

 

But this morning I put in the new master cylinder.  Took several tries to make sure the brake line screwed into the master correctly and without forcing them in.  While the master cylinder was on the mounting studs I did not bolt it down.  This enabled me to move it a bit and get the threads on the brake line nut to catch and go smoothly on.  So that job is done.  The special bleeder cap for the pressure bleeder should be here this afternoon.  We will be gone all day tomorrow so the first chance I have to bleed the brakes will be on Sunday.  

 

 

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Sunday, April 9th.  Bled the Suburban's brakes using the Motive pressure bleeder.  Filled it with one quart of new fluid and then pumped it up to 10 psi.  Opened the rear passenger bleeder and watch the air and fluid being pushed out.  Within five seconds it was just pure fluid.  Then I did the remaining three.  Used about the entire quart of DOT 3 fluid.  Put the tires back on and headed out for a test run.  The brakes pumped up just fine to a hard pedal.  I made a few normal stops at speed and then a couple of panic ones.  Perfect, no issues and it stopped straight.  In a couple of days i will again check for any leaks and then put the driver's side fender splash panel back into place.  ABS did not throw any codes and I did not have a check brake light on.  Success.

 

Tomorrow I hope get the Jaguar up on the lift to start its repair.  Things i want to do.  Check the alignment of the exhaust pipes as they are not parallel; check the front brakes to see why it is pulling to one side; replace all  the coolant lines; and the oil cannister fix and change the oil.  And also plan on bleeding the brakes with new fluid.  

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Hi John, haven't chimed in in a long time but still read of your adventures.  I was coming home from Kentucky Saturday heading east on I-68 between Morgantown WV and Cumberland, MD when I saw a Jag of your vintage heading west.  Very pretty convertible in either green like yours or tan, not sure.  It was running strong on an uphill and I noticed it a little late but looked good flying down the interstate!

 

Now that I am home the spring list of work starts.  This includes trying to figure out the erratic left bank exhaust backfire in the Avanti, getting the '31 Hupp back to the engine builder for an oil burning issue and getting the rest of the fleet up and running.  Can't wait to get going on everything and doing some serious house work this summer.  But I still gotta find time for a tour or two....

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John, been on vacation in Arizona, so I'm somewhat behind reading posts. 

 

How do you like the Eastwood welding table? How thick is the top? I tend to tack weld pieces to the top of a welding table to keep them straight while laying down heavy beads, but it takes a good heavy chunk of steel to do this. I need a decent portable table, that's why I'm asking. 

 

Comment on blasting media: if you use sand (silica), please use a good respirator or air fed hood....That silica is hard on the lungs. That's why a lot of folks use the black slag. 

Edited by r1lark
Added info, and spelling errors (see edit history)

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Paul, I would call the table as a light or hobby use.  The steel top is about 1/4 inch.  I am sure that Eastwood has the specs on their web site.

 

Opps, make that 1/8 of an inch.

Edited by unimogjohn (see edit history)

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This afternoon we had a nice visit from Al Gerisch (AACA Lifetime member) and his wife Mary Ann.  They were travelling thru the area on their way home to NY.  Al always met me on the show field at Hershey and gave me plenty of great advice on what the judges expect.  And Al has many, many car and judging stories, I could just listen for hours.  Anyway, we had a great couple of hours at the farm.

 

Al gave me pictures of some of his cars.  He has a 28 Gardner, 53 Chevrolet, 65 Corvair convertible, and a 29 Chevy coupe.  He also has several other cars.  He and Mary Ann go on several east coast tours each year so look for him if you are on one of them.

 

Thanks for coming by Al.

 

 

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Edited by unimogjohn (see edit history)

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After Al left and headed back to NY, I got busy on the Jaguar.  I decided that I would make repair to the oil filter cannister first.  After about a hour I had the assembly off the side of the engine.  No wonder the top was leaking.  The plastic like gasket on the canister attachment bolt had split with age.  Also the gasket between the assembly and the engine was totally worn and crumbled in my hands.  So cleaned up the mating surface, and it is ready to go in when I get the correct gasket for the bolt.  I also drained the oil out of the engine.  And of course I did not have the correct gasket for the filter canister itself so had to order a couple.  Looks like it will be a few days before I can put everything back together.  Here are some pics.

 

Oh, and I also straightened the tail exhaust bracket.  Both tubes are parallel to the ground now.  An easy fix.

 

 

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Since it looks like I am waiting for parts, I decided to work on the Jaguar's front brakes and why the car pulls to the left when stopping hard.  The front wheel drum brakes are of self adjuster design.  So with the car on the lift I decided to just spin the front tires to see how much rotation they have.  Pulling down the tire by hand reveals that the passenger side tire will continue spinning almost 20 rotations, the driver' side barely 5.  Tonight I will review the factory service manual and tomorrow will pull of the drums to see what is up.  

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April 11th, Tuesday, PM.  Worked on the Jaguar from 8 till 5.  A long day for sure.  Took that long to replace all the rubber coolant lines.  Got them all done.  The ones on the front of the engine were a struggle.  All were hard as rocks and stuck.  Had to cut a couple off to remove them.  One line to the heater was almost closed.  No wonder we had low heat output.  Refilled the radiator with new anti-freeze and will recycle the the old stuff.  The $61 hose kit was good, but did have to do some trimming.  But everything was there and even have a couple of short pieces left over for the future.  The old hoses were a combination of sizes and types.  Must have been replaced as needed.  

 

Tomorrow Porsche Jon is coming over with his new Suburban.  We are going to change out the shocks.  It will be going off to Dan at some point for new brake lines.  They are rusted like mine.  

 

 

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Edited by unimogjohn (see edit history)

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