Project 80: Codename Grey Ghost

[Chris]

Oh cheers Frank! Well I have a spare 'just about everything else' with me. I couldn't believe it when I pressed the clutch first time. Have to say that now it's really nice.

Woke this morning to find derv dripping from a pin hole in the breather pipe back to the filler neck. Tried to seal it but nah. No chance. So I just cut out 10" and grafted in some 12mm fuel hose. That has to come off anyway when I put the twin filler neck in. Lovely. All ready. But what's this? Leaking fuel? F*** me double, backwards. There's a sodding leak in the main filler neck just in the support bracket where it turns for the main tank. Nothing I can do about that now. so I just used my by pass filter and pumped the excess fuel into a Jerry can. Won't brim the tank each time. It can wait til I get back and do the sub tank. What a twat.

 

[AndyCook]

Argh - hassle with leaks. Nothing worse than these last minute problems, but better than happening on trip. I had wheel bearing and alternator fail on LC within a couple weeks of Morocco trip last autumn, stressed out was an understatement. But at least I had spares for both in hand ready to fit.


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[Chris]

Well had to stop at Ipswich. A squealing developed under load and was getting worse. Slackened the AC belt a little and the pulley actually stopped turning with clutch in and it really squealed like a stuck pig
Oddly did make the noise with the AC off when driving. So we need to get going and see if it's still there
Not speed related does it out of gear not clutch related
Can really only be alternator water pump or belts now
Got new belts with me and spare dynamo
If it's the water pump screwed I don't have one of those

 

[Gary820]

Hope no further problems and the holiday goes well.

 

[Jon Wildsmith]

hopefully irrelevant but I have a new OEM water pump in my spares kit if you haven't left the country Just so you know that's all.

 

[Lorin]

No, the silver one WAS the mud plugger C'mon Andy keep up. I sold that a month ago.

You did......? How'd I miss that? Not just you Andy! Have a good trip Chris

 

[Chris]

JW the pump does have a little play in it so it seems bit I have found the problem
Frigging EGRs the plate I made has lifted and when the turbo blows it's screeching like a train whistle. Thing is that it feels like on of the studs is stripping. Plan for tomorrow. It'll be sorted before we cross

 

[yogi]

Well had to stop at Ipswich. A squealing developed under load and was getting worse. Slackened the AC belt a little and the pulley actually stopped turning with clutch in and it really squealed like a stuck pig
Oddly did make the noise with the AC off when driving. So we need to get going and see if it's still there
Not speed related does it out of gear not clutch related
Can really only be alternator water pump or belts now
Got new belts with me and spare dynamo
If it's the water pump screwed I don't have one of those

Did you replace any belts lately?

I developed the exact same problem in Slovenia a few weeks ago.I did the water pump and timing belt etc, all OEM a couple months before that and decided to change the alternator belts and A/C belt a couple day before leaving for aftermarket cheapo jobs I had in my spares box (just took a stupid notion).

Anyhow, I had to overtighten both (or all 3 if you want to get technical) to stop the squealing (bit of a worry as I left my spare alternator at home!). Had to tighten the whole lot again in Belgrade (about 3500 kilometers later) on the way home and I see now (herself is using the cruiser not me since we got home) that the alternator belts are on the loose side again (and yes I loosened and tightened the lock nut correctly both times and checked the mounting brackets, before you ask). And yes it was rubbish from Milners again, new OEM belts in transit as we speak!

Funny thing was, it wasn't until it got really hot (which didn't really happen until I was in Germany) that the problem started (kind of like the weatrher in UK now!!)

 

[frank rabbets]

To diagnose belt noise just pour water over it or WD40 whilst running. If the noise stops it's the belt. They bed in quickly and become schreatchy if that's a word quickly.

 

[yogi]

To diagnose belt noise just pour water over it or WD40 whilst running. If the noise stops it's the belt. They bed in quickly and become schreatchy if that's a word quickly.

Thats a handy trick Frank.

Bed in fair enough, but they shouldn't keep stretching though? If I wasn't sick of them, I would be tightening them for the 4th time in 9000 kilometers now. I've never had to do that before? They got so loose that the alternator wasn't charging properly at idle in the course of 500km from just a little bit over 1/2 inch deflection that morning.

 

[Jon Wildsmith]

Frigging EGRs the plate I made has lifted and when the turbo blows it's screeching like a train whistle. Thing is that it feels like on of the studs is stripping. Plan for tomorrow. It'll be sorted before we cross

Hopefully just the stud tightening in a bit more. Good luck, hope things get better from now on!

 

[Chris]

It's not belts lads it's deff the EGR cover plate with Missus revving it I can see it blowing
Put new bolt in and it is not tightening properly I can feel it starting to go soft

 

[adrianr]

Good luck mate, if anyone can sort if you can

 

[sae70]

Could you not turn the bolt into a stud and fit it in place with some stud lock, liquid metal or metal putty then run a suitable nut down the stud when the fixing has cured. I'm guessing your still in ipswitch and able to swing by a halfords or a motor factors.

 

[frank rabbets]

Stainless steel cable tie.

 

[Chris]

Steve that is exactly what I did. Only had RTV at the te and it blew again now at ferry and just done it again with exhaust paste
Nice and hot should bake before boarding
Rest of truck is 100%

 

[Chris]

Took the offending clutch back to Milner today. No quibble. Immediate refund and apology. Can't say fairer than that. They don't cover expenses incurred due to fault and this IS in there terms and conditions, but they were aware that it had cost me to have it removed at no fault of mine. Whilst that doesn't pay the bill, It was a gesture much appreciated.

I had a good chat with them about customer service issues that people had experienced and they do understand that one bad experience gets relayed more than 10 good ones.

 

[Jon Wildsmith]

I had a good chat with them about customer service issues that people had experienced and they do understand that one bad experience gets relayed more than 10 good ones.

I was going to get one of their clutch kits but obviously won't be now!

 

[Chris]

No. Don't. The picture on the web is NOT the same as the clutch I took in. The finger springs are half the thickness and there are twice as many of them. You can bend them down with your finger. Not going to take the torque of an 80. I will keep in touch with them on this and next time I am in, I shall have a look at the clutch covers. They are Valeo - Valeo Korea not Valeo France.

 

[Chris]

Update time. Took the day off today since stalking at the weekend was a bust. Thought I'd do some work on the inside so that the weekend was totally free to get the sub tank in.

I really wanted to get my booty plundered from the Good Ship Olazz (Derf) in and sorted.

Before all of that, I found some of those Landie cargo pockets and found that one fitted perfectly just here. Handy for bits and pieces.



The cargo barrier did need a little adjustment to get it to fit as I wanted it. Lazz had it on Black Widow drawers and as mine are AO with all the electrical gubbins mounted on the back end, the standard brackets were no good. So I made some new ones.



Two 8mm bolts should do the trick. Nice stainless dome head (free!) ones.



I also had to lengthen the top stays too. No problem with a Miller.

I love the top deck. It really does make better use of the space up there. And it takes a surprising amount.



I decided to stick some of that tie down rail at the front of the drawers so that I could put straps up to the top deck and keep all the stuff we will cram in there from falling out all of the time. yes that is a magnetic rail. It's great for holding tea spoon, car keys, tins of cigars etc etc to keep them handy



I got the water tank connected up for a trial. Awesome. That works a treat so the next job will be to connect it to the heat exchanger. In the pictures above you can see the plug and socket when it plugs in behind the barrier.

The tank is a 60l Black Widow with built in pump. Not sure if the pump is enough to push it all round the system and back to the shower head. I can always fit an additional pump slaved from the original if necessary.



Last job today was to get the fridge drop slide in. Hmm, now that DOES make getting at the beer a lot easier. I fancied making one of these but looking at it now, I'd have need a brain transplant to get that right This will be especially helpful when I get my Slinky spring lift on. At some point. Everntually. When hell freezes over. Pigs fly. I find a 4 leaf clover. At the end of a rainbow. When there is a month of Sundays. Delivery times are one thing, but whan it takes 4 months just to place the order, it's getting a bit ridiculous. Hey Ho.