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Gearbox is back from it's strip and rebuild. All new bearings and seals, tarted up, looking sweet! My end casing was rusted through, luckily I had a spare R19TD box with a good one so that got pinched :)

That sold for more that I thought it would!

I'm in dammit. I can do the advanced and visual basic including direct SQL integration. We will have such fun.

I took it apart again, cleaned everything AGAIN and examined the shells closely - what I had neglected to do before it seems was look closely at the back of the shell and I found a splodge of something on the back of one of the shells. Maybe a squshed bit of oily cardboard or something? I dunno...

I've taken ID measurements with a mic, it's round as far as I can tell to the nearest 0.1mm, I think I need someone with more accurate kit to have a look at it...

The big end cap & rod have locators for tabs on the bearing shells. These tabs must be on the same side/faced together. If I keep all the tabs on the same side of the engine then this one cap faces the other way up to the rest. If I put it so the cap orients the same as the rest, the side...

It's not, they are usually all the same way around. Thats why it seems odd to me. No, I was measuring with a micrometer Absolutely 100% it's the original part Small end is fine, checked that. Checked that too, it's normal. It's defo the big end as it turns fine when the big end is finger...

Got some replacement studs and swapped in a pair of old big end shells. Still the same issue. WTF. Took it back out again, took the shells out, gave the cap and rod a super hard clean/polish with a dremel and fine wet & dry, fitted the new shells again and reassembled. This time I can turn it...

Indeed. The fact i've bothered to buy all new kit makes it even more frustrating. I've got new studs on the way, all I can think to try now is swap the shells for the old ones, if it turns smooth after that then it must be the new bearings out of spec!

Gearbox is back, completely rebuilt, new bearings and seals, vapour blasted etc. Hefty price tag though, £450 :eek: Decided to reassemble the engine now the bearing shell shenanigans you may recall from xmas were resolved. Or so I thought. I fitted the pistons/rods and did up the big ends...

So - engine bay - what do I do? Clean it up, 2pk prime & paint Clean it up, gravitex, 2pk prime & paint ...do I laquer it? When I say clean it up, obv I need to remove loose paint and rust but what sore of prep do I need to do for the primer? I've only ever sprayed my (new) roll cage in...

I managed to get the welding done Saturday and also the majority of the underside clean up and BHH80 done too before I knocked off about half 8, I was knackered! Sunday this meant (after cleaning the Grand Modus I am about to sell) I could get the Bonda primer on, then get ready to Gravitex the...

Saturday I wanted to get the majority of the welding done for the "Adey style" recomission, so I hit it full speed. I did 7 small patches on the tops of the inner wings, then found a "small" patch of surface rust on the NSF inner wing/scuttle was actually a gaping rust chasm so I set about that...

I do seem to be improving, I tell you what, it's a bloody useful skill to have! I think I qualify as a passable amatuer now :) Because French! Ive just put so much paint and underseal on it that it wont matter if the metal rots away, the goop will hold the rust together LOL

Yesterday I got about 3 hours spare so I popped out and did some underside cleanup, wire brush on a drill to shift the caked dirt, knotted wheel for any rust spots followed by BHH80, then I went to work on the drivers side floor & sill with Gravitex - pleased! The reconstructed jacking...

After a VERY exhausting week off, working on a number of different things, included in there was a bit of work on the 9 :) New water pump arrived, bit of a touch from autodoc special offers at £20 along with wishbones and bottom balljoints for about £26 as well! Dragged my new subframe out...

It's bolted in I think but it holds the brake and clutch pedals, not sure if thats a dash out job. Further investigation required.

Slapped some seam sealer on, will smooth this off before I paint it. I think it had started to go off a bit in the tube, as it was a half used one. No skirts on the Phase 1 so below the ridge line of the sill is just black underseal, Silver paint above. The join of the paint/sealer is covered by...

As promised, managed to get both sills and jack points rebuilt, put some seam sealer on the joints and left to dry. OSF jack point - did this in less pieces than the other side this time. Sill prep And fitted - this one was a lot harder, the fit wasn't anywhere near as good...

I'm going to glue some sand to it for the sputter effect :D :D I built the garage myself - 17 page, 3 year build thread here! https://turborenault.co.uk/threads/my-new-garage.16605/

Working on the inner sill and floor Floor is super duper thin so was difficult to weld but it's in now and strong, once I slap paint on this side and Gravitex on the other nobody, including me, will give a s**t :) Not far off refitting the full sill - should be on that this weekend :P

And BH Monday I did half a day on the OS sill and started cleaning up/patching the rotted out shite Evidence of an old get-it-past-the-mot-repair by yours truly, from well over 15 years ago This side is worse at the front f**king OW, knotted grinder wheels are savage!

Finished patching the floor and made the jacking point reinforcement & welded it on, on BH Friday, then attached the OS sill. Should last a few years that!

No, I bought it, but I left the entry gate open one night and some light fingered little prick nicked it and used to to carry off some booze he nicked from my neighbours garden. found it on my CCTV after enraged searching for the wheelbarrow about a week later.

Before After

I've tried many, many types and the Milwaukee ones for the money are very good, as long as you dont overspeed/overheat. I must have dimpled over a hundred spot welds with my current 2mm Milwaukee bit. Bosch are also pretty good. As a general rule you get what you pay for.

Believe me i've done plenty of absolute shite as well :D this just seemed to come together though!

By this time the primer was dry so I started refitting the outer sill panel. It's a non-OE one so not perfect, but better than making something from scratch! Punched some spot holes. Cleaned up the welding surfaces and away we went (after about an hour of messing and adjusting and trying to...

Sunday I was supposed to be going somewhere to do something but it was cancelled last minute, so I dived straight back in the garage hoping to get the outer sill back on. I painted the inner with Bonda... While that was drying I stripped out the remainder of the fuel pump and lines, the...

Chopped the rust out, chucked some BHH80 around inside the rest of the section Started piecing it back together That finished off Saturday - pretty good progress!