Thursday 21st May
The good weather is upon us and I have run out of time for the preventative clutch replacement operation; I actually contacted a couple of mobile mechanics but nothing came of that, so I've put the car back together for summer use. Looking through the inspection window in the transaction shows a bit of life left in the clutch, so it should do for the rest of this year at least, then I can tackle it next winter.
I effected a minor repair on the cat heat shields where water had gathered around the factory rivets and corroded the shield thus allowing the rivets to pull through. I repaired using much larger stainless rivets.
View attachment 143226
I found one of the nylon vacuum lines was routed in a way that meant it was crushed upon installation of the lower airbox. I moved it out of the way when refitting.
View attachment 143227
Tailpipe Restoration
The four remaining studs in the rear tailpipe sections snapped last year when I removed the silencer. I attempted to drill them out in situ this week but it was game over as soon as the bit reached the lower section which is welded them to the flange; the metal has become too hard from welding to easily drill out. In view of this I opted to remove the tailpipe sections and use an angle grinder to cut off the welds (green arrows), and then for reassembly I will use stainless bolts rather than steel studs. My car came with Capristo brackets fitted so the other two studs were already removed (if they were ever fitted at all - I don't know).
View attachment 143228
I decided to restore anything on the parts I had removed to make future maintenance easier. The AccuSeal clamps fitted at the factory are advertised as being stainless steel but really it is just the clamp section itself - the fastening hardware is steel and hence a recipe for disaster.
View attachment 143229
View attachment 143230
I replaced the AccuSeal clamps with 100% stainless Mikalor clamps. The smaller two are 47-51mm.
View attachment 143231
The larger are 63-68mm - the originals have to be cut off with a grinder as they are tacked to the exhaust. The Mikalor clamps don't cover the slits but this isn't an issue as there is 25mm of sealing surface behind them.
View attachment 143232
The exhaust valve actuators are also stainless steel but come fitted with copper plated lock nuts which also corrode heavily. I replaced them with stainless nuts and stainless shake-proof washers.
View attachment 143233
I refreshed the stainless exhaust tips with 80 grit wet and dry paper. I am careful to use the paper horizontally to each the tip in order to create a brushed effect.
View attachment 143234
Refitting the exhaust is a doddle and the rear bumper can stay on; I place a rag in the exhaust wells to protect the body and then pivot the exhaust around the 90 degree bend before the tips and it slides in without touching any of the bodywork. I used fairly liquid on the joints to make the whole thing easier to assemble. It only takes five minutes to adjust as the rear silencer ties everything together leaving only a little bit of adjustment via the joins behind the cats.
View attachment 143235
A shot from underneath showing the new hardware and Capristo brackets.
View attachment 143236