[Peter Bremner]

In from the top, using the handle of the mallet to knock them in.
Don’t worry about the 120⁰ ring spacing, they rotate by themselves anyway.
When you put the sump back on, make sure the sump and block faces are properly lined up so the gearbox mates exactly.
There is enough slack to end up with a step at the sump block join.

A cheapo Machine Mart engine makes life easier. You will have to modify it a bit.

[Peter Bremner]

Hello, I’ve been in Wales visiting my son and grandchildren. We went down the Big Pit, very interesting tour below ground of a coal mine.

I had bought a lump of plastic used to protect knock-in fence posts, the sort with a spike.
That lump fitted perfectly. I then used a club hammer to knock seven shades of it out of the liners.
I did have to bash them really hard. No heat used, the block is too big.
I just kept bashing away until they came out.
I had the block bolted to an engine stand. I propped both ends on the block with 4×2 wood so the block couldn’t move. A Workmate is no good, it is too bouncy.
The paper gasket area took a lot of work, scraping with my best wood chisel until completely clean. I used Hylomar Blue on reassembly.
Once installed, I did hold the liners down with bolts and washers.

[Peter Bremner]

The 5th gear has an usual selection process.
3rd, 4th then somehow back to 3rd for 5th.

Adie and Jamie were working on a more intuitive system, not sure what happened to that idea.

[Peter Bremner]

Bonnet and upper tailgate in place. Now comes the interminable fannying around to set the shuts. Great.

[Peter Bremner]

This shows the bracket attached to the water pump housing.
I used a flat bar from a starter motor bolt to adjust the belt tension.

[Peter Bremner]

Some gearboxes have a mounting area for a compressor. I hung mine from the water pump housing.

[Peter Bremner]

The condenser or condensers are the pain.
I fitted a cheap and cheerful one in front of the radiator on my DSuper5. It works ok.
On the Safari I have laid it the strapontin area with a hole in the boot floor.

I would like fit either a smaller pulley on the compressor (not possible) or a larger one on the hydraulic pump, again not possible.

On a BVH I think it’s the John Titus solution. Compressor replaces alternator, the alternator sits above it.

[Peter Bremner]

Me? Go2 Bluetooth speaker velcroed to the AC evaporator.

[Peter Bremner]

The U-Pol dust is working magic on the grass. I only ever dry sand. I do get complaints from the wife about her car getting dusty!
My garage is a major trip hazard. One trick I’ve perfected is leaning over the engine, moving my foot back, standing on the air line, which acts like a skateboard, face planting me onto the rocker cover.
I have multiples of most tools. If I’m lucky I can find one of the six Stanley knives. I buy six 8mm 1/4 drive sockets at a time.

[Peter Bremner]

At least you can see your floor.

[Peter Bremner]

I’ll try not to. I did fill in the two holes left by the aftermarket bonnet handle.

Like this

[Peter Bremner]

Thanks for the offer. I’ve started so I’ll finish.
U-Pol Dolphin Glaze today as only very thin skims of filler needed. Dolphin Glaze is the bee’s knees. No pinholes and easy to sand.
A few more thin layers still to go on, then I can fit, ready to line up wings and doors etc.

[Peter Bremner]

Somewhere in the mix there are two types of 5 speed boxes.
One is close ratio, the other has a taller 5th gear as in the DSuper5.

I bought a 5 speed box from France via Leboncoin. Yes, it was the close ratio box.
I sent it Harry Maartens for a rebuild to DSuper5 spec.

[Peter Bremner]

Handy if you’re in France. I also carry ‘Je repair moi DS’, a less bulky version of the DS workshop manuals.
I didn’t need it when I had a puncture in Loire, just a new ‘chambre d’air’.

[Peter Bremner]

When I had a Marcos, the steering column went through the fan belt. The trick was to fit two. One on the pulleys, one tied up out of the way.
Maybe cable-tie a spare to the new one. Similar to a spare clutch cable in the non Pallas roof channel.

[Author]

Posts