DJ rebuild... piston damage....

Big lumps of metals and spanners. Including servicing and fluids.

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spanishfly
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Location: Launceston, Cornwall

Re: DJ rebuild... piston damage....

Post by spanishfly »

Welded a nut on to the stud stub, looked good but it broke off .... does this often take several attempts? Any pearls?
Not making much / any progress with the blow torch or freeze spray with double nut and chuck gripper. If just one would come out it would feel possible... :x
!987 Westy Joker 1.6TD
1988 AFN Mosaik...maybe?
1987 Dehler Profi 2+2

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Oldiebut goodie
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Re: DJ rebuild... piston damage....

Post by Oldiebut goodie »

Blow torch on the ally and freeze on the stud immediately on removal of heat. I don't envy you trying to do it.
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Stesaw
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Re: DJ rebuild... piston damage....

Post by Stesaw »

Try to tighten one gentley after heating it might help release it. I used a breaker bar on my remover and when putting pressure on the stud id tap it end with a hammer to shock it. I ended up rocking the bar back and forth gently on the stud to get them to start moving, although still didn't help me as 4 broke.. 

Takes a bit of grunt to shift them but once they make that horrid ping sound you can generally shift them. Just dont go ape on them and take your time. I was going to try welding nuts onto the end of my broken studs but after thinking about it I took it to a local engine shop as I thought they'd do a better job... I was wrong about that. :x
1985 LeisureDrive 1.9DG 5 Speed- Syncro project.. soon.. ish.. along with a 2.1 soon..ish..

spanishfly
Posts: 220
Joined: 09 May 2013, 14:43
80-90 Mem No: 12044
Location: Launceston, Cornwall

Re: DJ rebuild... piston damage....

Post by spanishfly »

Thanks for the hope! I've been grinding down nuts and welding them on 5 times so far, everyone a better weld than the last but still not moved. Will persevere! :|
 
!987 Westy Joker 1.6TD
1988 AFN Mosaik...maybe?
1987 Dehler Profi 2+2

spanishfly
Posts: 220
Joined: 09 May 2013, 14:43
80-90 Mem No: 12044
Location: Launceston, Cornwall

Re: DJ rebuild... piston damage....

Post by spanishfly »

Pushing on whilst awaiting parts. I can't remember whether the longer of the straight original tank straps goes on the right (looking forwards)? Not obvious in Bentley, thinking longer on the right??
ImageImageImage??
!987 Westy Joker 1.6TD
1988 AFN Mosaik...maybe?
1987 Dehler Profi 2+2

spanishfly
Posts: 220
Joined: 09 May 2013, 14:43
80-90 Mem No: 12044
Location: Launceston, Cornwall

Re: DJ rebuild... piston damage....

Post by spanishfly »

This must have been covered elsewhere but having now received what I hope are the missing parts of the puzzle, STD main bearings, hydraulic lifters and hopefully a Cam all that stands in the way (in terms of materials) are the corroded studs... if their successful removal is utimately unsuccessful and the case is too damaged to reuse would a 1.9 DF case with the same serial 025 101 101 B work instead? or are there other differences that make this difficult?
:?
!987 Westy Joker 1.6TD
1988 AFN Mosaik...maybe?
1987 Dehler Profi 2+2

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