Not logged in. Login...  

Daily Updates: Monday 22nd January 2007

Tuesday, 30th January 2007 - Sump Guard

I've had a mission of a day... I've been to Tesco to pick up a list of 50 bits and bobs and spent £90.10 on Malarials as well as knocking up the sump guard for Leo.

The sump guarg is made of Dexion, industrial shelving angle iron. I bolted a section of Dexion to the chassis, just behind the front bumper, so I could secure the main struts to the front of the car.

The front to back members of the sump guard have been trimmed flat, and shaped with a huge hammer (not an easy task - it's 3.5mm steel) to mount onto the suspension mountings.

I also stuck on the stickers that Tantu supplied us.

Team Flapjack's Lancia Y10 1.1 ie FIRE, with the hub removed
Team Flapjack's Lancia Y10 1.1 ie FIRE, with the hub removed
Team Flapjack's Lancia Y10 1.1 ie FIRE, with the hub removed
Team Flapjack's Lancia Y10 1.1 ie FIRE, with the hub removed
Team Flapjack's Lancia Y10 1.1 ie FIRE, with the hub removed

Monday, 29th January 2007 - Heater...

After determining beyond reasonable doubt that the head gasket is fine, I decided I'd try to fix the heater. Unfortunately, I forgot to bring my camera so no pictures, sorry!

The hoses to the heater were not getting hot when the engien had warmed up, so I elimnated the airlock with a process of tubes, funnels, water and thumbs over pipes. An extra pair of hands at this point would have been handy! Don...

Now even though both heater hoses get piping hot when the engine is warm, the heater;s feeble effotrt can only be described as being on the cold side of tepid.

Hmm... a 180 watt ceramic heater that plugs into a cigar lighter might be an idea...


Sunday, 28th January 2007 - Hung over

Too much to drink at our party. Got to bed at 6am. Oh dear...


Saturday, 27th January 2007 - Party...

Today we got together with close friends and family, for a bit of a send off party. I took no photos whatsoever that night, but a photographer friend of mine, Istvan took a shed-load. They'll be put online as soon as he gives me copies!


Friday, 26th January 2007 - Finishing the job...

Having acquired the necessary jubilee clip yesterday, I chopped off a length of the "one size fits all" jubilee clip and fitted it around the driveshaft gaiter. The bonus is, the kit comes with 3 meters of jubilee strap, and 6 of the clamps, so we won't be stuck for jubilee clips on our travels. :)

I also stuck on a few more stickers... I finally got round to sticking on the Plymouth-Banjul Challenge stickers on each door, as well as another big Teenage Cancer Trust sticker on each side of the car.

I took Leo for a spin, and he behaved perfectly - a big relief after the traumas earlier in the week. His good behavior was rewarded by a photo shoot in the car park of Ampthill Park. Shame it's winter, the car will look great in the sunshine - roll on Banjul!

Split driveshaft boot on Team Flapjack's Lancia Y10 1.1 ie FIRE
Team Flapjack's Lancia Y10 1.1 ie FIRE, with the hub removed
Team Flapjack's Lancia Y10 1.1 ie FIRE, with the hub removed
Split driveshaft boot on Team Flapjack's Lancia Y10 1.1 ie FIRE

Thursday, 25th January 2007 - Err, non-car stuff

Today I've been acquiring various bits and pieces for the trip, planning the Send Off party of close friends and family, and generally planning the final few days before we go! I've bought the jubilee clip I need to secure the gaiter, most importantly!

Split driveshaft boot on Team Flapjack's Lancia Y10 1.1 ie FIRE
Team Flapjack's Lancia Y10 1.1 ie FIRE, with the hub removed

Wednesday, 24th January 2007 - Parts arrived - panic over!

This morning, just before I went out to work on the car, the driveshaft boot arrived - one day earlier than expected... It seems my sob-story on the phone to Betacar worked!

I removed the remnants of the old gaiter, and discovered that the new part was not quite the part I needed. The oil seal and bearing were for a different thickness of driveshaft, though the diameter was the right size. The larger end of the gaiter theat mates to the gearbox mounting plate is also frustratingly the wrong size.

So, Plan A turned into Plan B, and I heated up the gaiter to make it more malleable, and eased it onto the larger flange on the gearbox mounting plate. That made it sound easy - it was not, I assure you!

I extracted the oil seal bearing from the new gaiter, heated the gaiter again, and eased the gaiter over the bearing. I then jubilee-clipped the gaiter in place on the bearing.

At the other end, I have used tie-wraps to secure the gaiter. I do not trust these for a moment to hold for long, so a big jubilee-clip is on the shopping list. I just wanted to see if this fixed the problem!

Fix the problem, it did! I put the front suspension and brakes back together, which was a much quicker task than taking it apart. I filled the transmission with the requisite amount of oil, and put the anti-roll bar back on. When I took the car for a spin, the gearbox was back to its usual quiet self, and was clearly sounding happier than it was before the gaiter split, just for having had its oil changed.

Split driveshaft boot on Team Flapjack's Lancia Y10 1.1 ie FIRE
Team Flapjack's Lancia Y10 1.1 ie FIRE, with the hub removed
The nearside wheel hub, carrier and brake disc from Team Flapjack's Lancia Y10 LX ie FIRE
The Lancia Y10's driveshaft, pictured from below.

Tuesday, 23rd January 2007 - Driveshaft is out, awaiting delivery of parts.

This afternoon, after another hour with breaker bars, a lump hammer and more grazed knuckles, I gave up trying to undo the tie-rod. It just flately refused to come apart, inspite of having been soaked in penetrating oil.

I continued on with the dismantling, and removed the hub carrier, hub and brake disc as one unit. The tie-rod not having been undone made extracting the driveshaft more tricky, but I got it out!

The photos show the damage to the inboard driveshaft - a great big split, that allowed the oil level in the gearbox to get very low. So, we've come up with our options, they are as follows:

Plan A
The CV boot arrives on Thursday as planned. Once fitted, the gearbox is fine.

Plan B
The CV boot doesn't arrive by Friday. Buy a random CV boot, and modify to fit with jubilee clips and goop. Once fitted, the gearbox is fine.

Plan C
It's the end of Friday, and the gearbox is at fault. Source gearbox, fit it, the gearbox is fine.

Plan D
It's Monday, and we've either got the wrong gearbox, or the new gearbox is also faulty. Buy a new car...

So, I'm really hoping for one of the first two options. To speed things up we should investigate sourcing a CV boot for Plan B, and a replacement gearbox for Plan C ASAP, such that we can be prepared for the worst, should it happen...

Split driveshaft boot on Team Flapjack's Lancia Y10 1.1 ie FIRE
Team Flapjack's Lancia Y10 1.1 ie FIRE, with the hub removed
The nearside wheel hub, carrier and brake disc from Team Flapjack's Lancia Y10 LX ie FIRE
The Lancia Y10's driveshaft, pictured from below.
The side of the Y10's gearbox, with the driveshaft removed. From our Uno and Panda manuals, the suspension is definitely Panda, and the engine and gearbox are late injection Panda. However, the design of the inboard driveshaft joints appears to be Uno. Confused? We are!
Team Flapjack's Lancia Y10 LX, before being modified for the Plymouth-Banjul Challenge 2007
Team Flapjack's Lancia Y10 LX, before being modified for the Plymouth-Banjul Challenge 2007

Monday, 22nd January 2007 - We have a serious problem!

At the weekend, we drove the Y10 to Bedford, to get some bits and pieces from Halfords. Seemed a good excuse to take the car for a run. However, on the way back from Bedford the car's gearbox started grating loudly in 1st, 2nd and 3rd gears. Just what we need with only 10 days to go - not.

So, we grabbed our Haynes Manuals for a Fiat Uno and a Fiat Panda and got investigating. There is no Haynes Manual for the Y10, which isn't helpful, but the car is essentially a cut 'n shut of the two. The first thing we did was check the tansmission oil level, which was woefully low, hence the noisy transmission.

Upon topping up the transmission with oil, it became apparant where the problem lies. The nearside inboard CV boot had split, causing the transmission to lose most of its oil.

I rang the dealer we got our spare head gasket from, and he said that the parts required to fix this problem, a CV boot and oil seal, are no longer manufactured. Not good!

We found a Lancia specialist, Betacar through an auction on ebay, who could supply the parts. They will hopefully(!!!) arrive on Thursday, 25th January - one week exactly before we leave...

In order to save time when the parts do arrive, I have started to dismantle the suspension in order to withdraw the driveshaft - quite an exercise.

I've undone the main hub nut, taken off the brake caliper, removed the anti-roll bar and split the bottom ball joint and the steering arm balljoint. Getting the tie-rod off is proving tricky. More tomorrow!

Team Flapjack's Lancia Y10 LX, before being modified for the Plymouth-Banjul Challenge 2007
Team Flapjack's Lancia Y10 LX, before being modified for the Plymouth-Banjul Challenge 2007
Team Flapjack's Lancia Y10 LX, before being modified for the Plymouth-Banjul Challenge 2007
Team Flapjack's Lancia Y10 LX, before being modified for the Plymouth-Banjul Challenge 2007

Registered Charity No: 1062559
www.teenagecancertrust.org



Team Flapjack are doing the Plymouth-Banjul Challenge in an attempt to raise £3000 for The Teenage Cancer Trust.

Each day in the UK, 6 teenagers will find out they have cancer. Young people often get a raw deal, receiving hospital treatment in inappropriate facilities alongside children or elderly people. In many cases, cancer in teens is not picked up early enough as symptoms are dismissed as just being growing pains. Because teenagers are undergoing growth spurts, their cancers grow faster than other age groups and they can be at greater risk.


Team Flapjack is Carbon Neutral for this challenge
Team Flapjack is
Carbon Neutral
 
 © 2006 Team Flapjack  All Rights Reserved