Bumper Teardown

So I decided to have a go at tearing the bumper down a little more.  It needs a bit of work doing to it and a repaint.  You may remember that the stiffener was very corroded also.  Here are some pics of my process.

The bumper as it had came off the car. 

 On this pic you can see that the stiffener is held onto the bumper via some melted plastic tabs.

I used my heat gun to soften the tabs and pry the stiffener off from the bumper. 

 Coming off.

 And its off.  You can see in this shot the headlight washers and the bumper absorbers are still attached.

 Bare bumper.  Its alot lighter and less stiff now.

 Bumper absorber attached to stiffener.

 Headlight Washers off - I have a new one for the broken side.

 Absorbers off.  The stiffener looks way worse than it actually is from a corrosion perspective.  It was originally galvanised.  I will have it sand blasted and paint with some zinc primer and possibly epoxy paint.

Bumper absorbers.  Note the sheared fasteners.  These are the ones I broke when removing the bumper from the car.   These are NFP from Peugeot and new ones are £100+ on ebay so I thought I would have a go at refurbishing these.

Closeup of sheared faster.  Its plastic welded into the absorbers. 

 Heatgun used to melt plastic and remove brackets.

 Melt melt....

 Off it comes

 I have tried to retain as much of the original plastic as I could to aid refitting.

Brackets are corroded.  Its mostly surface rust though.  Looks like they were originally zinc plated.

Into a bath of Deox C

After first 24hr dip. 

After second dip and wire brush.  Turned out pretty good.

I need to get the fasteners drilled out and new ones welded in.  I reckon a normal bolt with a bit of weld will do.  I will then get the lot electroplated and re-attached to the absorber.

Job for another day though..

James

Wishbone, ABS Unit & Master Cylinder

July / Aug 2016

So its been a while since I posted anything.  I have been making some progress on the car but its painfully slow as my spare time is quite limited.

Here are some teardown pictures of a few bits.

Passengers side wishbone. 

Bush looks ok but aged. 

Little bit of cracking but probably still got a wee bit of life left.  Still whilst its off I decided to replace it. 

This bit slides into another bush.  Think it should be rust free.  Nothing some emery cloth will not sort out. 

Cleaned up stub 

Cut top of  bush off - no going back now!

Bending centre in on top of itself. 

Out the middle comes. 

This was the easy bit. 

Outer bush.  This was much harder to get out.  note how chewed up it is from me trying to gte it out. 

Inside is clean though.  Just need to dress the edges. 

Whole bush.  I will replace this later one I have painted / powder coated this wishbone and obtained a new bush. 

The ABD unit looked like it could do with some TLC. 

Whipped the lid off.  This will come up nice with a bit of effort. 

Looks clean enough inside. 

Its been sitting in water in the scuttle due to a blocked drain.  This fastener is badly corroded. 

Its an odd oval shape. 

I ended up cutting a slot in the middle and using a screwdriver to remove. 

Thankfully the electronics do not seem to have suffered.

Some nice 1980's tech here.  Looks in excellent condition. I assume it still works.

Part no for reference.  Seems to be used on a number of cars.  Looks like I will need to repair or replace the casing.  Its got a hole in it from the corrosion.  Plenty on ebay for not alot of money.

I tore the master cylinder down a bit more.  Some bad corrosion where it mounts onto the servo. 

Signs of corrosion internally also.  Almost certainly needs replaced.  From the prices on ebay it looks like this will be cheaper than an overhaul kit anyway. 

Injectors removed from manifold.  Will need to get these serviced. 

ABS Controller mount.  Needs electroplated. 

Fuel rail.  Again needs electroplated. 

Part of the windscreen base.


That's all for now.

James

Starter Motor Refurbishment

So I am a few months out of date.  I'll try and bring the tread up to where I am now.  Not made a huge amount of progress to be honest but a few things are further than they were.

I have refurbished the starter motor.  The old one looked like it had seen better days.  If I remember rightly this was a refurbished unit when it was on the car so I decided to strip, inspect and repaint it.  Here are the pics of my progress.

Before I started.

End cap off

Removed the long bolts

 Solenoid Off

Pull off end cover

Used a small wire wheel and dremmel to remove paint / corrossion

Prepped for paint in a homemade spray booth.  Don't tell my wife where the dish rack went !! :lol:

Inspecting commutator and brushgear  Looks in reasonable condition

Stator out ready for cleaning

Rotor ready for cleaning

Cleaned Rotor

Stator cleaned and ready to strip off paint

Under the paint was the original markings.  This suggests this unit is an original Valeo unit that has been refurbished.

Painted

All painted

Ready for rebuild

Completed Unit

Turned out nice

James