Thursday 24 September 2015

More Crack Testing and New Suspension Wishbones

Second batch of items sent for crack testing, comprising the steering rack & components including the pinion, as well as the steering column, pedals (all three) plus the brake balance bar. 

Fortunately, no cracks found in any of these items. 
I am replacing the steering column with a new one however had the original checked just in case I do end up using it at some stage (you know, just in case Niki Lauda happened to call and express interest in taking the car for a spin, perhaps at Goodwood, if Lord March also called).

The above photo is of the tub with pedals removed which more clearly shows that the the pedals were mounted in two optional positions (for both a shorter and taller driver) during the car's racing history.

New Suspension Wishbones

Elwyn Bickley (photo above in his element) has finished manufacture of the new suspension components, using the originals as patterns.

Original and New

Suspension Manufacture Jigs

One thing that I did ask of Elwyn was to make jigs that would be suitable for reuse. Whilst I hope I am never involved in an accident that would require re-manufacture of these items it will be of benefit for future owners and if needed will simplify manufacture either for myself or in the future.  This includes knocking blocks and templates for some fabricated plate elements. 

The new and original suspension wishbones etc are going off to Stephen Hooker for crack testing tomorrow and I will also be asking him to test the structural integrity of some of the original items. The above photo illustrates the nice pile of rust released from inside a radius arm when the ball joint was removed and is a good reminder that these items were in most cases not really designed / treated to last 40 or more years of use / storage.

Yet More Special Tools

Crawford Hall has also been busy making yet more special tools necessary for the setup / assembly of the gearbox by Garry Simkin and myself next week. The above photo is of measuring blocks and a dummy bearing to set the height of the new Pinion shaft. The dummy bearing is required because the actual bearing is a press fit into the bearing housing and also over the pinion shaft, which does not facilitate a series of ready removals and refits of the pinion shaft when measuring and checking spacer thicknesses.

Rear Drive Shafts

Save the best news for last they say.
Following further investigation and additional crack detection and some fine polishing to remove the surface cracks from a couple of the splines, with subsequent shot peening of the splines the two rear axles are now crack free and fit for use.

Pinion is cracked however and is being replaced along with the ring gear with a new set acquired from Hall and Hall.