Tango Van - 1972 westy..

tango_van wrote:

When I was pressure bleeding the system, it started to pour brake fluid out under the front end, collecting in the chassis rail at the low point behind the servo/master cylinder.

is this fixed?
the master cyl front seals fail and fill the servo up with brake fluid

well not sure tbh...

brakes work. van stops. handbrake works.

there was no 'dampness' around the front of the master cylinder..

I think it was due to pressure bleed building up too much pressure (only had it at 20psi) so it maybe blew the seals on the header reservoirs on top of the master cylinger.. as it only pushes in..

will get some pics up.

oh. also. stabbed myself in the face with a screwdriver. just missed my eye. told ya I was stupid.

So pics:

CV boot replacement and axle referb


noticed that the CV's were not put together right.. rebuilt and put back the right way round..


has some wear.. so will replace in next couple of months



axles cleaned and repainted


All fitted and regreased etc


hoverbus


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brake bleed time..


had problems with the handbrake on drivers side ... lever was touching the hub..


handbrake balance bar now even

MOT tomorrow....

Yay! It'll be fine!

Just a tiny bit of welding to sort: front n/s jacking point to central x-member tab cracked. Prob a result of having to jack it up some many times sorting out the brakes!



It's staying overnight and booked in for tomorrow to have it's undercarriage tickled.

Yay! Mot passed.

Tip top!
Oktoberfest here we come!

well. van made it there and back with no issues. Running a bit lumpy, so time for a service and tune up I think.

tango_van wrote:

well. van made it there and back with no issues. Running a bit lumpy, so time for a service and tune up I  think.

Didn't sound lumpy when you caned it past me on the way home!

Exhaust blowing all the time now. Leaking at the head. Copper gasket rings (type 4) not sealing properly.

Took exhaust and header off last night. All rings have a leak.
Need to rework/file exhaust header flanges so they sit evenly and also remove some of the metal from the "ears" to allow the flange to seal up tight against the head.
Will add some pics later

tango_van wrote:

flange

haha, you said flange

You're going to add 'flange' pics??

Correct ... There was flange mentioned... a leaking flange at that..

I find my ears stop my head sealing tightly with mrs griffs flange 😬

Pop a bit of red gasket sealant on first then

Right then here we go: Type 4 1911cc turbo thomas 1" 5/8ths exhaust header issues

here's the copper gaskets that were on there: placed in same order as heads they came from. You can see that there is not alot of sealing going on! Each one shows signs of leakage, and number 3 is very bad.


Here's the new ones ready to go on. (Marks are from test fitting) note: they are not annealed yet.


Muffler and header off


Took a closer look at the flanges and ears on the header. found some issues
cylinder 1
ears are not correct depth to allow flange to contact with gasket


flange looks ok...


until gasket is on, then can see gaps


This was case with all of them.. some worse..

cylinder 2




cylinder 3



cylinder 4





Annealing the copper gaskets: heat them up to high temp then pop in water..



in the water they go:


Clear change in colour:

Ready to sort flange shape out and file down to make a flat even contact area with a bastard file


Re-shaped all to remove leaks around the gasket: trusty hammer and metal bar/flat approach with some heat applied
then..
Filed down, and checked with copper gasket to see if level



Next was to sort out the ears: needed to be 30mm minim from flange to ear so had to grind down the ears...





more to come

Next as the task of test fitting it a few times..

then when happy, applied red gasket sealant to annealed gaskets, popped them up onto the head and then fitted up header (hammer, jack and wood to hold it in place)

made some cut down washers/tabs, and fitted spring washers and 11mm copper exhaust nuts.


lots of patience needed (or next time another pair of hands! and a ramp..)

new exhaust rubber mount fitted and gasket sealed up for muffler..

Also: fitted new earth strap for main batt
old one:

new with a quick release clamp:


Then:
removed spark plugs and checked gaps, condition etc.. all ok
Then set about doing all the valve clearances.. no.3 exhaust valve had closed up lots.. replaced cork gaskets etc.

Checked distributor cap and rotor arm, no corrosion on contact areas. It's fitted with electronic ignition, so no points to worry about. (one less thing to worry about)
Re-fitted plugs etc.
Test ran for 20mins, no leaks on header or rocker covers.

re-adjusted idle to 900rpm on relatively cold engine.. so prob 1000rpm when warmed up.

Re-tightened header nuts up, once it had warmed up enough.

sounds much better (quieter now). Took it out for a spin around the block.. need to play with timing/carbs/idle etc.

So, was all ok but then started to hunt and back fire randomly on way to work..
Didn't think much of it straight away..
Then had a flat batt after work, so had to jump start it ...

Go home, still running bad and sounding strange.

Had a look around the carbs.. And found this..



Time to fit new gaskets tonight

Does it show that the gasket is broken and out off place???

The exhaust fitment looks like a nightmare to properly get right, when the fixings are not straight. Looks like you've spent some time on getting it to be just right. (Congrats on that) I hate it when things don't bolt together and fit properly when they should.

Once you fix one thing, you think it's ok for a while, how wrong we can be. Good luck on fixing the leak and curing the recent popping and banging, let's hope it's as simple as that.

The engine I'm stripping down is one of those "Well I didn't expect THAT", few good things but mostly bad. I've just found out it didn't like being stored under cover in the back garden since May 2014, bugger.


SCOOPS when will the TIME CLOCK POSTINGS be correct?

Sorry. Yeah. Gasket has broken away and looks brittle. Starting the carb strip down now.. In the rain
So should have a better idea of the issue.

Yep took ages to look me the exhaust up. It's a pig of a job. Knuckles have suffered , as has lying on my back etc

There's always something to fix on the dub!! And it'll always cost you x3 the amount you've budgeted !!

(Yep clock is confusing)

I have to say, I've never seen a header from a Type 4 engine before.
Every day's a school day.