Nimminz' LSD GLT Daily - Part1

[Nimminz]

X reg is only just modern lol Gonna practice some bodywork welding on it, fixing stuff and making it look a tad nicer.
Here's a pic or two of mine and my mates:



Anyway back to volvo matters
Picked up the Diff case off Atchi tonight, this ones a different ratio to mine so the LSD probably wouldn't have fitted mine anyway

So after I get back from a little camping holiday on saturday its fit the diff in it's housing, fit housing to yellow gearbox, get the bellhousing off and free the release bearing from the 4" of prop left in it, put all back together, make some better gearlinkages that will unbolt as the welded on ones wouldn't fit the transmission tunnel, torque tube on, gearbox and diff on, fill with oil.

Then, project 2, Drop off all the front suspension. Fix radius arms, the threads look ok so it might just be the nuts that are buggered finger's crossed. Renew a few parts, Drill holes in the plates welded to the underside of my bottom arms to fit the older style ARB along with new poly mounts and ss bolts. Renew brake disks and pads and possibly brake lines while I'm at it if the funds come through. Will speak to atchi again about the adj. camber and take him the x-member, wishbone and radius arm.

Project 3, I'm hoping to make a Hydro handbrake fom a honda civic (5th gen) clutch Master cylinder. Will be placing it on the floor and covering with carpet along with a removable handle for OEM-look

Project 4 may involve that 5-link axle if its still f/s and I have the cash at the time

Project 5 id bodywork touch up, rust, scratches, dints, bubbles and underseal. Will get some paint mixed in a rattle can or 5 and some filler

Project 6 is the oil cooler, still gotta work out guages as the Lancia ones require lancia senders. thinking green 7-segment displays housed in a spare centre clock housing for OEM look again

Loads of other stuff like new splitter for front, wheel refurb, engine bay tidy, sunroof bodging and maybe more flocking

I've got some photos of Atchi's LSD and our 'workshop' for last wednesday I'll upload them when i get round to it

[SteveP]

My question would be, how can it have rust that needs welding when it's an X reg?! Has it had a bump? Headlight/wing/bumper look suspect. Still, absolutely good idea regardless of what car it is if it means you can get on with the 360

[Nimminz]

the main rusty bits are the boot lid and fronts of sills, both seem natural. and the wheel well but all corsas go there. the metal seems very thin everywhere as does the paint, cant think its ever been really looked after. its had loads of bumps i think, bumper and headlight are just snapped plastic clips, bonnets fine. Rusty X-reg corsas aint uncommon

[jon-ovlov]

Not bad Matt! Long list but sounds awesome. Need to have some time for mine to sort stuff like brake lines and the master cylinder. I might get round to it at some point.

Good choice on workshop btw, saw the pics on FB. Nice and dry! Like the sound of the suspension, again, now I've got some time on my hands after formula student, I can finally put some time into mine. Keep up the good work bud!

[miniswift]

Hi Matt,

I saw your car parked next Durham Johnston's foot path, today.
Get back to working on your cars!

Cheers
Atchi

[Nimminz]

Cheers Jon, aye was raining so Plan-A the picnic area was abandoned in favour of Plan-B underpass

Will be nice to go back and do things I rushed, Properly.

Atchi, Yeah was helping my dad clean up a student house (he rents them out) Second I'm back from Camping (Saturday) that diff case is getting assembled with the LSD and bolted to the gearbox

[Evoman]

Im very confused as too why the car is under that bridge lol

[Nimminz]

'cos I have no garage

Here's the pics the facebook folk have already seen


Random shot in the wet


Atchi's LSD


Atchi's LSD


Next to standard


The workshop


And the underside

[MCHUDD]

Hi Matt.
Great photos. Pitty about the reflection in the puddle. It would look like
it was walking on water
Cheers Mark.

[Nimminz]

Cheers

the miracle Volvo

Got something in the post while I was in Scotland...



Its a Volt meter, bright green. Gonna build a Guage pod in this spare clock housing I have, oil press. Oil temp and volts and the engine light for LH2.4 (eventually)

After my 700 mile round trip to scotland in the corsa, I've decided I'm sortening the is of things to do to the volvo before it's back out - Transmssion+LSD, Front suspension and tiny bit of welding p.s. Never buy a corsa with 105K on the clock and no service history I've burnt 3 litres of oil in the last week saying that, for the milage I've saved £220 on fuel

Here's pics of the new ARB whie I have the phone plugged in





Cheers,
Matt

[Chris_C]

saying that, for the milage I've saved £220 on fuel

FFS, your 360 is broken dude

[Nimminz]

So decided to crack on - well about half an hour a day.

Got the diff case off the yellow gearbox and fitted the LSD diff case (which is now gloss black) onto it loosely as I'm waiting for the gasket to arrive at the dealer. I was going to get new bearing carrier o-rings, oil seals, bolts and the bolts/studs that hold the diff and gearbox together and possibly bearings them selves. All these parts bar the gasket and one set of screws for the gearbox-diff were available So i need to find an o-ring off the old diff, i seem to have misplaced them. Anyway, Atchi's LSD in and bearing carriers bolted down and it works! feels like a welded diff at the mo, i'm only using hand pressure on the axles shafts.

Problems so far:
-How to fab some new gearlinkages, or more how to hold the plate in the right place
-Reduce the backlash on the crown wheel - pinion shaft - am i right in thinking it's increasing the shim thickness on one of the bearing carriers? I'm sure the shims will be NLA
-What can the prop be stuck in? Thrust bearing, clutch or fly? pretty sure it's not the housing

Tonight I'll probably swap the front covers as the yellow gearbox's one is buggered

Pics - again from crap HTC phone



first fit


Started painting


Cleaned the inside


More painting


Ratio - the one for the LSD


Most important bit


messy 'workshop'


old and new


snapped pinion shaft bit from old diff


Getting there


Mmm

Also started thinking about that little display i mentioned before, now looking into using an Arduino type thing and having a full MFD type thing using some LED displays I have, this is the inspiration and shows the displays I have, i have 5 : http://www.davidc.net/blog/201107/teens ... 16-display
Fingers crossed I can make it display anything, oil press. temp, water temp, AFR, EGT and loads more... We'll see I'm not all that clued up on digital electronics

Also going to get some 185/55 15's for the cups, I need new tyres now as the corsa's arches took a dislike to them. I punished the arches accordingly with a wheel brace on the scottish borders Oil pump's packed in on the corsa so it's rattling like f*ck and burning oil through the intake Should speed up the volvo's recovery

Cheers,
Matt

P.S. Could anyone give me a photo of how the original gear selector plate sits in the car? maybe some measurements liek height above trans. tunnel, distance between things? Just I need to make some brackets BEFORE the torque tube is in the car and I can have a play. Cheers!

[charlieog1243]

looking great dude keep it up!

[Nimminz]

Cheers! cant wait to get it back on the road!

[Nimminz]

Right so I now have everything i need, well nearly - a bearing carrier o-ring, o-ring off the gear selector rod plastic bits and i've gotta make some brakets to hold the gear linkage plate to the torque tube. last thing i picked up was the diff to gearbox gasket which is probably tomorrows job if i finish work early

Today I bolted down the front cover off my orig. box after lots of cleaning and painting and new bolts from volvo and a gasket

Painted gear selector rod, torque tube, bearing carriers all gloss black and heavy duty laquer

Next job is to make brackets - same as the rubber and metal ones that hold the selector plate to the torque tube but out of metal and with 2 bolt holes on the outside rather than one. then 2 o-rings and we are ready to go.

Also ordered an 'Arduino' board and a display or two and some sensors for making an on board telemetry system that can be logged to SD card