shavenYak

Took the van down for new years at Papamoa beach.

Awesome weather and the van went really well - even on highway 29 over the kaimais on the way back. Surprising power from the 12R!

Only issues were:

Leaking clutch cylinder somewhere that meant I had to keep re-pumping the clutch - made parking and city cruising a bit awkward.

Noisy petrol pump sometimes - possibly drawing air from somewhere, will investigate.

Petrol gauge didn't work until the way back. Ironically ran out of petrol on the motorway once I got back to auckland.

Very noisy overall above 80kph. Think the driveshaft will need balancing as it was pretty noisy even coasting down the bombay hills in neutral. Carpets in the front should help too.

Next trip is at the end of Jan, then I'll probably put it back on hold and the complete stripdown will begin!

Went for wof today..

Adjusted the brakes while it was still on the hoist during the wof, so that's ok - getting tires tomorrow morning and also got me a wiper blade!

The exhaust was basically snapped just after the muffler, and also the muffler had a "tear" in it from forkhoist damage. The guy at the workshop welded the tailpipe back on, then welded the hole in the muffler. It looked pretty rough, and sure enough after I got it home and patched up a small hole further up the pipe the muffler was still leaking from the weld.

My awesome spray-can-steel ghetto fix:

and the mechanics not so awesome ghetto weld:

Anyway so gonna go look for a muffler in the yard at work tomorrow while I'm getting tires. Here are some photos of the van once I got it home. Dog likes it.

Started chipping off bog from the side of the van and found a big dent. And LOTS of bog.

My paedo shutters / gangster gun slits

pulled out some of the manky cupboards and dad helped me extend the bed base so it's reasonably roomy now.

Sleeps 2 people plus a short person comfortably!

It's so sweet having a van.

how the fuck are people supposed to control where their cats roam?? They're not dogs, they jump over fences you know! Although I do keep my cat indoors at night, I have no control of where it goes during the day.

It seems the problem is that you're not able to keep your toy properly secured - if cats can get in, what's stopping theives?

I know it's annoying getting your stuff pissed on but please do not use methods that will injure or kill cats.

Regardless of what you or anyone on the forum thinks of them, it's incredibly painful losing what is effectively a member of your family - and would be even worse knowing that it died because some twat and his precious car.

edit: how do you email the neighbourhood anyway?

So once I get back from the two day cruise over new years I'm gonna get some paint on to the thing. Having trouble deciding what to go with - definitely don't want anything newschool like ford zany orange / kermit green or whatever..

here are some ideas:

digging the greenish/grey one and the red one, also quite like the white with white grill. of course there's nothing wrong with the glossy black with whitewalls. hmmm decisions decisions..

One thing I do know is that I'm gonna try paint using rollers. Seen a few examples/guides online and looks like people achieve some good looking finishes. Everything I've found suggests using "Rust-oleum" which is a paint-on-steel enamel they have in the states. Think I can get it here at MMP coatings in Mt Wellington. Might call in on tuesday and see what they've got.

Righto - had a productive day today, pretty much 12 hours solid working on the van. Want to get it ready and legal for new years and take it down to tauranga. With christmas only days away the clock is ticking..

So here's the progress:

Petrol tank: Sorted. fixed with "Minute Mend" (knead it) sandwhiched between steel riveted together. shh don't tell my wof guy.

Driveshaft: Sorted. Dad the good bugger found a donor shaft from a lancer - shortened it and welded the universals onto it. He's not a certified welder so again, just keep this between me and you and everyone else who reads this.

Jacked the back wheels up and tested it up to about 90 kph and it seemed nice and balanced so should be all tickedy boo.

Had a few more hurdles:

After filling engine with oil it kept dripping from the sump drain plug. Figured it was because there was no soft washer on it so got one of those, tightened it up and refilled - still leaking.

So pulled the sump off and had a look from the inside, and noticed some sunlight shining though the steel right next to the plug. So it seems whoever drained the car has been a bit brutal and somehow punctured it.. So fixed that the same way as the petrol tank - good old epoxy putty!

Also more forkhoist damage - the gearbox mount brackets were a bit mangled, but managed to straighten them out alright. Also the muffler has a huge hole in it so gotta get that sorted too.

But all in all pretty successful day - engine runs well and most if not all the electrics work.

These next few days before christmas will be tricky as I'll be at work right up till the 24th, So will need to make any purchases I need during lunchbreaks etc.

If anyone wants to help me make this a very special hiace christmas, I still need:

Front brake shoes (drums) sorted

Rear half exhaust + muffler fixed/replaced soon to be sorted

Reverse gear light switch sorted

Any hookups / recommended places to go would be mucho appreciato.

Photos next update!

ahhhhh gay update of gayness:

so got the engine back in, yup sweet as etc took it for a quick drive - goes good etc, sounds like a 2 cyl petrol powered sewing machine.

So then I had a bright idea and would put some CLR in the radiator to fllush out some rust in the pipes and stuff. Anyway left it like that and went out, then got home really late so I didn't empty it and it sat in there overnight and then the next day while I was at work. Keep in mind that it was only about 2 tablespoons (if that) of CLR mixed into a few litres of water.

Anyway so the next day I went to fire it up and it was a real bitch to start. When It finally spluttered into life it ran like shit and wanted to keep dying. So I let it idle for a few minutes and it was still running rough - had a look in the radiator: foamy and bubbly, had a look in under the oil cap: milky crap.

GRRR so looks like headgasket will be next on the shopping list - so far have had no luck finding one, so once again I ask anyone with the access to suppliers to please have a look for me. Engine is a 665cc EK42. Should be listed as Subaru Ace, Sherpa or Rex.

Oh and also while I took it for a drive I managed to back into a metal drain curb thing and pop my tire that I'd only just bought. WOOOOHOOO!

right so now I've got this:

plus a clean one of these:

and also these:

according to the manual I have to somehow combine the things in these three photos.

Will see how we go this weekend perhaps.

and now it's clean!

clutch should arrive this week some time. Having trouble sourcing some parts, such as the rear crankshaft oil seal. Been to several places including three seal specialists and no one seems to be able to source it!! Think it was the cause of the clutch failure, there was heaps of old oil on the inside of the bellhousing. For anyone in the biz, it's an NOK AH7143H. If anyone can find one that would be super sweet.

oops, got a bit carried away in the workshop and slightly forgot about the meet... err see you all next month - enjoy the pizzas!

Well, the dog likes it:

Got started pulling the gearbox off to get to the clutch:

using my nifty home made pulley:

voila!

clutch was very fucked - the pressure plate side of the clutch plate had all the material completely worn off and a nice rivet gouge on the pressure plate. Have got a clutch kit sorted out which should arrive some time this week. JOY!

Notice the nice black oil gunk all through the housing.. figure it's either come out of the crank seal, or through the sump gasket. Will remedy this before reassembly.

Figured I might as well pull the engine out and give the bay a good clean. Broke my pulley and dropped the engine sideways into the engine bay.. Had to call my brother over with some slightly more robust gear. No damage done though apart from some ugly scratches on the timing cover.

ALL GONE!

Cheers guys

forgot to also add - getting a flywheel machined. Where's good to go, and what should I expect to pay?

OK.. I need some recommendations for:

- Making a new driveshaft (from gbox to diff) where I will supply ends.

- Welding up a pierced petrol tank

Preferably around Onehunga or East Tamaki etc. not on the shore.

Also weird it's simultaneous fire, the exhaust note must sound so weird? surely one piston must be opposite phase than the other, but the coil would fire (like wasted spark) regardless - seems like a good way to get rid of a distributor.

Yeah I'm still a little confused by it.. someone with more knowhow have a look at the engine chapter and clear this all up:

http://www.box.net/shared/6qdr7m7dmr

Sound like this I guess:

but man that's a crappy video.

Yeah that's what I thought at first.. but nope it's simultaneous firing! So yeah the "distributor" only has a contact breaker, then the coil (which has two terminals) goes straight to the two sparkplugs (which are on the sides of the head). WEIRD.

Again, if anyone in the biz can hook me up with a good price (ie: under $200) on a clutch kit that would be mega-super.

Chassis code is KF3-00515 and engine is EK42 665cc

Clutch plate dimensions are: 160 x 110 x 3mm, 23 spline.

Discussion: viewtopic.php?f=18&t=20792

Had this little baby come into work the other day - it still had plates and three months rego so I thought what the hell, there's always room for another car. Especially when it's this size.

Collect the whole set!

Pretty weird little engine - it's a four stroke two cylinder..

Had to tow it home because the clutch was completely gone. Got the gearbox off this weekend and sure enough the material had completely worn off the pressure plate side, and there's a nice rivet gouge in the pressure plate disc..

Went to Sterling Clutch and brake and they could do a clutch kit for just over $200. BNT was more expensive around the $300 mark, and Subaru wanted $600 for one from Japan.. So looks like Sterling will be the go, unless some kind OS soul can hook me up with a better price? Will love you forever.

Otherwise it's pretty tidy, the odd supermarket ding here and there, and the usual rust at the bottom of the fenders, and a little bit in the sills, but nothing too scary. Much less than in the Suzuki...

OK BAI

I'll be there sipping a forty

edit: might bring my sweet new ride:

dick smith, jay car?

am going on the hunt for some electrical bits today so ill keep my eye out

yeah should really have stopped in to jaycar today - kinda hoping for somewhere cheaper though.. where would auto electricians buy from?

What's a good/cheap place to get spade connectors? I need a whole bunch of non-insulated femaile ones - I have a relay box that I want to use, so I want the ones with the little tab on the back that locks them into plastic connectors.

Repco don't do them, except for included in the packs of those white narva connectors, and surplustronics used to do them but now dont.

http://www.thetoolboxshop.com/0-011-24- ... 2509-p.asp

pack of 50 for £4.07 sounds alright.. but would rather buy locally!

Yeah was good, big turnout, met some good dudes, had good feed - took one photo:

I'll be at boigerfuel meet - wish the hiace was ready I'd rock that..

actually pulled into the carpark today and did a skid in the rain. was great

I take it this trip has already been tripped?

Got mikuni's new mags here and they are screaming to be put on a car.

Trip got canned, had to work plus mrs gran passed away - drama central at the moment

Lucky I didn't collect as they would have just made me jealous for their 4x100-ness

true, bummer about dramas - are you buying those hiaces, or parts of them?

Oh that would be wicked Nilly. What day were you thinking of heading up?

The hairless yak is on the north shore, so quite a way from Pukeko.

ps, vehicles still operate in the rain!

nahnah I'm not on the snore, I'm in Hillsborough - which is near Onehunga, and just off the "other" motorway - the one that goes to the airport. So I'm closeish to the Mangare pickapart. But I could always meet fuel at the pickapart?

I take it this trip has already been tripped?

Got mikuni's new mags here and they are screaming to be put on a car.

yeah man that's what I was thinking too - might get some other parts done in the same colour at the time - brakes, maybe even the block