Ivan's coupe: bodywork is done

[banpei]

It is starting to look like a genuine car again!

[Ivan141]

Does anyone here have experience with replacing the U-joints in the driveshaft?
2 out of the 3 u-joints in my driveshaft feel notchy, a clear indication that they are past it.
They are of a non-servicable type officially, so I cant easily find any replacement joints that should fit, although I suspect they do exist.
I read on Billzilla's old site that some common size may be fitted after some machining but I would prefer to avoid that.
A local driveshaft shop thinks they can get it done for me, but at €400 the cost is staggering.

[86aum]

I had my driveshaft serviced last year.
Replaced all 3 U-joints with: GMB 016-GUT24
Parts cost was 79€ and the replacement work and balancing of driveshaft was 330€.

[Ivan141]

Thanks.
I may just have to swallow the cost on this one. Proper u-joint installation would already be difficult enough, but getting these staked ones mounted correctly looks
a bit too difficult. Havent seen that part nr before, but the size looks familiar to others I've found (GMB 200-0024 / Febest ASM-CW5). Need to remeasure (cant find my calipers)
since I could swear the hole diameter was 24mm when I checked last time.

From what I've seen these solid ones are a better choice than those with grease fittings. In these small sizes those tend to snap when confronted with a bit of abuse.
The tricky bit with mounting new ones is getting them centered properly and making sure the axial endplay is within specification (<0.05mm). That last one is hard to do in a shed.
Rebalancing should not be necessary but it is probably not the biggest part of the cost.

[Ivan141]

Progress report:

-Bent up new cunifer brake lines for the rear axle. Not an easy task, but the result looks like it will work:


Next to crusty old suspension for contrast:


What's this? No more rotisserie, thats what.


The eagle has landed:


Todo items on my mind these days:
-Refurb driveshaft. I ordered 3 new u-joints for about €30. I'm going to attempt it myself. As long as I dont screw up the yokes I can still dump it at a specialist store if DIY doesnt go well.
-Prepare reconditioned rear brake anchor plates and hardware for mounting to axle. (zinc-plate the bolts/nuts, clean up my 'new' calipers.
-Buy some stuff for finishing off the rear axle (solid spacer kit, gasket kit, axle end plates).

When I have a working parking brake again the next priority is getting the shell reunited with the doors and trunk/bonnet so we can start 'mudding' the heck out of it.

[banpei]

That's some great progress! Finally she's on her own feet again!
So which car is next in line for the rotisserie?

[bozu]

Nice! Keep up te good work and the momentum. She’s almost ready for MOT!

[r.ave]

Nice work!

[Gtsi-R]

good work!

[Mylesmck]

I'm following this with much interest.... great work Ivan