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Sunday 24th August 2008
Burgo Blue
http://img.photobucket.com/albums/v1...sunday0094.jpg
Benns beast
http://img.photobucket.com/albums/v1...sunday0095.jpg
The PNG how to upgrade standard brakes to GSi ones in 45 minutes (if that!)
Just like an eposide of Overhaulin', the PNG rallied round and everyone chipped in to whip the old brakes off and stick the new ones on. I've never been so impressed at the way everyone was so co-ordinated! Real team work!
To start - car was jacked up which was fun on the soft ground!
http://img.photobucket.com/albums/v1...howtos0002.jpg
Wheels were removed and all parts laid out. The old brakes -
http://img.photobucket.com/albums/v1...howtos0003.jpg
and servo -
http://img.photobucket.com/albums/v1...howtos0004.jpg
Now - several "members" said you couldnt remove the servo without damaging the brake lines, or it would be impossible to remove it, or it wasnt worth it...except LEEH who apparantly got so angry when I posted the original thread he was screaming at his computer! For those who said it couldnt be dont - youre WRONG! Keep reading...
Dan started by "trying" to remove the dust caps...
http://img.photobucket.com/albums/v1...howtos0005.jpg
He hit them and hit them some more...
http://img.photobucket.com/albums/v1...howtos0009.jpg
Someone said treat it like removing an oil filter...so he did...
http://img.photobucket.com/albums/v1...howtos0010.jpg
He then applied his mighty strength and losened the caliper bolts - almost bending the allen key in the process...
http://img.photobucket.com/albums/v1...howtos0013.jpg
the old brakes were slipped off the disc and rested on the suspension - taking care not to stretch/damage the flexible brake line
http://img.photobucket.com/albums/v1...howtos0012.jpg
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Sunday 24th August 2008 - PNG brake change
Meanwhile Burgo (and his pants) were inside the car removing the retaining clip that holds the push rod on the back of the servo to the bar linking the brake pedal to the servo...
http://img.photobucket.com/albums/v1...howtos0001.jpg
Whilst the 4 bolts were losened holding the servo to master cylinder...
http://img.photobucket.com/albums/v1...howtos0006.jpg
The retaining brackets were losened on the inner chassis to free the brake lines to allow for some movement
http://img.photobucket.com/albums/v1...howtos0007.jpg
The servo was then "cracked" free from the bulkhead
http://img.photobucket.com/albums/v1...howtos0015.jpg
sliding it to the side -
http://img.photobucket.com/albums/v1...howtos0016.jpg
and disconnecting it from the master cylinder -
http://img.photobucket.com/albums/v1...howtos0018.jpg
and got it free...the old one is the smaller (obviously)
http://img.photobucket.com/albums/v1...howtos0019.jpg
no damage done!
The new servo was replaced (in the reverse sequence of removal) and tightened back up. The servo bar joint as seen from inside the car prior to being reconnected to the brakes
http://img.photobucket.com/albums/v1...howtos0020.jpg
and the new servo in place
http://img.photobucket.com/albums/v1...howtos0021.jpg
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Sundat 24th August 2008 - brake upgrade
Meanwhile - Lee set to work fitting the new pads to the calipers. First he applied some rubber gloves for added protection...
http://img.photobucket.com/albums/v1...howtos0008.jpg
then smeared some copper greese on the backs of the pads so they wouldnt squeal
Unlike Lee who squealed when his rubber gloves tore and he got brake fluid in a cut on his hand. Bless... Mike offered to lick it better (just to see what it tasted like)
After cleaning off the protective silicone coating with panel wipe, Lee fitted the new vented discs. A debate started before this about whether to remove the brake shields however the discs werent the bigger ones and fitted on perfectly.
http://img.photobucket.com/albums/v1...howtos0014.jpg
the new caliper was then offered up to check for fit -
http://img.photobucket.com/albums/v1...howtos0023.jpg
perfect -
http://img.photobucket.com/albums/v1...howtos0026.jpg
Lee then fitted the new caliper - when asked what torque setting should be used he advised - "Lees setting"...when checked later this was exactly the same as the Haynes!
http://img.photobucket.com/albums/v1...howtos0030.jpg
The old caliper was then removed from the brake pipe. Before doing this though the brake reservior lid was removed. Sturge suggested that by fitting a rubber glove over the end of the reservior you can create a vacuum keeping the fluid in and reducing the amount of bleeding needed -
http://img.photobucket.com/albums/v1...howtos0029.jpg
http://img.photobucket.com/albums/v1...howtos0031.jpg
http://img.photobucket.com/albums/v1...howtos0032.jpg
New caliper, pads, discs and pipe in place -
http://img.photobucket.com/albums/v1...howtos0033.jpg
Ready for bleeding
This required losening my rather long nipples
http://img.photobucket.com/albums/v1...howtos0034.jpg
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24th August 2008 (continued) - brake upgrade
I actually missed the bleeding exercise but believe it involves losening the nipple till no air comes out whilst someone pumps the brake pedal till its all hard. The nipple is then tightened and additional fluid applied.
The Haynes (which throughout this entire exercise was never used once) details the process apparantly!
Spring clips were then fitted to retain the pads and caliper and the job was a done!
http://img.photobucket.com/albums/v1...howtos0037.jpg
I took her for a small test drive and couldnt believe the difference! You ony have the touch the brake pedla just lightly and you can feel them bite!
No judder or anything - judder by the way (as explained by Mowgli) is caused when one of the 2 sliders on the old brake calipers stick causing it to rock back and forth on its mounting - this feeds back through the disc affecting rhe steering.
LeeH also decided to re-greese up his brakes after they'd started squealing
http://img.photobucket.com/albums/v1...howtos0038.jpg
http://img.photobucket.com/albums/v1...howtos0039.jpg
http://img.photobucket.com/albums/v1...howtos0040.jpg
http://img.photobucket.com/albums/v1...howtos0041.jpg
About this time someone shouted - "let's have a game of crazy golf"...
Oh my GOD...
about 20 of us headed for the craziest golf course I've played on in a long time. The "shark Island" course is surrounded by water. You'd think people would realise that whacking the ball dead hard is likely to result in a lost ball...erm - no...
Dan on the other hand didnt even realise it was golf and after seeing the white ball and green baize got down to pot the ball -
http://img.photobucket.com/albums/v1...08golf0003.jpg
and so did Mowgli -
http://img.photobucket.com/albums/v1...08golf0021.jpg
Benn on the other hand had difficulty getting over the hump -
http://img.photobucket.com/albums/v1...08golf0004.jpg
Whilst Mike and Hayley were battling it out in the arches
http://img.photobucket.com/albums/v1...08golf0005.jpg
http://img.photobucket.com/albums/v1...08golf0006.jpg
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Sunday 24th August 2008 - crazy golf
Myself, Benn, Mike and Hayley were have a right competiton on who got the least round - Mike went for it...
http://img.photobucket.com/albums/v1...08golf0009.jpg
and hoofed is ball into the reeds!
http://img.photobucket.com/albums/v1...08golf0010.jpg
Benn got all technical and went for a rebound shot - FAIL!
http://img.photobucket.com/albums/v1...08golf0011.jpg
In the end - despite some valiant efforts and a bit of cheating - Mike won our round!
http://img.photobucket.com/albums/v1...08golf0012.jpg
The rest had an equally "interesting" time - Lee going for the classic lets face the wrong way and make an ar5e of it approach -
http://img.photobucket.com/albums/v1...08golf0014.jpg
Hannah clobbers the ball into the reeds (again)
http://img.photobucket.com/albums/v1...08golf0015.jpg
Sturge and Ash get all technical...
http://img.photobucket.com/albums/v1...08golf0016.jpg
http://img.photobucket.com/albums/v1...08golf0017.jpg
Whilst Lee pouts at the ball...
http://img.photobucket.com/albums/v1...08golf0018.jpg
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Sunday 24th August 2008 - crazy golf continued
Mowgli's daughter Molly - (the wee lass next to Dan in the pic about) I believe got the only hole in one and also maimed Mike (i think) with a serious HOOFER!
She also was the only one on the last hole to boot the ball so hard it went for a swim!
lol
Like Lou - although she found "a ball" - not sure if it was hers though
http://img.photobucket.com/albums/v1...08golf0019.jpg
http://img.photobucket.com/albums/v1...08golf0020.jpg
Eventually the golf came to an end and there was only one thing left to do - take it to the track!
The PNG headed for the go Karts...be prepared for the events most epic fail ever!
2 heats set off - the winner from both would fight it out in a third race to decide the pNG go karting champion 2008...
http://img.photobucket.com/albums/v1...08cart0002.jpg
http://img.photobucket.com/albums/v1...08cart0010.jpg
http://img.photobucket.com/albums/v1...08cart0011.jpg
http://img.photobucket.com/albums/v1...08cart0015.jpg
http://img.photobucket.com/albums/v1...08cart0016.jpg
http://img.photobucket.com/albums/v1...08cart0020.jpg
http://img.photobucket.com/albums/v1...08cart0022.jpg
http://img.photobucket.com/albums/v1...08cart0024.jpg
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