[Damo]

A little update on this ongoing project. Perhaps I should make that longoing

Part of the modified handbrake cable.


Here you can see more of the modified handbrake cable where is goes to the caliper. Also the T that's now in the brake line.


The new flex line for the driver's side. It's really close to the housing here, and even though it should be OK with the coil sheath I might look at making a bracket that keeps it off the housing. The passenger side is fine.


As it stands at the moment. All the brackets on the housing are stock except for the ones for the flex lines. Handbrake cable is half custom, half stock and should bolt straight up to the standard handbrake.

[Damo]

Moar

[Hybrid]

Looking good Damo. I wouldn't bother making a bracket to move the flex line of the housing. Its not like there will be much movement with that coil sheath and even if there was your zuk would be dead well before wearing through it.

[steve]

a bit too flash damo, what about when you reverse in to rocks and stuff and crush all that nice tube

[Damo]

steve wrote:

a bit too flash damo, what about when you reverse in to rocks and stuff and crush all that nice tube

Aint no rocks in the carparks that I use

The brakelines and cable are all in the stock locations, and i've never had any problems before. Now that i've said that there's a bloody good chance I will rip the shit out of them first trip out

[steve]

ohwell... that'll give you something to do when you crunch it.

Are you putting this diff in your current car or building something new?

[Damo]

steve wrote:

ohwell... that'll give you something to do when you crunch it.

Are you putting this diff in your current car or building something new?

It's going in the current vehicle.

[Damo]

It would seem I have hit a snag

I started reassembly of the brakes yesterday and it appears something is wrong with the size of the brackets. When I slide the axle shaft into the housing it does not go in far enough. The bearing sits proud of the surface of the flange and does not allow the bearing retainer to be bolted down properly. This is what I have at the moment:-
[align=center][/align]

OK fine. So the obvious solution is to make the middle plate (yellow one) thicker. The next size up is 8mm plate, but that will not be thick enough, I could go 10mm but that will leave me a gap between the bearing and the bearing retainer (outer plate). I'm not sure if that much gap is acceptable???
[align=center][/align]

The nice way to do it would be to have it cut from 10mm plate then machined down to 8.5mm. Kinda like this:
[align=center][/align]

That would be kinda exy though, and time is also a factor. I'm even thinking about just spacing the outer plate (bearing retainer) with some washers for the time being until I figure something else out.
[align=center][/align]

Ideas/suggestions?

[Damo]

I've just had another think about this. I might put the washers/spacers in temporarily and once my lathe arrives i'll modify the bearing retainers like this:
[align=center][/align]

[Damo]

Well I finally got to have a good look at these bearing retainers. It's ended up being a whole lot more dicking around than I imagined but they are sorted now and I can get on with putting the diff back together. I still need some rotors and a rear brake line though.

As for the retainers, I couldn't mount them in a chuck so I bolted them up to the faceplate. The rebate I wanted to machine is concentric to the centre hole so I made up an jig using an arbor that's mounted in the chuck in the tailstock. It ended up working really well.


A bit of machining


And hey presto, one bearing retainer.

[Hybrid]

Nice work!

[joeblow]

damo, i have just checked the cad, the middle plate is supposed to be 8mm ( fu#@en laser cutters.), also my rw507 does not sit out further than 8mm, nor have the others i have done. could ther be something not letting it be driven home properly?

[Damo]

joeblow wrote:

damo, i have just checked the cad, the middle plate is supposed to be 8mm ( fu#@en laser cutters.), also my rw507 does not sit out further than 8mm, nor have the others i have done. could ther be something not letting it be driven home properly?

There could be but I did have a really good look. I measured the whole thing a few times and even with 8mm plate in the middle the bearing was still proud of the surface. I have to pull the axles again so i'll have another look then.

In any case they fit now, lol.

[Fatzook]

One solution would have been to have a shim laser cut in the same shape as plate 2 from 2mm or 2.5mm sheet, making it a 4 plate arrangement.

Looking good tho.

[Damo]

Fatzook wrote:

One solution would have been to have a shim laser cut in the same shape as plate 2 from 2mm or 2.5mm sheet, making it a 4 plate arrangement.

Looking good tho.

Yeah that crossed my mind, and in the end would have been quicker. Live & learn!

[steak_knife]

Nice diff & a great read, please let us know how much of an improvement the rear disc is..

Wish i had a workshop at home.

[Damo]

I picked up some new brake rotors yesterday so started putting stuff back together. And bugger me if the passenger side had about 2mm runout. It all seemed to be assembled correctly so I took out the rotor, chucked it up in the lathe and measured the runout. Nope it was OK. So I took out the axle shaft and measured that, nup that's OK too.

Hmm something wacky going on. I checked the driver's side and it's fine. I'll try putting the passenger side back together and you watch the bastard thing will be fine too.

[303zuke]

Damo wrote:

Yesterday I mocked up the brackets on the axle housing to check clearances. I also notched out the 3rd bracket to allow easy axle changes.

This is the number 2 bracket in position. You might notice the orientation is different, I was trying it in a couple of different positions


Spacing is about spot on now that I added 1 washer about 1.5mm thick. It's possible I could get away without even using that washer. I'll run it like this for now and see how it goes.

Damo, the RW507 bearing has a 1mm step on the inner race similar to the stock Suzuki bearing. It should however, go on the retainer side, not the hub side. In the top pic, you've mounted it outward in the same way you'd mount up the stock bearing. This places the oil seal on the outside instead of the bearing sheild, and locates the axle shaft (and therefore the rotor) 1 mm further out. As the bearing is already 6mm wider than stock, that is 7mm less spline engaging the sidegears in the diff. Mounting it the other way round would eliminate the need for the washers on the caliper.

I'm still waiting to hear back from Joeblow.

[Damo]

303zuke wrote:

Damo, the RW507 bearing has a 1mm step on the inner race similar to the stock Suzuki bearing. It should however, go on the retainer side, not the hub side. In the top pic, you've mounted it outward in the same way you'd mount up the stock bearing. This places the oil seal on the outside instead of the bearing sheild, and locates the axle shaft (and therefore the rotor) 1 mm further out. As the bearing is already 6mm wider than stock, that is 7mm less spline engaging the sidegears in the diff. Mounting it the other way round would eliminate the need for the washers on the caliper.

I'm still waiting to hear back from Joeblow.

Bugger me, I had not even noticed that. I have the long side axle shaft out of it at the moment, i'll have a look at it.

In any case I don't think i'll be able to get the bearing off without destroying it, so I might just need to run it as-is for the time being

[tanshi]

i would have thought you should be able to press it off with out damaging it too much damo?

[Damo]

tanshi wrote:

i would have thought you should be able to press it off with out damaging it too much damo?

Maybe, if I had a press

[tanshi]

i happen to know some one who has a 10 T press
unfortunatly that would involve a trip to ipswich

[Damo]

tanshi wrote:

unfortunatly that would involve a trip to ipswich

Geez, it would be almost worth buying new bearings

I'll have another look at these bearings this arvo and see.

[tanshi]

almost worth buying a press

[Damo]

tanshi wrote:

almost worth buying a press

Good point!

Running out of room in shed though

[tanshi]

http://www.tradetools.com/Catalogue/Pro ... de=SP05301

thats not too bad i guess

[31zook]

If the bearing is only just pressed on and new it will come off, i did it about a week ago. I got all excited about using my new 12T press and forgot...

[steak_knife]

31zook wrote:

If the bearing is only just pressed on and new it will come off, i did it about a week ago. I got all excited about using my new 12T press and forgot...

Forgot what?? Milk? Dish washing liquid?? Shaved almonds??


We`ve all done it, but we fixed the f*#k up before anyone else found out!!!!!

[want33s]

Ummmmmm backing plate/retainer.

[steak_knife]

I know..