Sheet metal work to install the fuel tank #2

This weekend I repaired the trunk floor around the fuel tank using the formed sheet metal I made last week.

First of all I made the holes on the formed sheet metal for riveting. I emphasized sturdiness rather than a smarter appearance.

I used steel rivets with 4mm diameter.

Aluminum & steel rivet or stainless rivet was more popular. But to avoid the erosion I looked for the all steel rivet.

I placed the formed sheet metal on the part to be reinforced and made the holes at the same position on body side.

Then, the remained POR-15 tank sealer was painted on the body to be repaired and both sides of the formed sheet metal. POR-15 hardened rigidly after drying, so it would be very effective for both the rust prevention and the reinforcement.

The remaining POR-15 was wrapped in a plastic film to be shielded from the air, but the surface had already begun to harden. But the inside was still soft and usable.

The formed sheet metal painted with the tank sealer was riveted on the body.

As a finish the tank sealer was painted on the rivets and stuffed in the small gap between the formed sheet metal and body.

I guess that its appearance was not very smart, but strong enough.

I also painted some other parts with remained sealer to utilize it as much as possible (it would be completely hardened in next days).

(My original blog was written on 28th Sep. 2008)

Comments

Tip to repair rubber parts

I disassembled the rear axle before. There had been no progress on it because I started the repair of the fuel tank during my summer holiday. While painting the fuel tank , I repaired the torn rubber boot of the parking brake wire. I guessed it didn ’ t cost high because it was small rubber part. But I wanted to try the repair method I read on the magazine article before. This was the condition before the repair. The rubber was torn apart and separated almost. I used this self-adhesive type butyl tape. I pasted lots of small pieces of the butyl tape on the back side of the rubber boot. As time goes by , these tapes would melt and stick together. After this I applied plenty of adhesive “ Super X Black ” on the rubber boot. On the magazine of MOTO MAINTENANCE , I read the article that the motorcycle seat was repaired with this method. So , I wanted to try it. After drying 1 day , it became like this....

Clutch master cylinder overhaul #3

I was still struggling with the sticking piston of the clutch master cylinder. I thought I should give up and look for the new part for the replacement. And to for my curiosity , I started to destroy and disassemble the clutch master cylinder piston by drilling. When I was drilling the piston halfway , I didn ’ t have any specific idea , however , I thought to tap the piston to make the thread. I started to turn the tap handle , and I felt the feeling that the piston was moved. So , I tried to pull it , and then suddenly the piston was removed from the cylinder. Finally I could extract the rusty piston! I observed the extracted piston. It looked there was no risk of the leakage of the fluid because the hole I made in the piston was not penetrated. Thinking the function that this part only holding the rod connected with the clutch pedal , it could be reused if the hole would be filled by the hard material. However , be...

Clutch master cylinder overhaul #2: tough match

I disassembled the removed clutch master cylinder. And I found that the piston was heavily rusted. I tried to hit it with a hummer , Pushed the piston using the vise clamp like this. However , the piston was heavily sticking by rust and it could not to be moved today. The brake master cylinder was replaced in the past , however , the clutch master cylinder was not. Therefore , the condition of the clutch master cylinder might be worse. Tentatively , I would spray the rust-penetration lubricant from both sides of the piston and try again in a few days. If it doesn ’ t work , I would give up the overhaul and order the new part. ( My original blog was written on 2nd July 2009 )

The day my "onboro ALFA" would revive

Search This Blog