Keflaman

Author Topic: Keflaman  (Read 34676 times)

jscribble

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« Reply #15 on: March 05, 2012, 07:58:24 PM »
Dave here as always, but this time with great questions, instead of excellent answers!

+1 on the electrolysis q's. Seems almost magical, and a handy set of skills for any petrol head.
Betty - Sold
Sabine - 2004 325xi

keflaman

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Electrolysis Bath
« Reply #16 on: March 06, 2012, 08:56:08 AM »
At the risk of sounding a bit narcissistic I would say my inspiration comes from you guys leaving positive comments on my thread.  After reading several build threads and member profiles I realized I might have a few ideas or areas of expertise to put out there for the benefit of others in the same way I have benefited from them.
   
The fact that I’m an aircraft mechanic by profession makes it impossible for me to accept “good enough” and my SOP is to go through every car I buy and rebuild the suspension/brakes at a minimum.  My long term plans are to have a solid, leak-free vehicle reliable enough to toss the keys to any member of my family and not have to issue any eccentric instructions for its operation.

How much more do I have to do to the car?  Let me put it like this…my Pelican Parts Project List is 11 pages long! :eek:  The suspension is finished and the brakes are almost done.  I have one more floorboard spot to repair before I can reinstall the driveshaft and then I can go on into the engine compartment and replace all the drivetrain gaskets and seals.  I’m finishing up with the rest of the rust repair and maybe top it off with a paint job, but that will most likely be next year.

And all the while I’m also dismantling an ’89 325 and putting the suspension, brakes and M50/ZF drivetrain into the 318is shell that’s left of the parts car I bought for the suspension and brakes for this car.  

And along the way for some reason I started picking up S50 engine components for a car I don’t even own yet! :p

But I digress…

There are three websites I used to put together my electrolysis bath and it is quite easy to get overly involved in different aspects of the procedure and process. I gleaned over what I considered the most useful information foremost being SAFETY, secondly efficiency and lastly economy. The usual disclaimer is that I don't accept any responsibility for how you use this information. It's not rocket science, but there are precautions you need to follow in order to preserve your health, life and property.

http://www.rowand.net/Shop/Tools/Electrolysis.htm
http://antique-engines.com/electrol.asp
http://www.stovebolt.com/techtips/rust/electrolytic_derusting.htm

Dave you are correct; this process is only for ferrous metals such as steel or iron. No chrome plating, zinc, copper, aluminum, etc.

Very simply, I use a five (or maybe six) gallon bucket and four pieces of rebar approximately 12 inches long and wired in series with 10 gauge copper wire around the lip of the bucket.  Attached in the center of the copper wire is the positive lead from the battery charger and the negative lead is attached to wire or chain that is used to suspend parts from a piece of non-conductive material.


My power source is a ten amp "dumb" battery charger. On a smaller scale my very first experiment used a 1.5 amp wall charger with alligator clips and a plastic Glad storage container.

I tried using Arm and Hammer wash soda and wasn’t happy with the results, but that may have due to dirty anodes. I have no idea what the exact ratio I now have, but I used about 1/2 to 3/4 cup of sodium carbonate to six gallons.

The rebar works well enough for my needs, but for efficiency sake the cleaner you keep it the better it works. I intend to source some graphite bars later on to eliminate using rebar.

d.hitchcock

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« Reply #17 on: March 06, 2012, 09:48:15 AM »
This is so cool in so many ways.

I love the cleaned up p brake adjusters. :D

Awesome work.
SHAZAM, GOMER, LOOK AHEAD!

keflaman

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« Reply #18 on: March 06, 2012, 06:56:12 PM »
Quote from: d.hitchcock;110804
This is so cool in so many ways.

I love the cleaned up p brake adjusters. :D

Awesome work.


Thanks. Positive reinforcement has given me a boost of enthusiasm that I needed.:p

Today I finished assembling the front calipers and installed them. It was a bit of a let down that brake fluid leaves "stains" in the caliper paint no matter how fast I wipe it down.

keflaman

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« Reply #19 on: March 07, 2012, 10:29:53 PM »
Today was spent torquing all the brake and suspension components. I decided to swap anti-sway bars and I was glad I did. The original was pretty rusty and had already started to chew up the new rubber bushings installed a few months before I bought the car. Tomorrow I will power bleed and flush the brake system and then torque the control arm attach bolts after I get throw on the wheels and get the car back on the ground.

With the assistance of my "helper" torquing the axle nuts and CV joint hex bolts was easily accomplished within a few minutes...

ose30

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« Reply #20 on: March 08, 2012, 11:31:28 AM »
Keith,
looks really good. Did you got my e-mail?

Here's few BMW brakes i did for a friend's E30.





Starting point of the front brakes



After citric acid bath



Before powder coat i blasted the surface rust off with glass beads


Brakes will be bolted on this 2.7L E30

« Last Edit: March 08, 2012, 11:34:12 AM by ose30 »

keflaman

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« Reply #21 on: March 08, 2012, 12:57:32 PM »
Hey Olli! I did get your email and haven't come through on what I promised. :(
Please forgive me, but the weather has been super mild and I've spent more time outside than I usually do. I'll get on that soon. Sorry! :o

As usual your work is beauty to behold and those calipers look super nice. What exactly does the citric bath consist of? Is it commercial only or can any average "Joe" from off the steet get it? I believe the next set of calipers I do will have to be powder coated.

ose30

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« Reply #22 on: March 08, 2012, 01:27:20 PM »
Keith,
citric acid i use is 100% citric. Same stuff can be found (milder though) from food and beverage, like Fanta etc.
I buy it from a local farming equipment store. It is mainly meant to heel sore stomach of pigs.... When you have cleand your parts, you can recycle the fluid and serve it to your friends as a lemon juice ;)
Glad the weather in VA has turned nicer. We still have a lot of snow and at the moment we have -10C. No hurry with our business, take your time.

keflaman

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« Reply #23 on: March 08, 2012, 09:23:03 PM »
I'll have to look into that. I'm sure citric acid would add a scent to the shop that smells better than rust, old brake fluid and stale gas. :p

keflaman

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Pressure Bleeder
« Reply #24 on: March 08, 2012, 10:03:13 PM »
Today I was excited to finally use the pressure bleeder my wife bought me for Christmas, but was sadly disappointed to realize it was a siphon bleeder. :(


I gave it a shot, but it just wouldn't pull the fluid through the lines.

Well, poop:mad:

Then I remembered a DIY pressure bleeder that I had started a few years ago based on this article: http://www.bmw-m.net/TechProc/bleeder.htm. I already had the modified master cylinder cap...


I put a different twist on it that was cheaper and simpler than the DIY. A small pressure regulator from Lowes with a barbed connector installed in the outlet port and a short piece of clear tubing (3/16" ID) connected to the connector on the master cylinder cap. I set pressure at 15 PSI and it worked perfect. :cool:


The pump sprayer has been sitting on a top shelf in the garage collecting dust...and it still is. :D

ose30

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« Reply #25 on: March 09, 2012, 12:51:20 AM »
Bleeder built in that DIY article, looks a lot like Motive item. Got one from a friend of mine, who is the Finnish importer for it

 

I suppose i will try next Keith's design :)  

Motive is OK, works well with most German made cars, execpt older Porsche 911's  :(

keflaman

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« Reply #26 on: March 09, 2012, 07:41:22 AM »
I like the Motive type units, but it's overkill for someone like me who would use it at the most only a few times a year. In fact, I'll post pictures later to show how you can add a pickle jar in series between the regulator and master cylinder reservoir to duplicate the exact same process:).

Olli, I invite you to paste a link to the Porsche project you are helping your son restore. To those who aren't familiar with Olli's work you will be very impressed!

ose30

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« Reply #27 on: March 09, 2012, 08:37:57 AM »

keflaman

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« Reply #28 on: March 10, 2012, 04:24:51 PM »
Quote from: ose30;110917
Actually nothing special in our project, but you can take a look at  http://forums.rennlist.com/rennforums/944-turbo-and-turbo-s-forum/561811-project-951-young-mans-first-porsche.html


Well, I was quite entertained for a few hours the first time I visited your thread. :p

keflaman

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« Reply #29 on: March 10, 2012, 04:40:59 PM »
Talk about entertaining, I spent some time going through the pile of records I got with my car and noticed the replacement of the antenna mast was performed a total of five times (six if you count the one I installed after purchase). The first mast was replaced at 11,114 miles and the antenna motor failed at 16,930 miles. The mast was replaced at the following mileages: 11,114; 45,769; 96,456; 120,789; 127,529; 133,663; 155,500.

The profile gasket was replaced at about 45K miles after the car was towed into the dealership. BMW did a goodwill repair covering 75% of the cost.

Like Desktop Dave said earlier in the thread, it's always interesting to go through the car and pick up clues to the previous owners. With detailed service records and paperwork I get a little more insight on the original owner. Funny how 20 years ago we threw our SSNs around and printed entire account numbers on the credit card receipts.:eek: