(Author: ikom Monday 6 September 2004,
Sep,06,2004Sep,06,2004
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Monday 6 September 2004 - Labour Day
I really do not want to look at another electrical wire terminal today so I decide to take care of the gear shift linkage instead.
I had deliberately put this task off because all of the parts were in separate boxes - The factory had obviously run out of stock and decided to package some of the linkages and joints as "owed pieces".
I attempted to gather everything earlier in the build, but could not find all of the pieces initially so I had put this off until I had time to gather the pieces. The task had slowly slipped into "not pressing" mode however and other portions of the build took precedence.
Today is the day for the linkage install though, so I rummage through the remaining boxes and find all of the requisite pieces.
My son joins me and we attempt to test fit the linkage. We quickly learn that the linkage rods need to be polished - the zinc chromate coating has to come off if the rods are to travel smoothly through the HEIM joints.
We use fabric backed (roll) emery paper (plumbers use this to clean up oxidation on copper piping before it is soldered) on the linkage rods. Once the Heim joints slide smoothly; we polish and finish the rods with metal polish ("AUTOSOL") until they feel glassy smooth to the touch.
We very carefully locate the hole in the rear bulkhead cockpit panel through which the linkage will travel to the engine side. I want this hole to have just enough clearance for the linkage to pass through without binding, so we measure and measure again.
We also use a makeshift linkage/bushing assembly to mock up the path and eventually mark it for centre punching. Small pilot holes are then drilled and the path checked again to make sure that it will be correct.
All of this checking pays off when we finally assemble and trial fit the linkage. The rods fit though the bulkhead without touching the sides of the 20mm holes.
I will drill the rods and universal joints on the drill press later in order to insert the roll pins before they are driven in permanently.
I also need to confirm with other builders the length of travel required for the linkage rods in order to shift the Porsche G50 transaxle properly. This will help in setting up the optimal rod travel and locations of the HEIM joints.
As a final task we once again carefully center the steering rack by rotating it to full lock (in both directions) and halving the 2.4 lock to lock rotational travel.
I mark up a piece of painter's tape with accurate lines to designate each 0.2 turn of the steering on the circumference of the steering rod and confirm the centre once again. We do all this so that we can mark up the hub portion of the wheel relative to the splined portion of the rod so that we can have it welded together.
All in all, a good productive "Labour Day". We call a halt to the work after supper at about 8.00PM.
