Hi Jin,
I beginning to think you are even fussier than me !
Have a look at rivet nuts (Rivnuts and various other spellings) for
putting threads into the fibreglass as well.
Even though you won't be able to expand them fully in the thick
fibreglass you can expand them a little and bond them in in a similar
way to your brass inserts.
A countersink on the gelcoat side with let the normal top hat version
sit flush, though you can get countersunk rivnuts they are less common.
Whats the problem with the heater holes, they look ok in the pictures.
Jim
On 05/01/2012 22:37, jin wrote:
well despite suffering from a severe case of man flu ive done a fair
bit today, actually it made me feel slightly better
started with cleaning out all the bulkhead holes with various stiff
bottle brushes mounted in the drill and lots of loctite solvent
cleaner
[IMG]http://i120.photobucket.com/albums/o192/jindal/DSC02346.jpg[/IMG]
this literally took hours to shift all the c++p out the holes like old
sealant and general ingrained grime, but the finished results are
worth it
[IMG]http://i120.photobucket.com/albums/o192/jindal/DSC02351.jpg[/IMG]
[IMG]http://i120.photobucket.com/albums/o192/jindal/DSC02352.jpg[/IMG]
the only holes beyond salvage are the 2heater matrix holes, i assume
at some point they leaked and the hot water / antifreeze has stained
and contaminated the bulkhead fibers, I've left them as they are at
the mo as a reference for the stainless plate, but once I've cut
corresponding holes in that ill chop out the damaged fiberglass
[IMG]http://i120.photobucket.com/albums/o192/jindal/DSC02353.jpg[/IMG]
also pulled out the steering column bush as it was very sloppy but no
longer available from ford but i have a cunning plan.....
got some nice brass thread inserts to use instead of the self tappers
in the bulkhead like on the catch panel / wiper motor, i just don't
like the thought of self tappers munching up the fiberglass which has
already happened in places
[IMG]http://i120.photobucket.com/albums/o192/jindal/DSC02348.jpg[/IMG]
these are brass M6, the holes need enlarging to about 8.7mm and i
found tapered reamers do a great job without ripping the gel coat off
[IMG]http://i120.photobucket.com/albums/o192/jindal/DSC02349.jpg[/IMG]
ill araldite the inserts in place to give a permanent and sealed
thread
inside i spent ages scrubbing away at the inner bulkhead ready to seal
up all the cut holes
[IMG]http://i120.photobucket.com/albums/o192/jindal/DSC02350.jpg[/IMG]
and now its looking to too far off
[IMG]http://i120.photobucket.com/albums/o192/jindal/DSC02355.jpg[/IMG]
more to come soon.....
On Jan 1, 12:05 pm, jin<[email protected]> wrote:
thanks for all the tips and encouragement guys, it helps allot
ill keep you posted on progress
On Dec 31 2011, 8:05 pm, Ian Harrison<[email protected]>
wrote:
Looking god Jin, keep the updates coming!
I really need to spend more time in the garage...
Ian
On 30 Dec 2011, at 14:40, jin<[email protected]> wrote:
update
ive removed the pop rivets and P clips that held the brake pipes on,
http://i120.photobucket.com/albums/o192/jindal/DSC02331.jpg
they didn't fit too well and the pop rivets didn't go through the
bulkhead so only served to swell out the fiberglass and let water and
dirt in, evidenced by the dirt that had crept within the hole around
the rivet, i chamferd the holes to remove the contaminated fiberglass
and gelcoted from the outside with a thin layer
http://i120.photobucket.com/albums/o192/jindal/DSC02333.jpg
then filled the rear with slow set araldite to seal the join and
hopefully put a bit more strength back in
http://i120.photobucket.com/albums/o192/jindal/DSC02336.jpg
the tape is just to stop it running out and keep it smooth
cut out the first hole for my cable glands, i found a cone step drill
very handy for enlarging holes (I'm using one of my extra? servo mount
holes that were drilled but unused?) since they locate and don't
wander about ripping the gel coat like normal twist drills, only thing
to do is drill both sides sins the steps are shallow,
http://i120.photobucket.com/albums/o192/jindal/DSC02332.jpg
tapped it out to the right size
and sealed the fiberglass with araldite resin and wound the gland in
http://i120.photobucket.com/albums/o192/jindal/DSC02335.jpg
then gave a wipe round the inside with more resin just to be sure,
these should be very water proof now, this one will be for the wiper
motor
as for the brake pipes, I'm not too sure how I'm going to secure the P
clips, I'm not going to use pop rivets fore sure, i may drill a few
holes and tap a thread then wind in a stainless stud with araldite to
seal unless anyone knows a batter way?
cheers for any info
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