Assessing steering/suspension damage

If you are going to try a breaker bar either by its self or with a length of pipe on the handle to increase the force, I would suggest investing in some single Hex (6 point) sockets like the ones they use on an impact driver. They grip the corners and sides of the head far better, don't slip as easily (less cuts and bruises) and rarely round the head corners.

Normal sockets are double hex (12 point) and grip just the corners of the heads.
 
Great advice. Hadn't put 2 and 2 together there. Thank you.

Yes I rounded a number of bolts trying with a regular socket.

The advice comes in time for removal of the donor parts though as they have to come off cleanly.
 
Well what a revelation my new breaker bar is. I would never have guessed it could provide that much extra leverage! So much happiness and saved skin for £20!

So the subframe from the donor is out.

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I'm not completely sure I did everything in a very logical order. It certainly pays to crack all nuts and bolts before taking anything off and I didn't do that.

The offside dust-guard was split which effectively renders the whole offside assembly scrap as the bearing would have to come off to change that and I understand the bearing is 1 time use only and about £25 new as a full hub unit plus cost of bearing puller. So I might as well just splash £30 on a secondhand complete hub/king pin/dust-guard assembly from ebay. The nearside looks okay.

The wishbones are both okay and paperwork with the car suggests they are only 2 years/10k miles old. Otherwise I'll be replacing lollipops, drop links and inner/outer track rods on both sides. The struts are being picked up Tue evening and are coming from a 40k 2.8 which uses identical struts.

I'll get the steering rack separated and then give everything a good de-grease. The old subframe still has to come off at the receiving end. I'll be waiting for my engine support beam to come before I do that. The project car is 6 cylinder not 4 like the breaker. So it's more to support and I'll be less amused if wooden props gave way on that one! On the breaker you might just see I propped the engine up with 3 pieces of wood! I'm still not sure how a support beam is going to work on a Z3 but we'll give it a go.

I think the hard bit is done now, putting it back together should be easier. I'll be using all new OEM bolts. But I'll have limited time for the next 6 weeks getting it all back together so we'll have to see how that goes.
 
Well if it's not too nippy tonight I'll be popping out after work and having the subframe out of the receiving/project car. Everything's off/loosened ready.

Here's my arrangement for supporting the engine to overcome the lack of inner wing rail. This is just the mocked-up arrangement. The other wing liner and the front bumper will need to come off to move the breeze blocks in enough to get the beam bases nearer the centre.

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There's 10 breeze blocks either side there to get the arrangement high enough and to leave enough thread on the central support rod to turn the handle. It's stable enough (these are high density 7Nm blocks) but I wouldn't want to go any higher. And for info 10 is a more sensible limit in the back of a car not the 20 I attempted. But my Alhambra seems none the worse for it.

I really didn't want to risk jacking under the sump. I know it would probably have been okay but I just don't want to risk it. That said I'll put a second fail-safe jack support under the sump in very light contact with a wood baton spreader.

Then I can build the front end back up, I hope fairly quickly!
 
Braver man than me in this weather, good luck
 
I am allowed to say this as I consider myself dual-nationality after living in Swansea half the week for 10 years :) But the weather is generally a few degrees warmer in Swindon than it is in Swansea/South Wales where you are. And a few inches of rain dryer :) Still b**dy cold though :(

Besides that I'm banned from doing any repairs on my Z3 in Swansea in case it 'lowers the tone' of the cul-de-sac! At my house in Swindon last night I was degreasing the replacement steering rack in the kitchen - her in Swansea would have had a fit!
 
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Well out I went in -1 deg. The irony is it's actually warmer in Swansea tonight!

I had the bumper and nearside wheel liner off to bring the block stacks in nearer. Yet again I'm reminded of how much cr*p can accumulate at the end of the sill under the wheel liner. It really is something all Z3 owners should attend to from time to time. In this car's case I've got there just in time before any real damage is done.

The steering rack is finally off. One of the 2 mounting bolts was seized in the hole (nut came off okay) and the joint with the steering column was very stuck despite being levered open.

Then my brain numbed over and I thought it was foolish to attempt the subframe swap tonight.
 
You can get too much of a good thing mate.

Tony.
 
Some folks are never satisfied! Oh, bugger.=))=))

Tony.
 
Well the good news is I sorted the subframe chassis thread with the tap. Thanks for the advice as I really didn't know what that tool was for previously and would never have had the thought/confidence to try it otherwise. It's a bit unnerving with shavings of metal falling out but the torque wrench click was excellent to hear when the bolt finally went home.

Now I was rebuilding the car for a friend with terminal cancer who we thought had at least months to live. I was so looking forward to giving him the car and he'd been telling everyone he was getting it. Unfortunately he went down hill unexpectedly over the last few days and died early today.

I shall carry on rebuilding the car in his memory and if I decide it's appropriate I'll be looking to turn up in it at his funeral.

So I best get those lollipops on the wishbones double quick. I have the struts and hubs on now. And the brakes will go back easily enough. A little more apprehensive about the steering rack but I'm sure it will be fine.

I've no idea how the car runs or what other mechanical work will be required until I drive it. It arrived with me straight from the salvage yard. But it looks good and the engine sounds sweet. I do of course have a few bits of bodywork to resolve, front o/s wing, front bumper and bonnet but I have a plan there :)

The wheel arches got a good clean when the struts went back. I was going to clean up all the suspension metalwork and spray paint it but timescales meant I had to skip that. It looks authentically used instead :)

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Really sad news mate, I know how much you wanted to hand the keys over.

Try and enjoy the festive season
 
Agree with recent comments and would be a great tribute to a friend
 
So sorry your friend passed away before you could complete the work on the car Rob, very sad but always worse at this time of year. It would be fitting if you can get it done in time for the funeral, hope you do mate.

Tony.
 
Thanks chaps. And I appreciate all the help you've all been giving me.

Do read up and get yourselves checked if you see any of the signs of prostate cancer. Easy to cure if caught early. Spreads disastrously otherwise.

Kevin set up a charity to raise awareness and screen men. He saved several men's lives in the short space of time it was operational. So the Facebook page is a good place to start if you want to check it out.

https://m.facebook.com/LoganBerryTrust

Anyway, enough of the depressing stuff.

Here's Debra with everything back together but awaiting final torquing up, anti-roll bar & chassis brace installation, brake service and power steering reinstatement.

No idea what else lays ahead until I drive her. But obviously needs a bit of bodywork and wheels sorted.

I'm picking up a set of Style 18s with tyres for £100 after Christmas. Not my favourite wheel but I think will look okay. Couldn't find an original matching wheel but even less fond of those anyhow.

Nice to see her offside wheel back in the middle. Contrast with initial pics :)

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Such a great cause Rob! Sorry to hear your friend has passed but I'm sure it will be appropriate for you to show up at the funeral in it!! JIM
 
Now if you've looked at the video you'll see me and James discussing the fact that the offside front wheel appears to be closer to the wheel arch at the rear than the nearside front wheel does. There was no damage to the chassis so I see no reason to think that is responsible. I hope it just needs a blast to settle the suspension and/or it will even out when the 4-wheel alignment is done.

I checked the silver Z3 in the background - not accident damaged and it has the same affliction!
 
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