MK7
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| posted on 15/6/03 at 10:42 PM |
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Is it me?
Hi,
I picked up my chassis yesterday (Saturday). The kit was missing the rivnut tool (and rivnuts) and I had to ask for the ball joints that I'd
ordered.
When I got the kit home and started to sort out the various bits and pieces, in particular the fitting of the polybushes, I came across a problem.
I'd ordered the chassis to be powder coated and very nice it is too. The wishbones and rear uprights also come coated. Unfortunately, the tubes
(sorry for lack of technical terminology) into which the polybushes fit are all (100% of cases) blocked to some degree with metal from when the tubes
were cut.
It's not a problem to remove this excess metal with a round file but I then end up with more bare metal than I would have liked, metal that
needs to be treated to minimise rust.
Have others experienced this or is it just me?
Are my expectations a bit higher than they ought to be? I'd have thought it would have been reasonable for MK to clear out these tubes before
powder coating, I'm sure that anyone cutting their own tubes would have cleaned them up before committing to powder coating.
I've tried fitting the polybushes into the tubes by way of a vice and plenty of soapy water but I'm getting nowhere. I've been
reluctant to file the insides of the tube so far but unless I get some better advice then that's tomorrow's task.
My aim here is not to criticise but to understand 
Thanks
Russell
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skippad
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| posted on 15/6/03 at 11:04 PM |
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is it me?
On my wishbones there was just a fine weld line on inside of tube, if yours is the same, the easiest way is to file a small trough in the
poly bushes rather than file metal (i used a dremmel mini grinder) then pressed bushes in with a vice & bit of grease. I hope this
helps.
p.s. my mk is up for test wed 18th 8.00am! Gulp!!!
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MK7
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| posted on 16/6/03 at 07:38 AM |
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Good luck with the SVA on Wednesday.
I took a look at the polybush website
http://www.polybush.co.uk/index.htm
which strongly recommends not taking any material off the bushes.
In my case the inside welds seem OK, but the inside diameter is reduced because the cut ends of the tubes are partially filled , see my photo archive.
It's not a big deal but it does somewhat negate the value of the power coating.
Good luck
Russell
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SteveO
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| posted on 16/6/03 at 11:20 AM |
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Hi Russel,
We met when u picked up your kit. I think we all had the metal bits in the tube. I took a tip from a build diary whee i put the bushes in the fridge
and took them out as needed. Had no problems fitting mine using a bench-vice.
Copper grease for the steel insert..smooth as Jack Dee..JB
Steve
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MK7
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| posted on 16/6/03 at 11:30 AM |
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Hi Steve,
I never thought of putting them in the fridge, I'll give it a go.
I've been using my black and decker work bench to push them in but without success. I've removed the excess metal so let's see how
the fridge trick works...
Russell
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MK7
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| posted on 16/6/03 at 11:42 AM |
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I'm amazed...
The fridge trick worked a treat. Thanks Steve
Russell
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SteveO
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| posted on 16/6/03 at 01:21 PM |
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Good stuff,
happy building matey
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Alan B
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| posted on 16/6/03 at 02:14 PM |
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Hi Guys, I agree that the burrs really should not be there ever, but even more so prior to powder coating......
However, I recommend getting a proper de-burring tool...much easier than dicking around with a round file...you just stick in in your tube end or
hole, a quick spin around and voila......beautiful burr free hole.
They are not expensive, the blades last a long time and are cheap....Noga is a good make.
[Edited on 16/6/03 by Alan B]
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James
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| posted on 17/6/03 at 03:01 PM |
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You guys are a bunch o' soft southern shandy drinkin' jessies!
Vices, workmates, fridges- pah! 
Put one bush in each end of the tube, cup it in your hand and squeeze together- voila!
Hope that helps,
James
P.S. If you can't manage that then put one bush on the edge of you table, sit the bush tube over it. Put other bush sitting on tube and crush
tube balanced on that.
Apply club hammer and smack 'em together in one- job done! 
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Ben 4x4 Shepperd
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| posted on 17/6/03 at 03:26 PM |
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Have to agree poly brushes were a bit tight but a qiuck bit of gentle persuasion with a wooden mallet (or club hammer wrapped in bubble wrap) worked
fine!!!
BTW Finished my GCSEs today 
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ned
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| posted on 17/6/03 at 04:17 PM |
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congrats ben on finishing the exams etc.
best of luck come august (21st?)
Ned.
beware, I've got yellow skin
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MK7
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| posted on 17/6/03 at 06:01 PM |
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Thought I'd best respond to this seeing as I got it started and particularly seeing as the southeners are having a go :-)
The burrs weren't a problem except that I've now got bare metal where there ought to be powder coating.
The bushes were a definite problem.
It took a great deal of vice to get one side in then I used an M12 bolt to pull the other in. It was a very, very tight fit. Having no previous
experience of dealing with such a stubborn bush :-) I just have to assume this is the norm. It seems like there's quite a bit of variation in
the spec.
As an aside, the other point that I found after fitting the bushes was the the mounting brackets on the Indy chassis needed a bit of adjustment (Large
rubber mallet) to fine tune both the width of the brackets and the spacing between the brackets.
Is it me?
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GJ Warren
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| posted on 17/6/03 at 07:16 PM |
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nice bush pun !!!!!
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