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May 20, 2018 16:38:20 GMT
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Here's half the bearing holder and a blank other half. No idea why these photo's won't upload the right way around! Both sides done. The four holes in each half are there so the bearing can be punched back out the holder should needs be.. Time to fit the bearing... Almost.. As the holder will have to be taken on and off MadTrax many many times, and a bit of drilling and grinding going on, rather than fit the bearing and risk it getting full of nasty stuff I made.... This fake bearing With a little bit of trimming to the inside half of the bearing holder a test fit was in order.. It's rather tight on one of the engine mounts, but it fit's Looks like the sprockets can be made to line up Now the big one... Will the shaft from the transfer box to the front fit without hitting anything and how tight will the UJ angles be? It fit's and the UJ angles are well under 33'degrees, if I remember right the rear UJ angle is about 12'D and the front is a tad over 20.. Much better than it used to be It's tight but there is plenty of clearance The bearing holder was drilled and a tapped so the two bit's could be bolted together.. A clean up on the lather later and the bearing was pressed in.. I couldn't of been happier with the fit of the bearing Fitted.. Just out of view behind the holder is a couple of tack welds just to hold the holder in the right place.. and yes the spocket is free to move at the moment as I don't know quite how far up/down the shaft it needs to go. Now onto another the fun part.. Getting the 90'd drive in the right place.. Which is where the bit of angle that is bolted to the drive will come in handy. If you look behind the air filter you can just see 3 more bit's bolted to the drive case.. They go up and get clamped to a couple of bit's of box.. This will hold things steady and give me enough adjustment to adjust it's postition. But before I square the drive up I need to make the last bit of the drive puzzle and fit a sprocket and bearing to the hollow shaft that's coming out of the drive.. The splined section will be welded on, then the whole thing can be turned down a little on the lathe to fit a sprocket and a pillow bearing. And that is this thread up to date again. I hope you all enjoying my ramblings
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My YouTube Channel www.youtube.com/user/UkWheelHorseBlokeQuote - D'you know, it's people like you, doing totally brilliant and pointless stuff like this that gives me a little hope for humanity
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May 20, 2018 20:46:30 GMT
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Very much so...
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Sept 22, 2018 11:00:40 GMT
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Very much so... Thanks George :-) Well, long time no update. Sorry about that. It's been a very very busy summer that has not really given me any spare time to do anything including forums and even YouTube! So what has been happening at the workshop has been happening at a slow pace, I have been taking photo's and videoing the action, up until a week or so ago I've not had any time to do anything with the footage! Sooooo... starting where we left off, the shaft that goes on to the side of the transfer box.. Here it is after welding on the splined part, turning the welds down, and a turned down bit to fit a bearing. But how to hold it in the right place for making bearing mountings as we all know splines always have a bit of play in them? This will do the job Slide over the shaft.. Once it is tack welded to the flat plate behind it will hold the shaft steady and put it in the right place to make a mount for the bearing that goes on the end... I hope that makes sense? Now another fun bit.. A long long time was spent getting the 90 degree drive in exactly the right place.. No mean feat considering it had to be right in so many planes! To make sure it stayed put, the tempoary mountings (bit of angle) were temporarily tacked in place.. In the last above photo you can see the square bit of plate bolted to the end of the 90 degree drive thingy... Well, it didn't stay square for long.. Ok, it's not perfectly round, but that's not a problem as you will see. But what to fit it in?? A bit of this 5 1/2 diameter pipe will do Yes I know it doesn't look that safe, but due to the weight of it, it wasn't going anywhere.. A 2 inch length of pipe with both sides faced off on the lathe. The lip I turned on the round plate makes it a perfect fit in the bit of pipe. Plonked on to have a look.. A lot of welding later including 3 long runs inside and I don't think the plate and pipe will be parting company anytime soon
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My YouTube Channel www.youtube.com/user/UkWheelHorseBlokeQuote - D'you know, it's people like you, doing totally brilliant and pointless stuff like this that gives me a little hope for humanity
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Sept 22, 2018 11:18:36 GMT
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As much as I would of liked to weld the big pipe into the frame to make it all very strong, I wouldn't of been able to get the transfer box out if I did! So I have made up some curved mounts which you will see a bit later.. But while I was at it I thought it maight be an idea to bolt a few bits in place to check everything still fitted.. With a bit of trimming and a lot of strengthening the bearing block can be made to fit flush on to the n/s foot rest which keeps things neat and tidy, but the footrest will need a lot of extra strength added. I did at one point think I would have to widen the foot rests as the chain, sprocket and bearing would take up so much space.. But with the bearing mounted flush the chain and sprocket hardly poke through at all, also the 90 degree mount only takes an inch or so foot space away from a bit of the footrest that doen't feel a natural place to put your foot anyway.. So no widening needed, just a bit of extra mesh to go over the chain.. Oh, I do have some much better looking mesh to replace the rather tatty looking mesh thats fitted already. A view of the back.. The chain needs to lose a link and a half and there is plenty of space to put a chain tensioner. Good news with the o/s footrest as well.. The drive shaft that goes to the front now takes up so little space (much closer to the engine etc) that all I need to do is put a cover over it so it doesn't try and grab my boot laces as it spins.. Plenty of space to mount the brake pedal as well Back around the other side.. Having got the 90 degree drive thing in the right place, it needed to be mounted strongly. The curved brackets were made by welding one end of a thick length of flat steel to the large bit of thick wall pipe and beating it around with a large hammer while it was still hot from welding.. I thought I had some photo's of that stage but I can't find them! As you can see it's all only tacked in place at the mo, it will only get fully welded once I know the transfer box etc can actually be removed from the frame! In theory they should, but you never 100% know for sure until you try.. A thrid mount will be going down to the frame but I couldn't work out exactlly where until I had made and mounted a strengthening plate that runs between the frame rails.. Of course I did not have a large enough thick enough bit of steel plate, so I had to make one.. Missing a few photo's here but I had to slice up a Wh 312-8 fuel tank/fender pan mount for the steel.. Clamped down ready for welding. Leaving a big enough gap to fill with weld. Weld won't stick to brass so a brass plate was clamped to the underside.. The black bit is ally which works as well, it just burns away a lot faster.. Welded, shaped and roughly put in place. To mount the plate I knocked up four of these captive nut brackets. In order to center punch the flat plate in the right place for dilling I drilled a hole though a spare bolt that was only just big enough to get my punch in.. It makes sure the punch mark is in the center of the capive nuts. Brackets tacked on. Lot's of chopping and welding later the plate now has some strengthening holes including one just below the odd shaped tube and bit of box 90 degree drive mount so a ratchet can be used to bolt it on.. A pic from the other side with the third tube mount tacked in place. I think now's a good time to drop in a video, anyone for part 23? :-)
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My YouTube Channel www.youtube.com/user/UkWheelHorseBlokeQuote - D'you know, it's people like you, doing totally brilliant and pointless stuff like this that gives me a little hope for humanity
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Sept 22, 2018 11:38:42 GMT
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With the above done the time had come to mount the bearing that holds the shaft out of the transfer box up. Here it is roughly in place, the foot rest thingy still needs a little trimming at this point. Quite a while back I made this collar/sleave/thingy to hold a shaft in the right place.. Now was the time to tack weld it on. The old steel mesh was removed from the foot rest (I have some new mesh which matches the exhaust guard) and a nice strong bearing mounting plate welded on. Oh, the top tube has also been sliced off and welded back on with a nice strong steel bar inside for extra strength. A view from the back, I need to get a half link to shorten the chain and make a tensioner thingy. One thing I was worried about was how much the chain would stick through the footrest... As you can see it doesn't stick though at all.. Me happy with that Jumpimg back to the O/S the rear brake pedal mount has been made. Quite a hard thing to photo if you don't have a clear different colour background! I have fitted the Quadzilla brake pedal, the mount was originally a flat plate that was bolted to all sorts of places to give it strength. As I couldn't do that I had to box it in. Here's the other side. Brake cylinder bolted on. The whole footrest/brake pedal mount thingy bolted back on. The rubber hose to the reservoir will sit just under the steel mesh when it's put back on. The pedal looks like it's lying almost flat, but it's in the right place if you pivot your foot on the end of the footrest which is where your feet naturally fall I will make a shield that uses the cylinder bolts to add so side protection to the cylinder.. Starting to look a bit busy with the exhaust and driveshaft plonked in place, the propshaft guard will take up a bit more space as well.
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My YouTube Channel www.youtube.com/user/UkWheelHorseBlokeQuote - D'you know, it's people like you, doing totally brilliant and pointless stuff like this that gives me a little hope for humanity
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Sept 22, 2018 23:17:47 GMT
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Yay, it's back! "...plenty of space..." is not something I expected to read in this thread - twice! As ever, it's great to see the thought process and skill going into this.
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Sept 23, 2018 10:05:37 GMT
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Yay, it's back! "...plenty of space..." is not something I expected to read in this thread - twice! As ever, it's great to see the thought process and skill going into this. "Plenty of space" could mean as little or as much as 1/4 inch with this build.. Right, let's get some more updating done.. Time was still lacking at this point but I did make a good start on the transfer box to from diff drive/prop shafts. I didn't take many photo's and even less video footage as I just wanted to get bit's done while I had the time. Holding a small shaft in place to measure up and work things out was a right pain until I quickly made this "bit of tube welded to box" which held the shaft in the right place. The shaft to the front had been extended and made a slightly bigger diameter to fit the new UJ.. Not welded up in this picjust in case any adjustment was needed. Here's one of the bearing brackets I made up.. Think it's going to need a lot of trimming now everything is a lot closer to the engine.. The original mounts were trimmed back until only the plates with captive nuts were left. Here they are bolted to the back of the bearings, ready to be tacked onto the frame. The random bit of angle is there to keep the tops in line. And without the bearings, just tacked on. A bit hard to see in the next two photo's, the bearing mounts now have extra strength with gussets added.. As ever not fully welded in these pic's. The front er... prop/drive/transfer shaft thingy has been welded up, I will be adding some extra rows of weld "just in case" and to tidy the shaft up a bit. The other end is fitted in place with a tight fitting roll pin. Oh, if your wondering the shaft does look like it's running true :-) One last thing to do before the drive system is finished... Attach all the sprockets to the shafts.. Starting with the first and second in line there was a bit of lining up work to do.. Here's No 1. A close up and you can see the chain wants to bend to the right or forwards if you will. A bit of extra space between the chain and bearing holder would also be nice.. At the other end of that chain things were also a bit tight between the chain and bearing.. To solve the problem this part came back out for a bit of turning so the sprocket could be moved away from the bearing. Before welding the sprocket onto the shaft (no space for a roll pin) Rob started toasting all of it.. As both the sprocket and shaft thingy were very cold, both were heated up so the cold metal wouldn't just suck the heat out of the weld. The 90 degree drive thingy out.. A big moment as it means everything will come out of the frame.. Phew lol While the drive system was out I was able to do a bit of extra welding inside the frame, as some bit's were only tacked together at this point..
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My YouTube Channel www.youtube.com/user/UkWheelHorseBlokeQuote - D'you know, it's people like you, doing totally brilliant and pointless stuff like this that gives me a little hope for humanity
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Sept 23, 2018 10:27:16 GMT
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For some reason I forgot to take load of pic's of the next stages, so the photo's might seem a bit random.. This bearing holder needed a few mounts.. Two mounts this side.. Making the mounts for this inside was more interesting, I also had to make lower mounts for the big blue bearing.. No photo's of this done but you will see it in the next video. Chain half kinks and a sprocket turned up, this is part of the chain tensioner, so the sprocket was bored out to take a bearing each side. The transfer box idiot light switches were removed as the exhaust would melt them also they are not really needed.. A couple of ally blanking plates blocked the holes back up. The finished chain tensioner thingy.. Right, that's enough of that.. Best explain things better in a video.. Followed by... Soooo did Madtrax drive??? Well your have to wait to find out as I've not edited the video yet :-D
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My YouTube Channel www.youtube.com/user/UkWheelHorseBlokeQuote - D'you know, it's people like you, doing totally brilliant and pointless stuff like this that gives me a little hope for humanity
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Sept 24, 2018 7:06:44 GMT
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My YouTube Channel www.youtube.com/user/UkWheelHorseBlokeQuote - D'you know, it's people like you, doing totally brilliant and pointless stuff like this that gives me a little hope for humanity
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Sept 24, 2018 7:27:18 GMT
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Dear Sir,
Dear God!
Please just fix any niggles (not that there'll be any) and pop it in a box addressed to:-
George,
Casa Santa Ana,
Manila.
Philippines.
Yours sincerely,
George.
No idea what I'll tell customs, but I'll bloody well think of something.
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spiny
Club Retro Rides Member
Wiki Admin
I am abivalent towards car electrics ...
Posts: 1,330
Club RR Member Number: 167
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Sept 24, 2018 20:53:18 GMT
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marvelous stuff
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Sept 26, 2018 20:23:12 GMT
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Just read the whole thread start to finish - brilliant!
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Sept 27, 2018 15:42:22 GMT
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no other word, astounded! love my yamaha raptor 700 injected quad for fun, but this looks ace!! but how much does it weigh?
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Last Edit: Sept 27, 2018 15:44:01 GMT by rwdrules
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Dear Sir, Dear God! Please just fix any niggles (not that there'll be any) and pop it in a box addressed to:- George, Casa Santa Ana, Manila. Philippines. Yours sincerely, George. No idea what I'll tell customs, but I'll bloody well think of something. Hi George, I did try taking it to the post office, but for some strange reason they didn't have enough stamps to cover the postage! Thanks for the video plug on your ever excellent Letter from Manila thread by the way. marvelous stuff Thanks Spiny Just read the whole thread start to finish - brilliant! Wow, you must of got through quite a lot of coffee's reading from start to finish, I guess you had a few days to spare no other word, astounded! love my yamaha raptor 700 injected quad for fun, but this looks ace!! but how much does it weigh? Astounded!! That's a new one.. Most people say "What the flock is that?" I guess it weighs quite a bit, though not realy sure on how much. The bare frame is quite light which is handy as I'm busy doing the final welding and the frame get's turned over quite a bit.. With the test drive done, MadTrax needed to go back up on the bench for final welding.. Pictures of the stripdown would be boring, so have a fun video instead The stripdown should of taken a day at the most, but when everything is being video'd using my Camera Panning Jig Thingy, one day gets stretched to five! With the frame stripped down I could make a start on the final welding.. Well, almost.. The last couple of bit's of "made out of a cheap office desk" Quadzilla frame were bugging me.. The only problem was important bits such as front suspension lower mounts and front diff mounts are made out of one big plate that's welded to the Quadzilla frame.. And it's kinda important to make sure these mounts stay in the same place. So after a lot of bracing including something to hold the said plate in the right place, the lower front got the chop! Would you look at the rust in that! At some point during the build the bit of tube that these two bit's of desk are attached to was welded in not quite where it should of been.. In other words it looked pished but wasn't noticable until everything had been stripped from the frame! Cleaning the suspension plate of the left over bit's of rusty desk took a while, here's the plate bolted back on where it should be.. A bit of space to fill to connect everything back up again.. Lot's of welding has been happening, I've just not taken any photo's of it as I've just been getting on with it, but I should take some as the frame looks better, and the front bit looks even better with some tubes welded in
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My YouTube Channel www.youtube.com/user/UkWheelHorseBlokeQuote - D'you know, it's people like you, doing totally brilliant and pointless stuff like this that gives me a little hope for humanity
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Jan 30, 2019 16:25:50 GMT
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Afternoon all, well it's been a long time since my last update, and quite a bit has happened.. Life on MadTrax has been grind, weld, grind, weld, chop some metal off, weld new stuff in, grind, weld..... you get the idea. The frame has spent most of it's time on one side or the other and even upside down at times! I think in this photo I was adding strentghening to one of the transfer box mounts on the frame. A lot of my "earlier" welds on the frame were done before my Murex Mig welder had an overhaul and a new gun... And it showed on the welds! So a lot of time has been spent grinding out bad welds and replacing them with good welds like this. The pressed steel rear suspension uprights had the outside boxed in a long time ago, the inside has been done now.. Cleaned up with a touch of red oxide. You may remember this orrible bit of Quadzilla frame that was at the front. Well, it has been cut out and replaced with some nice tube to match the rest of the frame.. Looks way better. A couple more views.. The engine guard has come in very handy when the frame is the right way up, it keeps the frame upright and makes it very easy to turn around on the bench.. On the next build I will try and fully weld up everything as I go along... I've had to do so much "finishing" welding and grinding it's quite soul destroying! I guess this is the right spot to drop in this video.. Don't worry, I'm much more cheerful in the next vid
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My YouTube Channel www.youtube.com/user/UkWheelHorseBlokeQuote - D'you know, it's people like you, doing totally brilliant and pointless stuff like this that gives me a little hope for humanity
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Jan 30, 2019 16:33:40 GMT
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With all welding finally done (have I said that before?) the frame now looks like this with a coat of red oxide in the right places.. Yes the bit I missed at the front has been done. You may notice a few bit's of metal bolted to the frame.. The bit's of metal happen to be foot rests and anything that sticks through them or near them.. This is the N/S.. Now skinned with some strong steel mesh and given a squirt of the red stuff. The O/S foot rest thingy taking shape, it also has to hold a a small guard so your legs can't get pulled in by the rotating driveshaft.. Never fun! That should do the trick. A few parts have been cleaned up and given a coat of the red stuff. This plate which bolts in the base of the frame to add some extra strength and protection has a lip welded on each end just to make sure it's strong enough for the job. A couple of captive nuts welded in the top tube of the frame.. Yes I did re-weld the top nut once this photo was taken. The captive nuts are for bolting this bracket on which also bolts to the top of the engine and is quite handy for holding up the coils
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My YouTube Channel www.youtube.com/user/UkWheelHorseBlokeQuote - D'you know, it's people like you, doing totally brilliant and pointless stuff like this that gives me a little hope for humanity
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Jan 30, 2019 16:39:28 GMT
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The time had come to sort out the only bit of bodywork on MadTrax, the fuel tank.. At some point I welded on an extension to the back of the tank so it filled a gap left below the seat.. Of course this all now needed to be tidied up, so que the body body filler! Looking a bit rough here still.. Lots of fillering and sanding later I gave it a squirt of white primer as it's all I had that wasn't red oxide primer! A careful rub down with 800 grade wet 'n' dry later the tank was then hit with 3 heavy red oxide coats... Once the paint had fully hardened it was them flattened back with 1500 grade wet 'n' dry to get it ready for the top coats. Carefully plonked on the frame along with the seat to have a look... Me likes As it turned out the frame was the only "out of the way, nothing can get dropped on it" place I had to store the tank, so a sheet was put over to keep the dust at bay.. Yes I need to adjust the filler cap.
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My YouTube Channel www.youtube.com/user/UkWheelHorseBlokeQuote - D'you know, it's people like you, doing totally brilliant and pointless stuff like this that gives me a little hope for humanity
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Jan 30, 2019 16:44:41 GMT
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With the tank and frame stored out the way I had some space on the bench to fill up with parts that need cleaning and painting. A wire brush on a drill came in handy for cleaning off all the years of crud. It leaves a slightly bright but rough finish which should dull down with age. The transfer box. Front end. Rear end complete with mounting brackets A front suspension strut in need of a de-fur and clean up. A fury front hub.. And a cleaned up rear hub More wire brushing and painting.. At least the calipers clean up really well
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My YouTube Channel www.youtube.com/user/UkWheelHorseBlokeQuote - D'you know, it's people like you, doing totally brilliant and pointless stuff like this that gives me a little hope for humanity
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Jan 30, 2019 17:11:09 GMT
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A pile of cleaned and primered parts stashed under the bench waiting for a top coat.. The rest of the suspension components were buried under a bench behind the engine, so of course the engine had to come out.. Might as well plonk it on the bench and have a look.. After cleaning the engine didn't look too bad, only a small bit of paint has come off.. Unsure it needs repainting at this point.. Will have to think on it. I also made a start sorting the radiator out. As you can see a lot of fins need straightening out.. it's one of those jobs that gets done a bit at a time sitting at my desk with the heater blowing at me The exhaust system has been cleaned up and any pin holes found (each section was pressurised to find any leaks) and welded up.. Just for a laugh I thought I'd bolt the exhaust on to the engine to have a look... It looks rather mad For a few days there wasn't anything I could do on MadTrax until the paint I had ordered turned up, so..... I had a bit of a tidy and clean up in the lathe corner of the workshop. The white doored paint cupboard came out from the corner behind the lathe and now lives in a place I can actually reach it The "lathe shelf" now looks a lot neater and emptier.. As most of the smaller tools now live in this labeled cabinet.. And to finish off the lathe got a much overdue clean up.. Finally last weekend my long awaited paint turned up, so Monday was paint the frame and engine day Which made yesterday "get the engine, transfer box and rear end in" day.. A bit thank you to Rob for all your help with this.. Ta muchly mate..
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My YouTube Channel www.youtube.com/user/UkWheelHorseBlokeQuote - D'you know, it's people like you, doing totally brilliant and pointless stuff like this that gives me a little hope for humanity
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Jan 30, 2019 21:04:04 GMT
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This is great. How have I missed this?
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