Bean Posted April 26, 2020 Report Share Posted April 26, 2020 I just love the colour pallet you went with Mike - looks amazing! Rabin Quote Link to comment Share on other sites More sharing options...
Mike T Posted April 26, 2020 Author Report Share Posted April 26, 2020 Thanks, it's worked out quite well. Truth is the interior is not done if you count the sliding glovebox tray and heater blower. But those are not difficult jobs. So I seem to recall Quote Link to comment Share on other sites More sharing options...
Mike T Posted May 4, 2020 Author Report Share Posted May 4, 2020 Mounted the glovebox on Saturday. REALLY hard to see under the dash...flat black. You can see the lock. Sunday I cleaned and sorted all my nuts and bolts into the proper sizes. Quote Link to comment Share on other sites More sharing options...
Mike T Posted May 8, 2020 Author Report Share Posted May 8, 2020 Saturday I'm going to rebuild the AEG/KF with a kit supplied by my buddy Peter van Deukeren from the Netherlands. The tiny bearings: The shaft seal: The kit: My two AEG PLF 5 pumps: And today, because I couldn't find the original clips for the dash pad, I made these out of 1mm thick spare rocker panel/sill material. They now have to be covered with a thin layer of black vinyl. They join the top of the soft dashboard pad with the soft A-pillar trims. Each one has been shaped by hand to fit each side very well. Quote Link to comment Share on other sites More sharing options...
PeugeotPilot Posted May 8, 2020 Report Share Posted May 8, 2020 It's actually quite inspiring to see this coming together, Mike. Your attention to detail is going to result in what is effectively a new car, and that's amazing. It also gives me the motivation to get to work on some of my own stuff. Quote Link to comment Share on other sites More sharing options...
Mike T Posted May 10, 2020 Author Report Share Posted May 10, 2020 Dashboard clips covered with vinyl. Passenger side: Driver's side. It was a pretty decent effort, I am pleased with the result. Quote Link to comment Share on other sites More sharing options...
Mike T Posted May 19, 2020 Author Report Share Posted May 19, 2020 Dismantling of the AEG/KF fuel lift pump. A little bit of electrical tape over the motor's drive pinion facilitated the armature's extraction from the pump body without in any way damaging the original grease seal, which is still supple. So I will leave it in place and use the same technique to re-insert the pinion through this seal. The freed armature. Making up some different sized slotted washers in the garage made short work of extracting the tiny drive pinion and nearly as tiny bearings. Armature mounted on a drill in a vise so I could polish the commutator/slip ring with fine emery cloth. Comparison between the armature of my car (4598609) on the right and that of a scrapped Canadian Cabriolet (6800519) on the left. 4598609 has done 83,000 miles. I bought the entire drivetrain from 6800519 in 1982, and at least the electric motor seems to show the traces of more like 200.000 miles... Quote Link to comment Share on other sites More sharing options...
Mike T Posted May 25, 2020 Author Report Share Posted May 25, 2020 Today I pressed the new bearings onto the motor shaft with a vise and then the pinion gear after it was inserted into and through the grease seal in the underside of the motor mounting plate. Checked the length of the original brushes: 6 mm and 9 mm....too short, so I looked in my spare parts stock and found two new or nearly new ones, both 12 mm long. Then the motor was tested and it was SO smooth! Next task: the hydraulic part of the pump, which sits below the electrical part. Quote Link to comment Share on other sites More sharing options...
Mike T Posted May 26, 2020 Author Report Share Posted May 26, 2020 Today I reassembled the hydraulic part of the AEG/KF PLF5A fuel lift pump. Bad surprise: despite the excellent condition of the electrical part of the original pump that equipped my car, the same could not be said of the hydraulic part. The idler pinion inside the pump chamber was seized to its shaft! The last time I ran the engine was about 2005 so the seizure occurred after that....I presume after I disassembled the car in 2016. Also, the lower plate that covers the pump chamber has a regulation valve that is supposed to be removed and checked during a rebuild like this and it too was seized! Anyway, all was not lost... ...because I have a spare lift pump from a car I used to own in 1981-1985 and its hydraulic portion was perfect. All it needed was a thorough cleaning. Cleaning nearly done and the last bits about to go back together.... And it's together. I did another dry run test with it all assembled and it sounded good. I should try a pump test, I suppose, though I have no reason to think it won't pump. Quote Link to comment Share on other sites More sharing options...
Bean Posted May 26, 2020 Report Share Posted May 26, 2020 Wow Mike - you really stock piled parts For this build! First reaction on reading the hydraulic part was in bad shape was feeling your pain, followed by “Well of course he had a good spare...” Well now played! Is the bad one salvageable for an parts or possible rebuild or is it too far gone? Rabin Quote Link to comment Share on other sites More sharing options...
Mike T Posted May 26, 2020 Author Report Share Posted May 26, 2020 After I had finished assembling the pump that will go on the car - and cleaning the fuel line banjo unions that are now on it - I had a closer look at the seized pinion. I got a brass punch and gave it some gentle taps and it began to move. Sprayed some WD-40 and it moved some more...then I was able to get it out. Cleaning the shaft and inside of the pinion made it work again when I reinserted it. It was not rust that caused it to seize. So I think it could be made to work. Although the driven shaft seemed a bit graunchy compared to the one I used, maybe graunchy isn't the right word, but at least less smooth. That too could be cleaned up with a full disassembly. The seized valve adjuster is a bit more of an issue. I suppose it could come out if I had the perfect screwdriver for it. I soaked it in WD40. The commutator is shot as seen in an earlier post in this thread but a kind soul in Hungary is sending me a spare new one he had made locally, for free no less! So perhaps one day I could put together a second well functioning pump with what's left. I also found another nearly new set of brushes inside the second motor.... Quote Link to comment Share on other sites More sharing options...
Mike T Posted May 29, 2020 Author Report Share Posted May 29, 2020 No actual work has been done on the 404C for a couple of days but today I ordered: a new old stock camshaft (specific to the KF2 Injection engine) from Loewendoctor in Germany; a set of 8 new lifters from Alvéas in France; a timing chain tensioner also from Alvéas. The cam was very expensive but I think a new old stock cam will be better than any regrind. A few weeks earlier I ordered new navy blue lap belts for the car, which should be here really soon. And a bit after that, some SEV Marchal spark plugs in NOS for the KF2 Injection engine is on its way from Italy. I hope that's the last of the new parts I will need to get the engine back in shape. I expect to get both in the next few weeks. Quote Link to comment Share on other sites More sharing options...
Mike T Posted June 1, 2020 Author Report Share Posted June 1, 2020 Quote Link to comment Share on other sites More sharing options...
Mike T Posted June 6, 2020 Author Report Share Posted June 6, 2020 I thought I'd treat the engine to a set of period spark plugs. This set came from Italy, S.E.V. Marchal 35HS. Quote Link to comment Share on other sites More sharing options...
Goce Posted June 7, 2020 Report Share Posted June 7, 2020 Mike, my experience with NOS spark plugs is they work better on 2 stroke mopeds and other stuff that has magnet ignition. New spark plugs are so much better and last much longer, i installed NOS spark plugs on the lada niva they wore from the early 90's never used, and failed with in 5000 km. I run LPG that has affect but the fuels now are like acid.You may want to save them for when you take it to a car show. Quote Link to comment Share on other sites More sharing options...
Mike T Posted June 7, 2020 Author Report Share Posted June 7, 2020 Yes, I have 8 NGK BP7ES on the way and I'll use those and save these for the historical value. Quote Link to comment Share on other sites More sharing options...
Mike T Posted June 7, 2020 Author Report Share Posted June 7, 2020 Painted the mirror body and mounted it today. Quote Link to comment Share on other sites More sharing options...
Mike T Posted June 14, 2020 Author Report Share Posted June 14, 2020 Second time doing the driver's door panel. The window winder was not happy staying in place and that was down to the padding under the vinyl being too thick next to the embellisher. I also had to remount the lower part of the vinyl in order to slightly recontour the lower edge to better fit. And finally, the screws under the armrest were mounted. I got new lifters and timing chain tensioner from Alveas in France, and two sets of NGK BP7ES from Rock Auto. Quote Link to comment Share on other sites More sharing options...
Mike T Posted June 17, 2020 Author Report Share Posted June 17, 2020 Zsolt Parragh in Hungary kindly sent me this tiny commutator for the AEG-KF fuel lift pump of the 404C - for free! Zsolt also has a 404C and his needed a new commutator, so he had a small batch made up. Very generous of him. Quote Link to comment Share on other sites More sharing options...
Mike T Posted June 23, 2020 Author Report Share Posted June 23, 2020 Couple of dark blue US-made seat belts for the front of the 404C. The car only came with two belts and soon it will have them again. Quote Link to comment Share on other sites More sharing options...
Mike T Posted July 2, 2020 Author Report Share Posted July 2, 2020 Seat belts mounted High temperature paint on the brake shoes - rear linings need to be changed Whipped the brush holder out of the the SEV-Motorola alternator - dirty inside Brush holder before cleaning clean slip rings Remounting. (the bolts holding the brush holder in are 1/8 inch, which is neither nor 5.5 mm. American parts! Quote Link to comment Share on other sites More sharing options...
Mike T Posted July 5, 2020 Author Report Share Posted July 5, 2020 Rear brakes mounted - handbrake connected and able to hold the car! A good step forward. Quote Link to comment Share on other sites More sharing options...
Mike T Posted July 12, 2020 Author Report Share Posted July 12, 2020 Front cylinders assembled: Autopsy on the old oil pump - trashed inside. The new one is perfect but of a slightly different form. I will have to use a later type oil strainer with it. Luckily I have one, but I would rather use a new one if I can find one. Quote Link to comment Share on other sites More sharing options...
Mike T Posted July 13, 2020 Author Report Share Posted July 13, 2020 Brakes mounted. It seems I may have lost or at least misplaced the brass connections between the front brake hoses and the forward brake cylinder. The hose can be screwed straight in but that's not correct. I'll find two of them somewhere. Quote Link to comment Share on other sites More sharing options...
Mike T Posted July 16, 2020 Author Report Share Posted July 16, 2020 Polished up the aluminium oil filter cylinder on a drill - worked quite OK! Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.