1967 S3 FHC rebuild

[ill_will]

Some of you may have followed an engine rebuild thread I've posted to tracking progress getting a 1700cc motor built up over the last 2 (actually maybe closer to 4) years. (Here viewtopic.php?f=39&t=49709)

The chassis body and gearbox had been sitting in a garage an hours drive from me since 2009 but recently, having the engine more or less back together, I got it trailered and its now it's only five minutes cycle away. Hopefully I can make some progress now, and thought I'd start a thread to track it in case anyone is interested.

The rolling chassis was put together in around 2009 by me with a lot of enthusiasm but a tight budget and without much knowledge and/or skill and there were a few jobs that I knew needed doing. My records of the specifics are a mess having gone through several house moves since. The known unknowns:

- One of the trunnion threads was worn although bushes were new.
- One of the outer drive shafts was worn at the interface to the outer bearing,
- Quaife ATB unit needed fitting in the diff
- The front inner poly bushes were missing inner washers.
- Steering rack was a little notchy.

I started pulling off the bits but fairly quickly realised I might as well completely disassemble it, so now have just the chassis, with brake lines and handbrake cable left in, and the bare body attached to it. The dash is still there but resting loosely as is the heater ducting.

[ill_will]

Predictably stripping it down has revealed a ton of other jobs which need doing.

The rack was not good - the pinion had some bad pitting as did one of the inner track rods.

I got a better donor Triumph Herald steering rack and had Kiley Clinton rebuild it. They have the roll dies available to shorten and thread the track rod inners without using a cutting die (there is not enough material to cut as the nominal diameter of the rods is smaller than the major thread diameter.) It was expensive but the service was good and the rack feels like new.

Stripping down the front uprights (vertical links) showed that one was fine but the other one was a bit worn at the top. I managed to source a couple of Stanparts replacement so have replaced them both. One of the (new, non Stanpart) trunnions I had was a bit tight on the new upright but TTR have Stanparts ones and that was a good fit.

Over the past few years I've collected a few other parts, and have some tubular wishbones for the front too, and TTR stub axles. The tyres will be wider and stickier than the original design so this seems prudent.

[alanr]

Be aware that genuine Stanparts that were made in the UK no longer exist.
Lots of parts with Stanpart inscribed on them are now actually made in either India or the Far East.

Alan.