I have been doing some work on this, but also been very lazy at updating the thread…
25mm spacers for the front. Would be too much without the negative camber, but close to perfect with the neg.
Wheel hangs out with the camber set to neutral, but tucked in when set to something useful.
Bought the wrong bearing for the tailshaft centre bearing.
Several EBay listings said they are a 6007, and I happened to stumble over one in the local machinery supply shop…
But no.
Began converting to power steering. Scored a PS rack from Phil’s stash, but no matching intermediate shaft.
Petey gave me one from Bluemobile, but I had two lower universal joints and no upper ones, so it took a but of juggling to make it all fit.
Have been massively over-complicating the location of the PS pump and alternator.
I want to avoid having anything in the space where the alternator is on an early OHC Redblock. This is partly to make everything easier to access, partly to try to reduce the weight on the RHF corner, but mostly to keep the relatively fragile alternator and PS pump away from the heat of the turbo.
I strongly suspect that I am reinventing the wheel, but currently thinking that the alternator will be mounted up high on the later alternator/AC bracket, and then the later style PS pump will be mounted down low.
Side note on the steering racks.
Rough numbers, but the manual rack has 4.3 turns lock to lock, the older(?) PS rack is 3.5 turns, the newer(?) PS rack is 3.25.
These don’t allow for the travel of the racks, but considering the amount of lock a 240 has, it supports my theory that a PS 240 has fairly quick steering for a car of their age/type.
Began cutting out the rusty battery tray, and realised the inner guard was a lot rustier than I thought - what looked like a hole about the size of a 50c coin, was much larger.
So I cut the whole lot of crappy metal out.
Tried to make it a fairly regular shape to make the patch easier to make, but then wondered about maybe fitting the PS oil cooler over this hole.
Mounted the intercooler.
All a bit rough and ready but should do the job.
I will make the top brackets tidier when I get around to it…
Committed to fitting the Tilton “forward mount” pedal box. It’s ridiculous overkill for this project, but it came as part of a package deal and owes me nothing, so I’m happy enough to fit a $1000 pedal box to a $300 car.
Roughed out where it will fit, but had to stop until the dash is back in and the exact location of the steering column is known.
I have taken educated guesses on the sizes of the master cylinders.
I have gone with 3/4” for the brakes and 7/8” for the clutch. For the clutch, I calculated it off the standard pedal ratio and adjusted it for the 6.9:1 ratio of the Tilton.
For the brakes, Petey is running the same front calipers with 5/8” masters, so the maths says that 3/4” is good with the extra pedal ratio of the Tilton.
Time will tell if any of this is right!
Cleaned up the interior a bit this morning, ahead of test fitting the dash and to make the fire extinguisher mount.
Somehow that snowballed into taking all the tar off the floors and the firewall.
The sections under the front seats were the worst by far, with the rear floors and the transmission tunnel both being super easy.
Still need to do the boot, the rear parcel shelf and the part under the rear seat, but a bit over 10kg has been removed already.