Well, I enjoyed that :) It was so hot I'm bringing a sun hat next time to protect my shiny pink hair and I think Orangebean did actually have a touch of sun stroke (I was watching you quite carefully at one point!) It was pretty tiring working in that heat but lessons were learned and we did reach a decent standard once we'd worked it out. I'm probably going to have nightmares about those grab handle recesses :(

Hopefully you've all eaten something since lunchtime so it's too late to blame me for any food poisoning and everyone seems to have got home safely!

I'm really chuffed with my new headlining and it has passed inspection from Mrs Morat whose only comment was "Who had the dirty fingers?" oops. I guess the cleaning kit needs to come out. Never mind, eh :)

I'm not going to tempt fate, but the Duchess has been parked outside since about 2100 (there was a crash on the M42) and she hasn't complained. That's all I'm saying. Thanks Marty! and thanks for organising the headlining kits. They really are top notch.

I hope Sloth got his suspension working properly, I felt bad leaving when it started looking fixed but the barby was packed away so I was no longer useful. Thanks everyone for bringing food and buns, and I think we can safely say that Waitrose mineral water tastes exactly the same as any other but their instant light barbeque coal is streets ahead of Tesco.

Best of luck to everyone :)

What was the final verdict on headlining colour?

You fellas go with Oatmeal to replace the original?

Good to see you all again and nice to meet you Smiler!

My EAS did indeed resume behaving itself - probably good timing that it decided to throw a tantrum then rather than half way home. Thank you to Marty for loaning me the valve block and driver pack! Note to self.. before deeming the shock as not compressing entirely, make sure you've pulled the airline to the correct airbag first... whoops.

And thank you to the chef that is Morat! Top work.

Well, I think we lucked out on the weather again - it's been horrible here today - but at least I haven't had a lot to do outside! though I still have to take the sunroof shade out and recover that..

Thanks to Miles for not only cooking food for us, but also supplying most of it! I hope the Duchess is sleeping soundly at night now (and letting you sleep soundly too!)

Also thanks to Smiler for looking at my tracking and getting that sorted out... I needed to tweak the steering box - wheel bar a bit to re-centre the steering wheel, as when I actually got to take it for a proper spin, it was a bit out again - but managed to get that done before the MOT... at least knowing the steering box - wheel is centered, I was able to do that bit by eye. You managed to do the hard bit, getting the toe all sorted with the tracking bars which is the bit I was only able to guess when I replaced the bar a year or two ago. Sorry it was such a pain to do!

My biggest thanks though have to go to Sloth... You're a true gentleman, mate, and total nutcase... After everyone else had buggered off to peace and normality at home, he stayed back (even after his fun and games with EAS) to give me a hand to re-fit my head lining card that we had covered that morning, and then stupidly to give me a hand to swap my ABS modulator, which I had been planning to do the year before, though had since pulled apart, cleaned, and assembled with new O-rings... and ideally wanted to get done before the MOT on Monday morning, so it was checked off my list and hopefully have decent braking for good.

That task started off well, after a bit of deliberating as to the best way to get the bloody thing out, around the coolant tank, myraid of brake pipes, and all the LPG cabling that runs past the modulator block.

We were doing pretty well until we got to the brake bleeding part - which although it went pretty smoothly just took ages, since the whole modulator was previously empty or fluid and full of air! we got it all done by midnight and took it out for a test drive to see how it felt... got out on the road and 'BEEP BEEP BEEP..... ABS FAULT... TRACTION FAILURE' Shit

Nanocom reported no connection on the RHF inlet solenoid - which was very quickly followed by the air turning blue on my part, and the dread of having to pull the whole modulator block again and swap it back, because the one I'd spent so much time reconditioning was obviously faulty....

A multimeter confirmed that there was no connection, on either the inlet or outlet solenoids (according to RAVE pinout) which resulted in another round of cursing. Before deciding to get violent and rip it all apart again I managed to slide my phone down the side of the modulator and get a picture of the electrical connector... to find this:

Which was kind of bittersweet to find... good in the feeling that we hopefully didn't need to pull it all out again as it wasn't likely to be a problem in the block - but bad in the fact that if we didn't drain it, remove it, etc to straighten the pins out of the vehicle, then we were faced with a stupidly tight squeeze to get in and work, and lack of being able to see a bloody thing. And if we snapped a pin, then we would STILL have to take it all back out again.

We decided to do a trip back to my place to grab the USB endoscope camera, and some smaller tools to be able to get in there and hopefully straighten the pins.. Followed by a stop at the 24hr McDonalds on the way back, as we hadn't eaten since Morat's meaty morsels in the afternoon.

Back to the workshop by about 3am, and surgery began. With Sloth draped across the top of the engine to hold the camera and tools, and me cursing at being scratched by what seemed like everything down the side of the engine, trying to get a hand in there we started, and luckily managed to get both pins straightened out somewhat... after gingerly connecting the plug part way to see if it would go on without bending the pins again, removing it and checking everything with the camera, we figured it was all good, so fitted the connector for good, crossed our fingers and turned the key to see if the fault was gone... other than the standard beeps, and messages the dash was clear, and Nanocom reported all the faults clear, and all the solenoids as working... Hooray!

A quick whip around to pack up all the tools, some of the rubbish etc, we were gone...

My view as I was leaving...

I got back about 4:30am, went straight to bed and was then up at 9am to empty all the crap out of the RR and take it for the MOT...
Luckily, it passed with flying colours... 1 advisory for O/S/R hub seal leaking a bit... which I will get under an check - but we also swapped the tyres whilst they were off and we were bleeding the brakes, and the RHF (which went to RHR) had a bit of a brake fluid mark down it - which looks very similar to an oil stain on the tyre from the hub seal... so whilst I'll investigate, I wonder if that's what they've seen and figured it was the hub seal and not some residual fluid from where we had drips whilst removing the old modulator. Even if it is a hub seal, the rears are easy to change.

So again, thanks to all who came along - and an extra, massive thanks to Sloth for staying behind and helping me out - I literally couldn't have done it without you, and you kept me sane when i was about ready to throw things!! I owe you 2 now... one for this, and one for the all nighter on the engine swap!

The good news.... the brakes feel amazing.. .I just hope they stay like that, and not lose their feel like they used to with the old modulator - because if they do the same, then I'm back at square one!

Marty

what a night(mare). All's well that ends well though.

Reading the bit about your steering wheel, what's the job behind that? Mine points between 10 and 11 o'clock. could do with centring it.

Holy crap - no wonder you've been quiet!
Really glad you got sorted out. I felt rubbish leaving you hanging but my pink ticket had expired :(
And you didn't really want me watching and making dumb comments until 4am did you?

Thanks for showing me how to fit and adjust a P38 sunroof and thanks for fettling the Duchess. She's been sleeping soundly ever since :) Great result.

I think the heat took quite a bit out of people this year. I've still got a sore neck from being out in the sun trimming round headlinings and I never usually burn in the UK - even when I venture south! Anyway, that San Miguel in the pub afterwards was freezing and bloody marvellous - and I don't normally drink lager.

Cheers all!

Steering wheel - it should be centered (flat) when the steering box is centered (the marker between the indicator bumps on the steering box). your front wheels should then have the tracking set with (from memory as to what Smiler told me) 5-15 minutes of toe-out. (0.6-1.8mm).

Once that is set and the steering box is known to be aligned with the steering wheel, you can then adjust the drag link from the box to the LH hub to make sure the steering box is centralised with the (now aligned) front wheels.

If the steering box isn't centered when the wheels are aligned, then you'll probably end up with it constantly drifitng, or having to apply more than normal steering correction when driving.

You shouldn't just take the steering wheel off and re-align it to center, as it a)won't have had any effect on the alignment, and b) can damage the rotary coupler, as that then won't be centered when the steering wheel is. RAVE specifies that the steering wheel can only be adjusted 1-2 splines MAX - if it's further out than that to the center of steering box etc, then you need to undo the lower steering rod and align THAT to the steering box by centering the steering box, and steering wheel and reconnecting it.

car drives straight as a nut. Just the wheel that's on the piss.

Morat wrote:

Holy crap - no wonder you've been quiet!
Really glad you got sorted out. I felt rubbish leaving you hanging but my pink ticket had expired :(
And you didn't really want me watching and making dumb comments until 4am did you?

Thanks for showing me how to fit and adjust a P38 sunroof and thanks for fettling the Duchess. She's been sleeping soundly ever since :) Great result.

I think the heat took quite a bit out of people this year. I've still got a sore neck from being out in the sun trimming round headlinings and I never usually burn in the UK - even when I venture south! Anyway, that San Miguel in the pub afterwards was freezing and bloody marvellous - and I don't normally drink lager.

Cheers all!

Yeah, I got the MOT done, and then had to go and catch up with my parents yesterday afternoon/evening as they were off today again to go visit some other rellies... Today, I've just been tinkering with the Nav system - finally got it to install nav program and maps properly (so now it's not just an expensive radio!) and tried to catch up on a bit of sleep..

Still got to get the vacuum/lint roller on the headlining material to clean the shite off it, and hopefully if it doesn't rain tomorrow, get my sunroof shade done.

You're more than welcome for helping you out with the Duchess - glad you got a few bits sorted and thanks for the help on the headlinings! I know what you mean about the heat - whilst it was nice, a bit more cloud cover wouldn't have gone amiss! I understand that people have the journey back to do on the Sunday - and you'd come a pretty bloody long way! If we do it again, then I wonder if it's worth trying to arrange it for a long weekend, so even though it would be 2 nights down in 'sunny' Swindon, you could have a few more San Miguels, and it wouldn't be such a long drive for only really a day's worth of workshop time once you take out getting there on Saturday morning and having to head off on Sunday arvo...

I would have come for a drink, but by the time I'd done a whip round/tidy up of old headlining material into bin bags, etc, locked up the workshop, and then realised I still had all the door/tailgate seals to re-affix, and some wiring to poke up so it wasn't in the way so I could then drive it back home - and the drive home of course, i was knackered, and ready for bed!

If anyone wants to email me through a pic of their nice new headlining, then feel free to do so - I'm going to drop Martrim a message a bit later this week to say thanks again for doing a group discount, and also to show them some of the results...

Marty

blueplasticsoulman wrote:

car drives straight as a nut. Just the wheel that's on the piss.

Then do whatever you want to sort it out.

I didn't explain right.

It drives straight, but the wheel aims at between 10 and 11. I understand that you can't just take the wheel off and move it. Would it be right to assume that when it was tracked by previous owner, that it's been done with the steering wheel not centred and to correct it, it will all need realigning?

Just because it drives straight doesn't necessarily mean the tracking is correct - as when driving in a straight line, the front wheels will 'find' their center point, which will then offset the steering wheel one way or another. But if the wheels are tracking outside the tolerances specified in the workshop manual, then it will lead to excessive/uneven tyre wear, and possible strange handling at times, even though in a straight line it might be OK.

Assuming the tracking of the front wheels was set correctly by the previous owner - or whoever they took it to to be done, and is within the tolerances specified in the work shop manual, then the issue of the steering wheel center would either be in the connection between the steering box and the LH front wheel on the drag link (as the track rod will be holding the wheels at the correct value, and as the vehicle drives in a straight line, they find their centre point, and the adjustment of the rod to the steering box is a bit short, thus pulling the steering wheel to the left ). Or the steering wheel may at some point have been taken off and turned to line it up center (before the vehicle was re-tracked). Or the steering wheel is centered to the steering box still, and the drag link needs adjusting to get the steering box and wheel back to center.

The easiest way to see whether it's the steering box/wheel or drag link is to stop with the steering wheel centered, and check to see if the steering box is centered. If it is, then with the steering lock off (Ign pos 1) adjust the drag link so the steering wheel is centered.

If the steering box isn't centered when the wheel it, then that alignment is out, and will need to be corrected. once the steering wheel and the steering box line up - then check to make sure the steering box is central when the vehicle's front wheels are centered.

ok. Thankyou.

Armed with the information, I can make sure it's done right you see. The last P38 I had, I watched the guy track it and he told me what he'd done and gave me the alignment printout which was correct according to the RAVE values. Still didn't drive right. Now I know there's more to it than sticking expensive equipment on the wheels, turning a couple of nuts and charging £50. I'm a bit stuck for reputable tracking places round here. I went to 2 garages that said they didn't do P38's as they were too old. A bizarre excuse I thought.

Marty, a word of advice on doing the sunroof blind trim. Make sure you wrap the material at the front right round so it actually goes up on to the top and don't get glue on the strips down each side that it slides on. Probably worth putting some masking tape on to keep the glue off it or you'll need to clean it all off again as Morat and Smiler had to on his.

Thanks for hosting a great weekend, we enjoyed it but as you say, with a 2.5 hour drive to get home had to leave when we did. Dina had one complaint though. With 6 or 7 headlining shells to strip the old trim, foam and glue off she kept herself busy doing that all day Saturday but was complaining she was getting bore on Sunday because there was nothing she could do. Although she is fully experienced at the old up, down, up, down routine when it comes to brake bleeding, I suspect she wouldn't have been too happy to wait until the early hours to help with doing it.

blueplasticsoulman wrote:

gave me the alignment printout which was correct according to the RAVE values. Still didn't drive right.

The problem is that there are two lots of adjustment that are quite separate. There is the tracking, which ensures that the wheels al point in the right direction but that doesn't necessarily mean that the steering wheel will be straight. As Marty said, check that when the wheels are straight ahead that the marks on the steering box show that to be centralised too. If it isn't, you need to adjust the drag link until it is. If the steering box is centralised, then it's the column between the steering wheel and steering box that need changing. Rather than taking the steering wheel off, it's easier to move the wheel by moving the splines on the centre column and there's less chance of damaging the rotary coupler too.

I've given up trying to centralise my steering wheel, I changed pretty much everything when I was chasing the clunk on my steering.
Adjusting from the shaft between steering column and steering box is so fiddly, the splines are so fine, might be easier with a helper.. I live with mine slightly on the scew,,

Happy to be of assistance! Who doesn't love some late night P38 shenanigans?

Such a relief when it finally stayed quiet and reported no faults, that's for sure.

My pitifully small collection of photos. I just never seem to remember to take photos whilst working.

Regards,

Smiler.

what colour is the headlining Smiler? Oatmeal from Matrim?

Whichever colour Marty odered. It is a very close match to the later pillar trims though (being a 96 model mine originally had the creamier flocked trims that look awfull once they've aged and had years of being rubbed by seat belts etc...).