PollyMobiles Rebuild

[pollyp]

2024-05-27 Adjustable Gear Stick Ball Joint

Been noticing the gear stick tends to shake a lot whilst in 5th gear cos the ball joint was worn & too loose

I tried to print a tighter fitting insert but getting the tolerances right was a PITA and doesn't compensate for wear

So I redesigned a whole new 2-piece mount that can adjust how tight it fits around the ball joint

Printed & installed new mount

added rivnuts so the mount can be screwed on from the top rather than originally getting underneath

fitment is soo much better, precise & zero play.
gear shift is slightly more precise and doesn't shake around anymore

 

[pollyp]

passenger door is still rattling near the front @ 3k rpm

I tried covering the back of the door card with soft felt

but still buzzes. kinda stops if i push the handle, yet still buzz if I remove that handle?
it's like the inner door frame is resonating louder than any other door.

the only time it's quiet was with everything stripped off the door, soo frustrating

 

[Micra Paul]

passenger door is still rattling near the front @ 3k rpm

I tried covering the back of the door card with soft felt

View attachment 88334

View attachment 88335

View attachment 88336

but still buzzes. kinda stops if i push the handle, yet still buzz if I remove that handle?
it's like the inner door frame is resonating louder than any other door.

View attachment 88337

the only time it's quiet was with everything stripped off the door, soo frustrating

I took the view that my old clunkers were supposed to shake, rattle & roll & that was part of the charm of banger driving?

Perhaps it is easier to try ear plugs or muffs & more fun then it is to chase down every little noise in an old banger?

bilsom ear muffs at DuckDuckGo

 

[pollyp]

I took the view that my old clunkers were supposed to shake, rattle & roll & that was part of the charm of banger driving?

Perhaps it is easier to try ear plugs or muffs & more fun then it is to chase down every little noise in an old banger?

bilsom ear muffs at DuckDuckGo

I do wear noise cancelling ear buds to help on long journeys but this buzzing door noise is more intrusively annoying. the stiff nismo engine mounts certainly doesn't help with shaking everything to bits lol.

but later on the next post I finally discovered the cause

 

[pollyp]

2024-05-29 Weld Rigid Passenger Seat Support

The passenger seat back rest shakes bit more than the drivers seat cos the upper bracket ain't joined directly to the subframe like the drivers side.
So tday I removed the seat

& added the extra bracket to join the two support brackets, making the seat more rigid

sitting in it feels more secure now

ordered a new 2.25" universal 400cell sports cat for the new exhaust manifold layout I'm designing

It's the same 4" diameter as the secondary cat that's under the car

The 400 cell honeycomb density looks exactly the same as the secondary cat, except this honeycomb core is 95mm long

Whereas the secondary cat has a shorter 75mm long core.
The Micra primary cat has a 80mm long core.

So hopefully this thicker universal sports cat will help with emissions

 

[pollyp]

2024-05-29 Fixed Door Rattle pt3

Had a nice weekly car meet.
The passenger door was still buzzing annoyingly whilst driving over

I even asked a friend to drive the car at 3k rpm whilst I try to locate the hidden buzzing but no luck

But when looking further, I soon noticed the passenger door stopper had bit more loose play to it compared to the tighter drivers side?
I removed the door stoppers and behold! it finally stopped buzzing and was a quiet drive home

I believe the loose cap on the ends of both door stoppers are the culprit. tack welded them into place

reinstalled & that has FINALLY stopped the buzzing rattles
nice n quiet smooth

 

[Tomk11]

2024-05-27 Adjustable Gear Stick Ball Joint

Been noticing the gear stick tends to shake a lot whilst in 5th gear cos the ball joint was worn & too loose

View attachment 88323

View attachment 88324

View attachment 88325

I tried to print a tighter fitting insert but getting the tolerances right was a PITA and doesn't compensate for wear

View attachment 88326

So I redesigned a whole new 2-piece mount that can adjust how tight it fits around the ball joint

View attachment 88322

Printed & installed new mount

View attachment 88328

View attachment 88329

added rivnuts so the mount can be screwed on from the top rather than originally getting underneath

View attachment 88327

fitment is soo much better, precise & zero play.
gear shift is slightly more precise and doesn't shake around anymore

View attachment 88330

View attachment 88331

that's impressive

 

[pollyp]

that's impressive

thank you

 

[pollyp]

2024-05-31 Electric Window Motor Support Bracket

The heavy electric motor hanging outside the window mechanism can be seen shaking around, which could've contributed to the annoying vibrations

I designed a support brace to anchor the end of the motor onto the door frame

Printed

Installed and now the motor sits rigid and doesn't shake/vibrate at all now

 

[pollyp]

added some draft excluder tape under the instrument cowl to reduce vibration

brought another cordless grinder which was on sale

visiting Jack for a catch up

replaced the old gear stick cover which had a broken clip

old socket tool holder was broke so I designed a better one

 

[pollyp]

replaced the rusty steel rivnuts on the scuttle planel with aluminium rivnuts

and had a nice car meet down Catterick tonight

 

[John_D]

replaced the rusty steel rivnuts on the scuttle planel with aluminium rivnuts

View attachment 88375

View attachment 88376

and had a nice car meet down Catterick tonight

View attachment 88377

Why replace steel Rivnuts with aluminium ones in a steel panel, taking steel screws in an obviously wet area Paul?? You are just asking for galvanic corrosion to occur, far worst than the original surface rust, on the steel Rivnuts....

 

[pollyp]

Why replace steel Rivnuts with aluminium ones in a steel panel, taking steel screws in an obviously wet area Paul?? You are just asking for galvanic corrosion to occur, far worst than the original surface rust, on the steel Rivnuts....

Replaced them with Alu screws

 

[pollyp]

spherical bearing on the BC BR coilovers are slightly crusty, so gave em a little clean up

 

[pollyp]

swapped from a high mounted alternator to a regular low mounted alternator setup.
wirebrushed all the rust off

painted & fitted

the old belt tensioner with extended adjuster had cracked, making extra rattles but easy enough to reattach

Yorkshire modified show coming up so I polished the wheels

ready for the wet show tomorrow

 

[pollyp]

2024-06-15 Compact Alternator Mounting Bracket

I've been redesigning the turbo layout for the past few years and the standard alternator locations are causing some issues.

The current layout from my previous turbo setup is a high mounted alternator using the air-con mounting brackets

But this fouls the turbo inlet on the new design

The original low mounted alternator on the other hand pokes out too far

& can foul the boost pipe going into the intercooler

I needed to reposition the alternator low down & very close to the block to give enough room for all the plumbing and avoid touching the electrical terminals too

Lined up the alternator & brackets to the crank pulley

Main bracket tacked up

Welded up

Alternator now rests against the block

To tension the belt, I first tried using the high mounted tensioner

But that was at the wrong angle & couldn't apply any tension

So I redesigned a vertical tensioner bracket integrated into the new mount

Tacked the new piece on. It's a tight fit cos it has to clear the engine mount next to it.

New alternator mount & tensioner completed.
The adjustment screw can be accessed easily from both ends.

Installed the new bracket & now the belt can be tensioned with the alternator sat closer in