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28-03-2014, 01:03   #61
Daved_XB
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This is just a quick update.. ever since I’ve had the car she’s had some small fuel weep issues from the hard lines that connect the 3 carbs of the 6 Pack together, now when I bought the car I got a new set of hard lines & blocks with her.. so I was a little disappointed when after I replaced all the lines I found that she still had a weep… seems from the research I’ve done this is quite normal for 6 Pack hard lines..



So I figured what I’d do is to make myself up a set of custom flexible braided fuel lines to fix this once & for all… so this is my hard line set up compared to my braided line set up



It fits up real nice to the 6 Pack… very happy with how this looks…



It gets pretty tight for space once I hook up all the vacuum lines, but everything fits & nothing fouls…. & most importantly nothing leaks….



I also got myself a new centre fuse block from painless wiring







The plan for this is to replace this crappy old fuse block under the dash with it… however this is going to be a new project for next winter, I don’t plan on extending this project any longer now..

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28-03-2014, 01:05   #62
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Well this is probably more of a garage tool update than an actual project update on the Chally… I have a few things that I still need to sort out before I’m 100% happy to put the car back on the road. Firstly the gearbox is still leaking.. I thought when I put the new pan on that I had solved that issue, but it now is clear that the selector shaft seal is also leaking.. a known issue for the 727 boxes, so I have ordered one of them now & will be fitting that soon. Now depending on who you talk too it seems that most recommend that this is a gearbox out fix, whilst some suggest that if you drop the pan off & if you remove the whole valve body assembly thru the bottom of the box you can then pop the seal out from underneath… I’m not sure which of those two options I like the sound of best, but stay tuned & you’ll find out….. I might try & see if I can squeeze my hand in past the exhaust & the torsion bar & get a seal pick in to stab the old seal & twist it out, it looks pretty tight in there so I’m not sure that can be done..

Also the fuel gauge has never been right in this car, F is full & E is hall full & then a ½” to the left of E is empty… the previous owner told me that he tried bending the pickup float in the tank to get it right but it’s far from right,



So I bought a new pickup & I’ll fit that in the tank when I’m underneath doing the gearbox seal.

Now it should be a whole lot easier to do both of these jobs as I finally decided to stop talking myself out of buying a hoist & I got one… so this weekend two boxes turned up.. one held the hydraulic pump



The next box if you could call it that was a 750KG frame of the actual hoist parts



This jigsaw did come with some instructions, but to be honest it was about 4 thousand words that where clearly written by someone who’d never seen one of these hoists & had only been given a vague description of how it all went together over the phone… six clear pics would have been perfect… luckily it’s pretty hard to stuff this up & with the help of a good mate to do some of the lifting of the bits we got stuck in..

Once we had the two ends assembled as per below



We noticed that they were so close to the height of the top ramp (which houses the hydraulic ram & is over 200KG’s as a result) that we could cheat & not lift the thing at all… so we wheeled the frame over using my trolley jack & then used some stands to take the weight as we unbolted the end frames off & then moved the hoist cross arms in to meet the ramp… too easy



No before anyone asks, I went for a 4 poster & not a two as I am only renting & drilling & bolting a two post in my landlords garage would not have gone down well… also this can be used to allow me to stack park some cars & get another car into the garage… & lastly because this specific model came with a caster option that means I can very easily move the hoist to any point in the garage I want





You can even move the hoist with a car on it… I don’t think I’ll do that a lot, but if the need if ever there it’s nice to know I have the option..

Now that I have one, the irony is not lost on me that I spent months on my back replacing all the suspension on the Chally cursing that it was so cramped a space…. Because I’m only 5’10” there is more than enough room for me to stand fully upright under the car



Even if the roller door is up I still fit…



& we still get all the cars in without using the stack parking yet… hmmmm maybe I need a new car now I have a spot to put it…

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28-03-2014, 01:06   #63
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Ok, so a bit of an update, first a couple of small jobs then the big one, the transmission job… so as I said earlier in the thread the fuel gauge has never been right in this car, F is full & E is hall full & then a ½” to the left of E is empty… the previous owner told me that he tried bending the pickup float in the tank to get it right but it’s far from right… so I had all the bits needed to swap this out & I decided that this simple task would be the first ever job carried out on my shiny new hoist…

So I had my new fuel sender



& I had a new filter for the end of it



I also has the fuel line earth strap that I noticed my car no longer has



Getting to the fuel sender is nice & simple, it mounted into the side of the fuel tank with a simple locking ring… you can see here that as the earth strap is missing someone made up an earth wire that wraps around the hose clamp now





Removal of the sender is simple, the lock rang is a castle style so you simply knock one of the uprights with a screwdriver (you can get a special tool also) & undo the lock



First thing I noticed when I removed the old sender, it has no filter… no wonder the filters in the fuel line fill with crap so much



If you compare the old manually bent one with the new one you can see where the old one is kinked just after it comes out of the body, with this bit no longer being straight it was never going to read right



I slid the new one complete with a new rubber gasket back into the tank



Then I tapped the lock ring closed & hooked up the sender wire to the gauge, the fuel line & of course the earth strap for the sender….



Job done, & it took about 2 minutes under the hoist & not a drop of petrol rolled down my arm & onto my chest whist I was standing up working on it… working with a hoist is so civilised… hopefully now I’ll also have a better understanding as to just how much fuel I have in the car
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28-03-2014, 01:08   #64
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Now the next job I tackled was one of the small jobs that I’m sure most normal people wouldn’t be bothered even doing.. but I can be a bit OCD with things & sometimes for me the little details matter more than the big ones… so I decided to fix something small that has be bothering me ever since the day I first bought this car…. This…



It’s an aftermarket aerial & it doesn’t bloody fit… it rattles around in the hole scratching the paintwork & generally annoying me every time I see it or worse hear it rattle.. the problem seems fairly simple, the aftermarket ones all seem to be fixed in size for a 25mm hole & the one on the Challenger is closer to 35mm & as such there is only a mm or two for the thing to grip..



Now also the aerial itself was snapped… so it rattled around & didn’t even work… so I removed it



Now, I don’t think I’ve ever even listened to the radio in this car… but I couldn’t leave the rattling bit in there & I couldn’t leave the empty hole either & I didn’t like the look of any of the bungs that I saw to cover up the hole… so I bought a genuine Challenger one..

The main body that sticks into the fender is huge compared to the aftermarket ones



The top piece is not just a flat plate that sites on top of the fender, it’s designed to use the two locating notches in the fender & to pass thru & actually lock into the bracket underneath & the curved bracket that tightens it up against the underside of the bodywork is much thicker & looks like it won’t bend as easily as the old one had





Then the final locking nut screws into the center of the whole deal





Then the actual antenna piece screws into the assembly… sadly this is not a retractable one, so I will have to unscrew it when I’m putting the car cover on or I’ll have to use the little kit that came with the cover to make an isolated hole for just such a requirement… right now I think I’ll just screw it off to put the cover on as it doesn’t impact the rest of the thru body parts



Again… I know that this is very very OCD of me… but I gotta tell ya seeing how this genuine piece actually follows the curve of the fender & just looks right made me smile.. but then as my other half & most of my close friends keep reminding me.. I’m not all there



When I get a chance over the next few days I’ll do up the transmission seal job…. Some good fun & games had there thanks to some previous mechanical muppetry… but sure it wouldn’t be my car without that…
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28-03-2014, 01:09   #65
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Ok, so last weekend was the date set to drop the transmission from the Challenger & swap out some leaky seals…. I’ve done a similar job on my XB Coupe a few times laying on my back using axle stands & a trolley jack to support the trans on the way out… so I was kinda looking forward to being able to stand fully upright under the car whilst doing this one… I had also splashed out on a new toy for the garage for just this job too..

Can you guess what it is yet..



Transmission jack fully assembled… hopefully no danger of dropping the trans on myself now..



So all of this work is to sort this small seal, this is a crappy pic.. but this is the selector shaft.. that’s the shifter bracket at the bottom & the kick down connector at the top… this is what is leaking



I will also be inspecting the oil pump seal & bush & the rear yoke seal whilst I have the box out to see if they need replacing as well whilst I’m at it.. now before putting the car up in the air there are two bolts at the top of the engine that have to be undone



They are had to get a good pic of & even harder to get my fat hand into… luckily for me my other half is happy to help as she has done many times in this project & has much smaller hands for just such an occasion



The other trans to engine block bolts are easy to get to from underneath so up in the air she went



Then I dropped the tail shaft out & started working out in my head the order in which I should start pulling stuff off… first was the speedo cable, simply unscrew & then tie up out of the way to be sure it’s safe

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28-03-2014, 01:10   #66
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Then it was on to the starter motor, even though this one is very compact, it pretty much touches the extractors… I might have to look into some sort of heat shield when I’m putting all back together.. once I had the starter unbolted, I tied it up out of the way





Then I unhooked the trans cooler pipes that run the coolant to the rad & the external cooler that is fitted up front





Also in the above photo is the bracket that holds the gear selector cable, that came off & I disconnected that cable & also the kick down cable from the selector shaft brackets



Then the neutral safety switch, that’s the thingy with the 3 prongs coming out form it..



I had to actually remove one of the cooler lines completely before I could get the access panel off that would allow me to get to the torque converter & the 4 bolts that hold it to the engines flex plate



Now I knew that the previous owner had had this gearbox out to get the TC repaired when he owned the car…. So the TC & the flex plate are already marked with alignment marks so that I put it back together in the same way it came apart… nice.. however I noticed that the drain plug for the TC is actually welded in on this one.. so I can’t drain it before removal.. odd but not a show stopper

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28-03-2014, 01:12   #67
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Ok, now I know what your all thinking…. Dave, where is the mechanical muppetry you promised us, fear not I won’t disappoint… so on a slightly closer inspection of the bolts that hold the TC to the flexplate they just don’t look right….







The next hour or so in the garage was entertaining for want of a better word… now in case you can’t make out from the pics above what’s wrong with the bolts.. let me jump ahead in the story & show you some close ups of the bolt heads after I finally managed to get them out of the car…







So.. somebody doing this job before rounded the heads off of these nuts.. so many of the nuts & bolts on this car where rounded off I’m starting to think that a previous owner only had metric tools & was too cheap to invest in some imperial ones for this car… anyway… someone rounded the heads off & then instead of replacing the 4 bolts they welded new metal to them & then attempted to grind them back to be somewhat bolt head shaped… or at least how I imagine someone who’s never seen a bolt head thinks that they should be shaped…. Now I’m all for recycling & I know that we will eventually run out of raw materials one day… but I cannot comprehend why someone would do this…. Oh & the cost of the 4 new bolts that I have bought to replace these….. $5.95!!!! so it’s not like they were made of unobtainium or something…

Now this would have been laughable & fun if the bolts had of come undone easy…. But no… whom ever did this made the edges great for tightening them, BUT left the edges rounded off on the sides you need to undo the bolts… & then they used Loctite on the them…. This issue was compounded by the fact that the bolt heads are half height just on 5mm thick & in such a tight space that a socket couldn’t get in… I spent a long time & I mean I long time heating each bolt & then teasing them out…



The last one was so badly worn that I ended up having to commit the cardinal sin of gripping it as hard as possible with a pair of vicegrips & using that to get it loose as the spanner just kept getting kicked off by the rounded edges.. at one point I pictured myself having to weld a nut onto the face of the bolt to give me something to get a spanner on… but finally after well over an hour I stumbled upon the correct line of profanity that allowed the bolt to come undone…

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28-03-2014, 01:13   #68
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Then I removed the cross member at the back of the extension housing, this needed me to unbolt the exhaust flanges to separate the exhaust from the extractors… but I only needed to drop the exhaust about 2 inches to get the cross member past them… so I was glad that I didn’t have to pull the exhaust off for this & then undid the last two bolts holding the bell housing to the engine & pulled the whole box back an inch to pop it off the dowels of the block…. The trans was now free from the car & resting solely on the trans jack







Then simply cracked the release on the jack & slowly watched the trans lower to a nice workable height..



I’ll give in here a bit of a clean now that I have the room to get in



Last thing to remove was the kickdown & shifter brackets off of the actual selector shaft itself



Now looking closely at the suspect seal, it’s hardly shocking to see that it was leaking.. I’ve always installed seals using something uniform flat & round to gentle knock them into place… this one looks like someone used a hammer & a screwdriver… it was dented as hell…



Once I popped the seal out I then gave the whole assembly a good clean



Then I put the new seal in…. finally



I now have passed the box onto someone who knows what they are doing to knock out the front pump bush & seal & replace them.. I just don’t have the pressing tools to replace a bush & I don’t want to risk damaging anything… so the box should be going back in one night this week… & now I also waiting for my 4 new bolts to turn up…. Ah the joys
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28-03-2014, 01:16   #69
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Ok, it’s been a long long time since I updated this thread & there are a few reasons for that… work was crazy in December & that added to Xmas happening limited my time in the garage & then to throw a big spanner in the works parts went missing in transit.. by the time parts turned up (my brakes are missing still, but more on that later) I was then travelling for the best part of 3 weeks in January & then I blinked & it was March already…

Right so where are we at then…. & I apologise in advance for the lack of a lot of pics as I had the CF card in my camera go dodgy & I lost some of the shots as corrupt sadly..

So the seals on the gearbox where sorted & then the box was put back in, sadly I don’t have a single picture of that… but it’s simply the reverse of the removal above so not rocket science really

The special bolts took a week or two longer that I had hoped & I had a bugger of a time trying to find any locally.. seems the half height bolt head was a killer. At one point I almost bought some standard head height bolts & then turned down the head height to what I needed.. but I just used the time to clean all the parts of the car that I now newly had access too & then the bolts finally came..



Once the box was back in I figured that was the last of my hassle’s it would only take an hour or so to reconnect everything & hook it all back together..



Wrong… you would believe how hard it was to find a set of these..



I spent a whole Saturday morning visiting every parts place local to me & even tried the two exhaust places close by… one wouldn’t sell me a set unless I brought them the car for them to do the work! & the other was manned by a very unhelpful child who proceeded to tell me that that what I wanted did not in fact exist & that all exhaust flanges are two bolt hole jobs only & he couldn’t get his head around how mine could have 3 yet not be a triangular exhaust system… I fear for the future some days… anyway off to ebay I went & then within a few days I had these in my hot little hands



So I was finally able to bolt the exhausts back up.. I forgot to swing past the exhaust joint to show the window licking muppet my triangular exhaust gaskets..



I took the opportunity to repair a small hole that was starting to appear in one of the mufflers.. I plan on replacing the whole thing once the car is officially on the road with some plates, so I was happy to just use some muffler putty for now



Then it was time to do some road trails as the car hadn’t ever moved on the new suspension & I wanted to drive it around for a bit to let it all settle so I could do another adjustment of camber & caster.. so got a permit to drive an unregistered car & did several test flights

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28-03-2014, 01:19   #70
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God that new suspension has made a huge difference to this car, it’s so flat in the turns & there isn’t a single trace of wallow now & she now just squats under acceleration & takes off (actually just spins the wheels easier now) whereas before the rear would sag & the whole front would pick up robbing the wheels of that lovely torque that should be propelling me forward & not twisting the chassis.. once she’s registered on the road & my second order of brakes (long story) turn up & get fitted I’ll do a proper write up on the improvements.. but for now I’m a happy boy..

So it was back to the garage to redo all the suspension setup now that it had a few miles on it to settle in



Back up on the hoist to check on that gearbox leak that I fixed… dry as… job done & happy me



She then developed a leak in the brake system somewhere & that lead to me having to do a lot of fault finding & brake bleeding so I bought a one man air driven system to make my life easier & to stop annoying my other half by making her pump the pedal for me



Then I managed to find a local sparky who was happy to work on a muscle car (so many people run when you tell them you want to work on something that isn’t brand new) so I gave it to him for a few days & it came back with all the wiring nicely tidied up & he was very impressed that the car hadn’t burst into flames at some point… he reckoned it was some of the worst home wiring attempts he’d ever seen, I made sure to point out that it was before my ownership… anyway the whole ignition was stripped & rewired



& my tacho finally works again… the needle used to just bounce around in a world of its own regardless of what he engine was doing & that would set the shift light off constantly which was distracting to say the least..





So now we’re back up to date again… this Saturday I have an appointment with my engineer for him to go over the car & see what he’s happy with & more importantly not happy with & she’s then booked in to have 3 point rear seat belts fitted & hopefully then I can take her for a roadworthy… so this week she swapped places with the XB on the hoist as the next project ramps up



Ok… & that’s it.. this thread is up to date as of March 2014, so updates will be in real time.. assuming anyone actually managed to stay interested the whole way through (sorry it’s a bit long)
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28-03-2014, 10:24   #71
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Looks like it's gonna be a stormer of a car. Lovely looking car and body on her.
Keep it up on it mate. Doing well.
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28-03-2014, 10:41   #72
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Best thread I've seen on boards in a while! Awesome machine, and incredible work gone into her.
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28-03-2014, 11:13   #73
Daved_XB
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Thanks... I'm doing it all for me but it's always nice to get the nod from other car people
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28-03-2014, 11:18   #74
 
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Beautiful car

Can you elaborate on where you first purchased it and what sort of outlay, and the amount of subsequent outlay to get it to this point?
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29-03-2014, 00:16   #75
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Beautiful car and probably the most interesting thread I've ever read on boards!!!!! This sub-forum is proving to be everything I wanted it to be and more


Looking forward to seeing the work continuing
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