So, I've a new "worse job on a 480" that replaces a turbo starter motor.
Front to rear brake pipe.
I *think* the flipping bangers guys covered it on Oli's TT, but OMG it's horredous.
The worse part of the pipe was across the rear panhard rod bracket, and where volvo went up and over it (WHY!)
First part of the plan was to remove that so we could gain some more access.
Fairly straightfroward task - 4 bolts from underneath, 2 from above, remove the brake pipes from the flexis. Much cursing as brake unions seized into flexi's, flexible hoses exploding whilst heating said unions... Hindsight says I should have to used mr grinder from the outset!
Crossmember bit off, was looking too fresh.. So attacked with mr grinder.
Lets not forget that that's AFTER Mr grinder too... and he can't get into the box sections either. If only there was a way to get that rust out....
"'old on lads, I've 'ad an idea!"
Yup! It's the science shizzle on a slightly grander scale!
So whilst that's fizzing away, I turned back to the brake pipes. I can potentially
get away with a single one (the NSR one). It's the one that has actually failed and by the time it's halfway back up the car, the pipework is excellent. So, there's a potential joining spot.
The the fun begins. If you don't know, the pipes route under the car, tuck behind the fuel filter, the follow the OSR chassis leg. The NSR pipe is the highest pipe, then the OSR and beneath that, the fuel line. It became very, VERY
quickly apparent that Volvo fit the pipes quite early on in the build, then
plonk the fuel tank in.
So fuel tank out time? Well, not if I can bloody help it!
Removing the old pipe is simple enough - Some snips, some vice grips and a big hammer makes short work of it. Rerouting the new one? Well, time to dig out Jeff's big book of swear words. Brake pipe clips are supposed to be pushed through horizontally; you push the pipe into them from above. Except you can't because the fuel tank is in the way. So instead you begin the 3d puzzle of trying to get a pipe that needs to be straight, through a clip that you can't see, whilst avoid crap falling in your face.
It took about 2 hours just to get the pipe thread along the chassis leg - That's 3 clips worth.
We're still not even close to completion on it either. Need to wait for the science stuff to happen, then paint the crossmember and re-fit. Once it's in place, pull the pipe along the new crossmember, then add new pipe clips onto it as I'm changing the routing to be a bit more sensible.
Deep down, I know I should just remove the fuel tank and replace the other line at the same time. Maybe I'll sit myself down this week and have a little talk with myself...