Update time........having had a heavy cold over the past few days, the brain is feeling a little foggy and the patience is wilting so decided that I'd leave the electronics for a little and the idlers and move onto the sprockets.
A few posts ago, I had filed and loosely fitted the sprocket rings to the hubs to check a possible issue with the tracks so I won't be going over that part again.....so here is the new stuff! This is what we are given and where ultimately, I would like to finish up.....
Now looking at the original, there is a lot more detail on it than the supplied part; that said, all the holes are there! One just has to adapt! Now I wasn't able to find a picture in the manual relating to fixing the hub cover plate; that's probably just me but it is more than likely secured and finished off using two sizes of M3 hex head bolts.
I started with the cover plate first which was filed down to remove any tooling marks then prepped for etch priming. I then made a grease nipple using an M1.2x5 screw and nut; the nut was secured with Loctite 243. i must admit, trying to put that nut on that screw pushed my patience to the limit
and then I had to do it again!
Once I'd taken a breather, a 1.3mm hole was then drilled on the angled side of the hub cover and the make shift nipple then super glued into position.
Now looking at the original picture, you can see that the hub cover is secured using castle nuts with cotter pins for security and dispersed between these are an additional 4 normal bolts at 90 degree spacing to each other. I did try to search for some M3 Castle nuts but decided it would be much more fun to make them ( yeah right)!
I made a jig up using an M3 bolt and two M3 nuts acting as a locknut and adjusted such that a nyloc M3 would be positioned at the correct height for cutting. The jig was secured in a vice using the lower nut and the slots cut by eye using a Dremel cut off blade. One down, 23 to go..... As for the cotter pin holes, scratch that, I'll save that one for the more experienced to demonstrate
WIth the castle nuts made, it was now the turn of the studs. I used M3 x 16 csk's and loctited them in with 243. Once dry, the heads were cut off at the very top of the thread.
A test fit of the hub cover was then conducted and identified that it was quite difficult to remove the cover from the studs even when pushing from behind which once fitted, you wouldn't be able to do. I therefore enlarged the 12 holes relating to the studs to 3.9mm. This allowed the plate to be easily removed using a lump of Blue tack.
Turning to the last 4 holes in the cover plate, I was considering using M3 bolts with a 7BA head but this didn't quite look right. I then tried an 8BA bolt and nut combination which seemed a lot better.....see below with 7BA head on the left and 8BA nut on the right.
Also, looking at the original picture again, you can see that these bolt heads appear to have a depression in them which can itself be created with the 8BA nut combination by lowering the thread in the nut; overall, I think the 8BA is the winner!
With the hub cover plate finished, it was time to concentrate on the sprocket ring securing bolts. looking at the original, these look like specific to type bolts; on top of that, Armortek say these need to be high tensile too. I don't think I will be able to buy a bolt like that although I may know someone who could possibly make some but I wouldn't like to estimate the cost so I'm going to use a square half nut and grind a bevel on one edge; its the closest I can get to the original given the cost implications. I'll still use the supplied bolt which is high tensile.
Each nut was held with a pair of electrical pliers to allow one edge to be bevelled..
The ring itself was given a coat of Loctite 638 on the back of the securing tabs and placed into position quickly then secured into position using the original supplied bolt and nut in alternate hole positions. Then immediately after, the remaining holes were secured using the original bolts and the squared half nuts using Loctite 243 as seen below....
The original nuts were then removed and replaced with square half nuts and again, secured using Loctite 243.
The following day, the threads above the square nut were cut off flush to the nut and the face of the nut ground flat with gentle pressure to ensure the Loctite didn't cook.
All done, with the exception of one small detail!!!
Did anyone notice the hole drilled into one of the sprocket teeth? Is it a timing mark or an alignment mark perhaps? Anyone know?