#ZedShed Davesters crusty Sport Refresh

[Davester2.2sport]

I would just like to say a massive massive thanks to @Lee and @GazHyde for everything they have done to my car at the Zedshed..
After several weeks of planning we decided to replace the rear and front suspension as well as any other parts that they deemed necessary..
I travelled up to basingstoke several Saturdays ago to drop the car off where I met the guys at the local breakfast van... as is tradition I believe lol...
As well as lee and Gary I also met another member trevor aka @Oldguysrule
Back to Lee's place for the first inspection... excited but nervous as well as no one wants to be told they bought a dud ... anyway one word the boys kept repeating was Krusty...
That word has stuck with me since and I'm finding I'm using it in everyday conversations lol..

Lee has written on previous posts what work was carried out so I wont bore you all again by repeating it but all i will say is my car has been transformed.. . It feels so tight now not wobbly like it use to be... it almost feels like a new car to me

Again I would like to Express my sincere thanks to the boys at Zedshed HQ.. not just on the car but also for the welcome they gave me as well ... not just a couple of new friends but also two Top Blokes as well

Dave

 

[Jack Ratt]

Nice testimonial Dave

 

[Lee]

Part 2 - Powder coating kicking off this Saturday.

 

[Lee]

This Zed has come a long way since last October. She’s had the engine bay sprayed, new sills, bumpers sorted along with wings and one lower quarter. We did a bush refresh last year but noticed the amount of rust was crazy for a car of this age it’s lived by the sea that’s for sure.

Soon as Dave spotted me listing a powder coated subframe he was quick to jump at the chance to sort his. Shame his was so rusty we couldn’t reuse any of it.

In the normal position.

Also security were away today so we had backup. Everyone’s favourite Z4M.

You get an idea of how bad it is.

The arms on the underside were unreal.

Beam didn’t look much better.

Just as well we have replacements ready.

The diff needed a fair bit of cleaning up with a wire wheel and a flappy disc. Removed the rust and smoothed everything off then sealed it in.

Now all the dirty work is done it’s assembly
Of all the clean bits.

 

[t-tony]

Great work Lee. Boy those old rear arms are nasty!

Tony.

 

[Jjim]

Great work. Looks like it was driven on the beach!

 

[Rha]

Nice job, another Z saved from the graveyard. Well done Southern Zed Shed.

RHA,ROY,

 

[Bazza]

OMG rusty or what, a great save lads

 

[colb]

Knew it was crusty when we had it in Zedshed Cymru sorting his airleaks last year, great to see its being fixed, he loves that car.

 

[TaffDaddy]

Great job

 

[Lee]

So to complete this build we put a few extra days into her. The rust was everywhere we had to take so much back to bare metal and seal. It’s been so worth it. The car is now so clean underneath. I’ll let the pictures do the talking.

Once we got the old subframe out it was evident that nothing was salvageable luckily we like to keep spares for this very occasion. First up rebuilding, torquing up the diff and subframe.

The old fuel tank straps fell apart in my hands trying to remove them.

You can also see some touching up we’ve done. Not something we normally do but I just couldn’t bare to see it.

Next I started assembling the swing arms. We had to build it like this due to the exhaust flanges being last it. It’s safer to not touch them.

The unsalvageable pile of metal or what’s left of it.

Powder coat vs rusty beam.

So this left today to finish the braided brake lines and test drive. Nice turn out of 8 zeds and the weather held out till later.

And some shots under the rear.

Also a quick couple of shots up front. Braided lines. Painted brakes and hubs. We did drop links and wishbones last October.

So test drive went well only low tyre pressures to sort which took minutes. Also a stubborn brake pad sensor this went out after unplugging and plugging back in.

Another happy Zedder.

 

[Mazza]

Well done Lee and co ( Gaz , Trev and Paul)

Another Zedshed HQ triumph.

 

[Lee]

Well done Lee and co ( Gaz , Trev and Paul)

Another Zedshed HQ triumph.

Another set of tank straps fitted. We’ve already started another Zed.

 

[t-tony]

Quality job that Lee, well done to all! On the subject of brake sensors I’ve had that before so now when I fit them I lubricate the rubber internal seal and not had one problem since doing that.

Tony.

 

[mrscalex]

I’ve had a persistent issue with a pad wear sensor. Replaced both still there. Had to do what I thought was an old wives tale and turn ignition on, hold brake pedal, turn off, turn on. Actually worked and only thing that would.

 

[Lee]

I’ve had a persistent issue with a pad wear sensor. Replaced both still there. Had to do what I thought was an old wives tale and turn ignition on, hold brake pedal, turn off, turn on. Actually worked and only thing that would.

I’ll bare that in mind. Never tried that before.

 

[colb]

Great job bet Dave had a smile on his face

 

[Mint]

Another superb refresh. You're getting good at this now

 

[g8jka]

Awesome work as usual and what a great turn out of zeds

 

[Mazza]

Hopefully when your new garage is built there will be similar weekends