bolt lock tabs and zerk for steering intermediate shaft

The boots had deteriorated on our GMC's intermediate shaft. The bolt lock tabs didn't live through the disassembly so new ones got made. Good use for a abandoned realtor sign. Put in a zerk too.

Tree 2UVR-C rapid

.750 HSS 4 flute end mill, mild steel, 300 rpm, 100% + doc, .060 step over, 2.4 ipm. Rapid feed over runs a ratchet clutch. Interesting sound I think.

spare hydroboost with matching input rod

Making a spare hydroboost with a matching input rod. Cut and threaded the rod to make a matching length booster to eye dimension. Eye was made out of cold rolled round steel.

Slug matches drilled hole angle and fits in the bottom of the hole that's not threaded. Load is on slug and not threads this way.

                         machining the slug

Rotor spacers

Bought a 6061 aluminium drop from Ebay approximately 7" diameter and 2.7 thick to make rotor spacers out of. It was band sawed on both ends and was turned with two eccentric diameters. Nothing was square. It was $27 shipped so a great price. The plan was to chuck it as best as possible, bore and face one end and then have something to base the rest on.

                                          Deep parting

                                          Done and chip pile

                               Ready for bolt holes

Lambke style caliper mounts

   Universal plates from Manny's Transmission to make fit D52 GM calipers and Lambke style forked mounts.

                   Measuring hole location on knuckle

Making a two axis fixture plate to run in the lathe

                                                    Making ears

   Bevelled for penetration, not a lot of clearance for the threaded hole that's not there yet

                                  Slotting two at a time

                    Making a drilling jig

                        Alignment bar bolted on

                                    Drilling for caliper pins

                                     Tapping caliper pin holes

         75 MM caliper test fit, Is GMC TZE original front

                  1976 Eldorado park brake caliper test fit.

                               80MM caliper test fit

                   80MM caliper on front knuckle, kinda hangs out haha

Harbor Freight press plate fail

I had read that Harbor Freight press plates might snap and they did.

Cast iron fails without notice.

 Priority mail flat rate box with 70 lbs of new press plates from Swag Offroad
link: http://www.swagoffroad.com/

8 1/2" x 10" X 1 1/2" thick steel, no more snapping cast iron.

Ready to go again. It only took two days from ordering to arrival.

Sleeving brake calipers

Saving a couple brake calipers by sleeving.

Inside the smaller bore is pitting where an oring is supposed to seal.

The flattest most square place to hold the caliper is the spot where the outer brake pad fits. Used a 2 inch square bar with a couple tapped holes to hold the caliper to the bar and have a solid mount to use on the mill.

Shims to get it square and concentric for boring.

Boring

Sleeves made from a scrap stainless pump shaft

Sleeves have flange to hold them. Brake pressure is on the flange end.

pressure side of the sleeve. I used Loctite 620 and a press fit .0015"

Touch-plate relay fix

Sue's Touch-Plate lighting system had a relay that wouldn't switch. Took it apart lubed the step wheel , shaft and ratchet with graphite and now it switches again. These things get cooked in the attic. This relay is a 1550B, no longer available and has been replaced by a touch-plate 3000 relay.

These have a 28 volt dc coil and are supposed to change state every time they get a pulse. This one just thumped and had quit turning off and on,

Relay bank in the attic

 disassembled and lubed with powdered graphite.

 Bench test using a 20 volt laptop power brick. Relays are 28 volt so if 20 does it 28 should too.

testing, now it works

 New style 3000 relay in the middle of the image, It is wider and has screw terminals.