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ZMotorsports Shop Projects 2.0

Bob Heine

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Oct 24, 2009
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Boca Raton, Florida
Thanks Jay. I'm not sure how many people want to see vacation photos compared to shop or project photos so I appreciate the comments.
Mike, having traveled across the US a few times as a pre-teen, your crystal clear photos of those places brings back wonderful memories. It was 1956 and I remember leaving Jackson Hole and driving along through rolling hills with nothing much to see. All of a sudden the Tetons appear and it's a sight that never leaves you. Once you know it's coming, it might not be as amazing. I remember leaving days later, after hiking the Paintbrush Canyon trail and not taking my eyes off the mountains until we drove out of sight. I, for one love seeing your vacation adventures. Don't stop on my account.
 
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zmotorsports

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Northern Utah
Mike, having traveled across the US a few times as a pre-teen, your crystal clear photos of those places brings back wonderful memories. It was 1956 and I remember leaving Jackson Hole and driving along through rolling hills with nothing much to see. All of a sudden the Tetons appear and it's a sight that never leaves you. Once you know it's coming, it might not be as amazing. I remember leaving days later, after hiking the Paintbrush Canyon trail and not taking my eyes off the mountains until we drove out of sight. I, for one love seeing your vacation adventures. Don't stop on my account.

Thanks Bob. My wife and I comment many times about how fortunate we are to live where we do that many of these places are literally in our back yard. We have friends who live back east and a trip to places like Moab, Yellowstone NP, Teton NP, Zion NP, Bryce NP or Capitol Reef are once in a lifetime trips yet to us we visit most all of them every other year or so. We are so blessed to live so close to so many of these beautiful places and get to frequent them often.
 
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zmotorsports

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We have a few items to address on my son's Jeep WJ so last night after work he stopped by so we could begin.

He had a list of things so we started with the most critical and will continue to work our way to the minor issues. There's not too awful many things but with the last few months of me being incapacitated they have added up a bit.

WJ pulled into the lift and prepped for work by adding fender covers.
wj1.jpg

He just washed it over the weekend and then as he was driving over to the shop from work yesterday we got a few drops of rain, just enough to add water spots. He wasn't pleased.
wj2.jpg

View of our Jeeps in the shop. I had just finished giving our JKUR a good detailing after last week's trip. It was filthy inside and out.
wj3.jpg

Started by addressing his A/C issue. He noted that late last year the A/C was blowing less and less cool air so with temps being in the triple digits now we thought we throw the gauges on it and see what's what. Looks like he was a bit low. For an 18 year old vehicle I guess it may need a little. Couldn't really see any obvious leaks but the compressor engages so it has some refrigerant in it.
wj4.jpg

Ended up adding about 10 oz. to get the system blowing 44-degrees on a 95 degree day. Pressures all looked good.
wj5.jpg


I told him to drive it for a day or two then we'll throw the gauges back on it and verify. He text me later last night after he and my DIL went for a drive and told me it was working fantastic and my DIL was pleased with the results.
 

gearhead1960

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Mar 21, 2019
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Manassas, VA, a small blot in history
Mike,

If nothing else, seeing the places you go and the scenery just adds to my bucket list of places to see. Your location allows you to see a lot of areas I'm not close to, but on the other hand, being on the East Coast near our Nations Capitol, I take advantage of seeing many things from the National Air and Space Museum to Shenandoah National Park to name a few. I guess it's all relative.....
 
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zmotorsports

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Northern Utah
Thanks for the comments guys. I'm happy to see the photos of various trips are enjoyed. My wife and I are so blessed to live where we do and more importantly to be able to enjoy the life we do after all these years of working our asses off. The fruits of our labors are coming to fruition and we are so enjoying this chapter of our life.

Sorry Jimmy, we have no desire for entertaining any adoptions at this time. :ROFLMAO:
 
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zmotorsports

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Last night we continued working on my son's WJ addressing a couple minor items on his punch list.

One item was to tighten the tie rod ends (Teraflex) on his tie rod and drag link so while I was working on adjusting those my son removed his rear sway bar links in order to replace the rod ends which had developed some play. I had ordered some new FK rod ends several months ago to replace the worn ones so I already had them ready to go. However, the original links that my son used from Evolution Off-Road used a stud style rod end and I ordered the through bolt style, so this required machining a couple of spacers to keep them in proper vertical alignment.

I was able to try out my new Edge work stop for my 5C collets. The body threads into the rear of the collet.
lathe1.jpg

Then the proper diameter plunger is inserted and set to the correct depth in which the part is pushed in until contact is made.
lathe2.jpg

Spacers can be easily duplicated when multiples are being machined.
lathe3.jpg

Sorry, I didn't get a picture of all four spacers completed nor installed but making multiple parts to the same length are more easily achieved with a work stop in your collet. All four spacers were cut slightly over length with the bandsaw and drilled to .5" diameter ID before inserting the work stop. After installing the work stop the parts were faced on one side then flipped around and faced to exactly .500" in length.

Thanks for looking.
 
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zmotorsports

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Hmm I was wondering how to chuck little parts like that.

Oh boy those adapters are NOT cheap.

Justin, if you are referring to the 5C collets themselves, you are correct, they are not cheap. Smaller (less pieces) sets can be obtained at a reasonable price but will come in the larger nominal incremental sizes, such as 1/16" or 1/8" increments. I was able to purchase this used but excellent condition set of Hardinge 5C collets for a fraction of the cost so I benefited greatly by purchasing used. This set consists of 72-pieces in 1/64" increments so I have excellent diversity of sizes to choose from. For small parts I much prefer to use collets vs. a 3 or even 6-jaw chuck.

As for the collet stop, the Edge Products version was only $29.99 plus I had a coupon code a while back for 10% off and by incorporating it into a larger order I got free shipping so it was relatively inexpensive but I've wanted one for a while and treated myself. This was actually only the first time I was able to use it. I put it on my want list last year when I had a run of 16 bronze bushings to machine for a gentleman.
 
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zmotorsports

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Northern Utah

Sorry, I didn't know you meant the collet chuck. Yeah, they're not cheap either, but mine is an import so not too terribly priced. I like the fact that it is a set-tru design and can be aligned perfectly with the base plate. Some of the less expensive collet chucks don't have that ability.

Since purchasing the collet chuck and the used set of Hardinge 5C collets several years ago, I find myself using collets exclusively for holding material 1" and under. The collets hold the work so much more true and the work can be removed/inserted back into the chuck repeatedly without any fear of concentricity issues.

I highly recommend getting a collet setup Justin. It will change your world. ;)
 
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zmotorsports

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After looking at this today.. I'd probably spring for the Bison from Ajax Tool. The imports are all over ebay and amazon.

This is an import from Matt @ Precision Mathews. He usually does a very good job of researching and sourcing before he sells anything so I would trust one of these from him.

As for mine, the import I purchased is a Lathemaster and it has been a very good chuck. Very smooth scroll engagement and easily dialed in having the set tru adjustability.
 
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zmotorsports

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Northern Utah
Those that follow my thread regularly probably remember several months ago when my old Snap-on bronze dead blow hammer came apart while I was rebuilding a rear end. My Snap-on rep said he would warranty it and ordered a replacement.

It has been on backorder ever since so there's been a disturbance in the toolbox. :lol: Last night I received a text from him saying that my hammer had arrived in his stock order so this morning he swapped it out for me.
hammer1.jpg

hammer2.jpg

I know I'm a bit weird when it comes to tools, at least that's what my wife and DIL tell me, but it was kind of a bittersweet moment when I handed him the old hammer and he handed me the new one. The new hammer is nice and has the newly designed handle but there was so much history in the old hammer, it just doesn't "feel" right. I feel that over time tools, as well as vehicles, can take on their own personality and are more of an extension of the owner. This bronze dead blow hammer was one of the first, if not the first, Snap-on tool I ever purchased when I started my career as an Industrial Maintenance Mechanic nearly 35-years ago.

When I was joking with my Snap-on rep I told him I didn't know if I had another 35-years left in me to train the new hammer.:unsure:
 

OutlawDrifter

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Jan 20, 2015
Messages
3,876
Location
KS
That's a lot of history with the hammer, Mike.

I totally understand. I've got a really nice set of screw drivers, but 8/10 times I'll grab the ones (there are two, slotted & philips) from my tool set I bought when I went to college.
 

PugetDude

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Mar 13, 2013
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22,398
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Superstition Mountains, AZ
The most aggravating thing about helping her was she couldn't get herself off her phone the entire time I was helping her. In addition, she didn't even care enough to offer me thanks or compensation (buy you a beer) or anything. Not that I was looking for any compensation, but a little appreciation would have been nice....
Bang her wife? :oops:
 

Bears Fan

Well-known member
Joined
Jan 26, 2012
Messages
3,438
Location
Indiana
Mike, I feel your pain on letting go of old tools, recently I sold off a Craftsman toolbox and a bunch of Craftsman tools that I purchased when starting out as a tool and die maker 37years ago, the stuff still looked new. I down sized eliminating double sets of everything and replaced some other stuff with Milwaukee, I'm real happy now, but boy was it hard to load up that toolbox and all those tools in the new owners truck and watch him drive away :cry:
 

Scuderia-F1

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Joined
Feb 9, 2011
Messages
1,198
Location
Stockholm, Sweden
Those that follow my thread regularly probably remember several months ago when my old Snap-on bronze dead blow hammer came apart while I was rebuilding a rear end. My Snap-on rep said he would warranty it and ordered a replacement.

It has been on backorder ever since so there's been a disturbance in the toolbox. :lol: Last night I received a text from him saying that my hammer had arrived in his stock order so this morning he swapped it out for me.
hammer1.jpg

hammer2.jpg

I know I'm a bit weird when it comes to tools, at least that's what my wife and DIL tell me, but it was kind of a bittersweet moment when I handed him the old hammer and he handed me the new one. The new hammer is nice and has the newly designed handle but there was so much history in the old hammer, it just doesn't "feel" right. I feel that over time tools, as well as vehicles, can take on their own personality and are more of an extension of the owner. This bronze dead blow hammer was one of the first, if not the first, Snap-on tool I ever purchased when I started my career as an Industrial Maintenance Mechanic nearly 35-years ago.

When I was joking with my Snap-on rep I told him I didn't know if I had another 35-years left in me to train the new hammer.:unsure:
I can totally relate, sometimes I even chose to keep my old Snap-on tool & pay for the replacement. 🤷🏻‍♂️
 
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zmotorsports

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Oct 20, 2009
Messages
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Northern Utah
I had a couple of items to address on my 2006 Duramax on Saturday so I figured I get out in the shop early seeing as how it has been in the triple digits here in northern Utah.

Several months ago I replaced the stepper motor in the gauge cluster for the volt meter but within about two weeks the small light bulb for the temperature gauge went out. It is not a difficult or time consuming task but I finally made some time Saturday morning to replace it.
gm1.jpg

Old bulb de-soldered and the new one soldered in place.
gm2.jpg

Ready to reassemble the gauge cluster.
gm3.jpg

Cluster reinstalled and key turned on to test before replacing the dash bezel/trim.
gm4.jpg

Next item to address on the Duramax was a sensor issue. About 7 or 8 months ago I got an intermittent P2563 DTC for a turbo pressure sensor. Seeing as how these sensors are not inexpensive, I opted to remove it, clean it and reinstall to see if that was the issue. I wasn't getting the P003A code nor limp mode that sometimes accompanies the P2563 so I figured it was just the sensor and not the turbo veins getting coked or carboned up. It has been fine for the past several months but then about 2 weeks ago I got the P2563 code again so I purchased a new sensor and had it on the bench awaiting time to replace it. I took a few minutes to replace it as well on Saturday morning.

The sensor is easily located on the turbo housing just under the resonator cover.
gm5.jpg

Follow the wiring and it runs down under a couple of the bail connectors to a connector mounted just under the upper coolant hose.
gm6.jpg

The wiring is run under and through the mounting brackets for the bail connectors and I have seen some merely cut the wiring and remove the sensor connector on one end and the sensor itself on the other but I prefer to remove them intact so a few extra minutes of removing a couple of connectors and the wiring is exposed.
gm7.jpg

Lastly, using a 1" wrench or socket with a groove cut in it, remove the sensor from the turbo housing.
gm8.jpg

I chose to use and OEM part for this repair.
gm9.jpg

GM part #.
gm10.jpg


More pictures to follow of the repair.
 
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zmotorsports

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Continuing on with the sensor replacement.


Old sensor assembly removed and compared to the new. Sorry for the blurry picture.
gm11.jpg

The original sensor had heat tape applied to the sensor to help protect it from the turbo heat. I have not had good results removing and reusing this heat tape so I have used some thicker heat wrap with great results.
gm12.jpg

New sensor wiring routed in the same manner as the OEM.
gm13.jpg

I used some .041" stainless steel safety wire around the heat wrap to keep it tight and a little extra insurance that it will stay put.
gm14.jpg

Safety wire tied to keep the heat wrap in place.
gm15.jpg

Repair completed and a couple of zip-ties to keep the wiring from chafing on anything.
gm16.jpg

Resonator housing reinstalled and everything put back together.
gm17.jpg

Before moving on to the next item on the list for the day I sprayed a bit of Tri-Flow on the pivot points of my Amp Research power steps. I try to treat them a couple times a year after a good wash job to prevent wear and worse, squeaks.
gm18.jpg


More to follow of some not so pleasant items to address......
 
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zmotorsports

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Moving on to the next item on the list and this one actually pissed me off more than anything. I've been driving my truck a bit more than normal lately and when I went to lunch last week with a friend, I came out and some ******* was parked so close to me that I had to crawl into the front seat from the passenger's side. I generally park well out away from other people when parking as the truck is a bit larger than the Jeep and not as maneuverable in tight parking lots so the fact that when I was walking towards my truck and I see someone parked right next to it and so freakin' close I was already upset as I approached my truck.

Well upon getting back to work and walking around the truck I found a nice scrape on the bedside right around where this assholes driver's door would have been. Then doing a little more walking around the truck and removing a couple specs of road tar with wax & grease remover I noticed two additional scrapes from other people's doors.

This one is just behind the fuel fill door about mid-way between the left rear fender flare and the fuel door.
gm20.jpg

I then found another on the passenger's side rear door.
gm21.jpg

This one on the driver's front fender flare was the worst one. This one appears that the person opened their door hard enough to put a straight line on the flexible fender flare and actually crack the paint. This was about a 2+ inch vertical line from a door edge.
gm22.jpg

This one was actually me. I was pressure washing the truck a few months back and the overhead hose brushed across the bedside resulting in a small scrape right above the left rear tail light on the left bed rail.
gm23.jpg

For small touch up areas I did find that the small Milwaukee M12 polisher works fantastic. For a bit larger touch up areas the Milwaukee Fuel M18 standard polisher also works well. After doing a thorough walk-around the truck to confirm there were no other blemishes to deal with, I started to polish out the scrapes.
gm24.jpg

This is the passenger's side rear door after polishing out the door scrape.
gm25.jpg

Here is the finished area from the one I put in it.
gm26.jpg

This is the left bedside blemish removed and polished out.
gm27.jpg

Truck wiped down and ready for service again.
gm28.jpg


Luckily none of the door scrapes resulted in any dings or depressions in the body panels, they were just in the outermost layer of clear coat on the paint.

I am still upset over the fact that people just don't seem to give a **** about anyone else's property these days. Hell, most don't respect their own stuff let alone someone else's. People piss me off lately and it is becoming harder to keep things nice with all of the assholes out there working against you. Although our truck is now nearly 17 years old and just turned over 112k miles, I still love it and don't see myself with anything else but it's getting harder and harder to keep things nice these days.
 

Mark_17

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Jun 27, 2018
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746
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NJ
Glad you were able to fix those paint blemishes so easily.

Living in NJ, I totally understand where you are coming from. People here can be animals and treat their very expensive cars with out any cares.
 

4 FN 27

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Minnesnowta
I am still upset over the fact that people just don't seem to give a **** about anyone else's property these days. Hell, most don't respect their own stuff let alone someone else's. People piss me off lately and it is becoming harder to keep things nice with all of the assholes out there working against you. Although our truck is now nearly 17 years old and just turned over 112k miles, I still love it and don't see myself with anything else but it's getting harder and harder to keep things nice these days.

This is why I park in the middle of nowhere if at all possible. We have assigned parking here just so I know who is parked next to me. I have the farthest spot from the door. Less traffic in that corner.

Good it all came out with out having to paint.
 
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zmotorsports

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This is why I park in the middle of nowhere if at all possible. We have assigned parking here just so I know who is parked next to me. I have the farthest spot from the door. Less traffic in that corner.

Good it all came out with out having to paint.

Thanks Pat. That's why I was so pissed, because I parked out at the far side of the lot in an end spot next to a curb and slightly under a tree for shade. No one was around me when I parked. The ******* parked so close in spot #2 from the curb that I couldn't get in on the driver's side and had to crawl in from the passenger's side. I must really be maturing because 20 years ago I would have caved his door in with my knee to send a message.

Glad you were able to fix those paint blemishes so easily.

Living in NJ, I totally understand where you are coming from. People here can be animals and treat their very expensive cars with out any cares.

Thank you.
 

Jarhead0408

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Apr 1, 2012
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Who knows?
I wouldn’t be surprised if if he parked near you on purpose because that shady spot is where he parks everyday. You “stole” his spot, so he decided to be vindictive.
 

Dodge

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Feb 8, 2008
Messages
557
Location
Illinois
I too am very careful where I park in parking lots. Not afraid to walk farther!! I have a friend that always has a new vehicle and takes very good care of it, but will park anywhere in the lot. Never gets door dings or scratches??? I know I wouldn't be so lucky!
 

SilverJimmy

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Joined
Apr 14, 2012
Messages
1,631
Location
Prescott/Flagstaff, AZ
Watched an old lady “bump” a shopping cart out of the parking spot she coveted. Before I could run and stop it it slammed into the side of a new truck, still had the temporary paper plate on it. Nice door dent! When I yelled at the lady, she just gave me the stink eye. So did her worthless 20 something spore….
 
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zmotorsports

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Watched an old lady “bump” a shopping cart out of the parking spot she coveted. Before I could run and stop it it slammed into the side of a new truck, still had the temporary paper plate on it. Nice door dent! When I yelled at the lady, she just gave me the stink eye. So did her worthless 20 something spore….

Yep, sounds like they're perpetuating the cycle of disrespectful drains on society.
 

Finallygotit

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Tucson, AZ
I swear, why is it that these entitled asshats have no respect for other people and their property?? Is it the disposable mindset? Never mind, sorry I don't want to derail your thread.

Mike, like you I have to get out the polishing compound every now and again to fix others fu-bar's. 🤬

:beer:
 

4 FN 27

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I must really be maturing because 20 years ago I would have caved his door in with my knee to send a message.

When I first read your post I was drawn back to my "crazy days"...knee??? I used a Framing Hammer, the Claw end. The paint on the ol'1976 1/2 ton wasn't even dry yet when that happened to me in a parking lot. Oh I could get in on my side and their passenger could get out but not without creasing the new Door Skin and Chrome Strip I had just spent my hard earned money on.

There were empty spots...highlight on spots to park in all directions...
 

gorilla

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Dec 13, 2007
Messages
1,652
Some clown parked hid Suburban so close to my car that I had to crawl in from the passenger side. Not so easy in a C-4 Corvette. I did no physical damage to his car but I did steal all 4 of his tire's valve cores.
 
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