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The R&D Department

Bogdan M.

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Bucharest, Romania
Best thing to do is to remove the fan, then the belt and turn each pulley by hand. The engine should be off.
It must be a bad bearing from one of the pulleys.
Great garage BTW!
 
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Worsedog

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While it's a bit late for this plug change, a locking extension is the answer to the plug socket dilemma.
 
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kensbey

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Location
Brisbane
Best thing to do is to remove the fan, then the belt and turn each pulley by hand. The engine should be off.
It must be a bad bearing from one of the pulleys.
Great garage BTW!

Thanks! I'm going to give this another try next weekend.

While it's a bit late for this plug change, a locking extension is the answer to the plug socket dilemma.

I just googled these, and you are indeed correct! Blast... missed opportunity to buy a new tool :p
 
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kensbey

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Thanks everybody for suggestions/help. Turned out to be the bearing in the pulley on the tensioner. New one on the way.
 
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kensbey

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A few months ago we bought a new injection moulding machine at work. Its a bit of a monster, about 5mx2m and weighing about 5 tonne. Anyway, it came delivered on the biggest shipping pallet I have ever seen. The base of the pallet was these 4 huge Pine sleepers, cross section roughly 240x50mm and almost 5m in length. When the pallet was being broken down I snapped those up and have had them sitting at home waiting. you can sort of see them off to the right side in the last photo. Should make a pretty nice bench top once I join them and sand it a bit. Not sure about finishing, I'm not super experienced with wood working. Maybe just an oiled finish will work? Otherwise some varnish or that liquid glass epoxy might look good. We'll see.
 

snapsimo

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Tongue Oil works well mate. Easy to apply and it is a great finish, nice and hard. Good thing is if you scratch the bench, just wipe on a bit more and your done. My floors in the house are done with it and it's great.
Love your floors. We got the quote and just need to sort out a few windows in the back of the shed before we get Rob in to do it. Can't wait.


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kensbey

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Finally got some time to make a start on the benchtops.

The timber is 240mm wide, so three widths together makes a 720mm deep bench.

Drilled each piece for dowels:
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Marked and cut reliefs for bench joiners.
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Glued everything, clamped together and then held in place with the bench joiners.
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Obligatory shop dog photo. He knows he's not supposed to be in the shed, but tries to get away with having one paw out the door.
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more to come once its dry and i can start finishing it.
 
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kensbey

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kensbey fantastic work on the bench top...

I haven't used those joiners before but they look the goods.

Regards

They are designed for joining laminated benchtops in kitchens for corners etc. I really have no idea how well they will work here, but it seems like they should work. I guess we will see :)
 

Terrick down Under

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K, "but it seems like they should work. I guess we will see ", please keep us non wood people posted, I am always looking for a way to work with stuff that doesn't end up in the fire.
 
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kensbey

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Hey Snapsimo,

This weekend was pretty full, got to take the e36 out to a light session at the track with a local BMW club. She held up pretty well!

I put a sealer coat of varnish on the bottom side of the benchtop quickly, but nothing very exciting so no photo. Next weekend I will turn it over and finish the top side. More updates then.

Thanks for keeping me active haha,

kensbey.
 
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kensbey

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So yesterday was brake day for the E36.

Get car in the air: check :thumbup:
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Calipers and discs come off: Check :thumbup:
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Shiny new disc on: Check :thumbup:
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Destroy caliper bolt trying to refit caliper: Check :( GRrrrrrr :headscrat
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whoooops :mad:
This was a combination of 20 year old bolts and my inability to read the correct toque spec :lol_hitti

The front caliper bolts are M12 and get torqued to 110Nm. The rears are M10 and only get 65Nm. Of course in my haste I read the front spec when doing the rears...

It gets better. These are M10x26.5mm, I kid you not....26.5mm long :wtf: because using a standard size bolt would be too hard. I love bimmers, but gee they don't make it easy sometimes. The stealerships aren't open on sunday, and the guy at the bolt place laughed at me when i asked if he had some 26.5 mm long m10 bolts. So it looks like I'm not getting these back together until until Monday. Hoping like hell one of the local dealers has these in stock.

Guess I will hit up some other maintenance tasks while it's up in the air.

kensbey
 
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kensbey

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Thanks cup,

It shouldn't be too bad. The BM parts network is amazingly efficient. My car is almost 20 years old and it's rare that I can't get a part on the spot or next day up from Sydney. They put a lot of effort into maintaining parts supply for older models. One of the advantages of selling basically the same models worldwide I guess.

Everything is a lot cheaper from the states, but it's good to know you can get it locally when time is critical.

Kensbey

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kensbey

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Brisbane
Hey All!

My apologies for being so slack on updates lately. Here is the progress to date on the R&D Department.

My current toolbox was getting pretty full, and was not large enough to fit the 750mm breaker bar I recently purchased.... Upgrade time :bounce:
View media item 72764
Back to the workbenches progress: I got the top for the electronics bench onto the frame and hit it with a couple of passes from the belt sander.
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One of my mates is a real wizard at woodwork, and he came over one Saturday with a fancy wood plane and we got the top nice and flat.
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I have since given it two coats of varnish, and its starting to come up nice. I think it needs a light sand and then one more coat to finish it.
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You can see the start of the PC bench in the back of this photo. It has been painted but no top yet.
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I also scored some metal stationary cupboards on gumtree (Aussie 2nd hand website).
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Gave them a quick sand and a couple of quick coats of black gloss spray paint. The finish isn't perfect, but I didn't want to spend days and days on it. Even found some red paint for the handles that is a reasonable match for the red on the new tool chest. Overall I am pretty happy with how they've come out.
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That's it for the moment! Thanks
 
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chrisBTSC

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Jan 13, 2015
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Folsom, CA
I like the idea of using Ikea cabinets in the garage. Their online planner works really well and their prices are very good for what you get. I used the same in my garage and they have worked perfectly. I did end up gluing all of mine for extra strength and so far they have held up really well.
 
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kensbey

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kensby, top marks all round, the top looks a treat..

Thanks Cup! I am super excited with how well it's worked given I have almost no woodworking history and its made out of an old shipping crate lol. I guess that's a testament to how much free information there is available online these days!

Great build kensbey, nice idea with the HMR particleboard walls.

Would love to get a shed that size, well done.

GB

Ta! I have just started reading your build, you have done some amazing things with limited space! Think i'm going to steal some of your storage ideas!

I like the idea of using Ikea cabinets in the garage. Their online planner works really well and their prices are very good for what you get. I used the same in my garage and they have worked perfectly. I did end up gluing all of mine for extra strength and so far they have held up really well.

Yeah their online planner is an amazing tool! We wanted the garage/laundry area to be a little bit nice so it was usable space for activities etc, so the Ikea cabinets really lift it.

Gluing is a good idea. We had some issues getting everything aligned because the exposed brick walls weren't dead straight. This made me hesitant to glue anything in case it had to come apart for adjustment.
 

bdbecker

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Nov 18, 2015
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Iowa
Nice progress and a good find on those cabinets! Have you considered putting a wood top on them (like you made for your new bench) and use them as additional bench space?

Also, concerning that caliper bolt - if you ever run into that issue again, its not a big chore to shorten a bolt, all you need is a hacksaw, a file, and a couple of nuts. First, you thread two nuts onto the bolt. Then you unthread the outside nut to the desired length, and use the inside nut as a jam nut to hold it in place. Double check your measurement before cutting. Then, put the assembly into a vise and cut it to length using the hacksaw, using the outside nut as a guide. Next, use a file to flatten the face of the bolt so that it is flush with the face of the outside nut. Then, unthread both nuts from the bolt - when you unthread the nuts, you will actually fix any damaged threads. Use the file to add a chamfer if needed. Finally, thread the nut back on/off to make sure there are no damaged threads.

Even though I have an angle grinder, I still usually use the hacksaw and file more often than not. On small bolts, it takes about the same amount of time to just cut and file it as it would to drag out the grinder, switch wheels, find my face shield, etc. On larger bolts, I've found that they usually get too hot to handle and you end up having to wait around for them to cool before you can assemble, so the job ends up taking just as long either way.
 
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kensbey

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Nice progress and a good find on those cabinets! Have you considered putting a wood top on them (like you made for your new bench) and use them as additional bench space?

Yes! this was the original plan. I'm not sure about timber though, they will have lots of grease and oil covered parts put on them while i'm working on the car. Perhaps a folded sheet aluminium top? However, I do need to get the car in again and check it will leave enough room in front of the car to work on it. If not the cupboards will get split up in other positions.

Also, concerning that caliper bolt - if you ever run into that issue again, its not a big chore to shorten a bolt, all you need is a hacksaw, a file, and a couple of nuts. First, you thread two nuts onto the bolt. Then you unthread the outside nut to the desired length, and use the inside nut as a jam nut to hold it in place. Double check your measurement before cutting. Then, put the assembly into a vise and cut it to length using the hacksaw, using the outside nut as a guide. Next, use a file to flatten the face of the bolt so that it is flush with the face of the outside nut. Then, unthread both nuts from the bolt - when you unthread the nuts, you will actually fix any damaged threads. Use the file to add a chamfer if needed. Finally, thread the nut back on/off to make sure there are no damaged threads.

Even though I have an angle grinder, I still usually use the hacksaw and file more often than not. On small bolts, it takes about the same amount of time to just cut and file it as it would to drag out the grinder, switch wheels, find my face shield, etc. On larger bolts, I've found that they usually get too hot to handle and you end up having to wait around for them to cool before you can assemble, so the job ends up taking just as long either way.

This (or something similar) was going to be my plan B. The only thing is that the factory bolts have large round heads, I assume to distribute load onto the caliper holder evenly. Not sure if normal hex head bolts would be an adequate replacement.
 

bdbecker

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Yes! this was the original plan. I'm not sure about timber though, they will have lots of grease and oil covered parts put on them while i'm working on the car. Perhaps a folded sheet aluminium top?...

Aluminum will scratch pretty easily, but if you don't care so much about how they look, then I would think that would be a pretty effective option. One thing that might be pertinent to this discussion... I've been keeping an eye out for a heavy rubber doormat so I can contain the mess on my workbench when I have to work with oily/greasy stuff, something like this:

http://www.americanfloormats.com/scraper-rubber-mats/

The thought being that I could catch and contain the mess while working, and then when I'm done, dump some floor dry on the mat for easy clean up. The only mats I've been able to find locally have too tight of a pattern for the floor dry, so I'll probably end up just ordering that one from the link eventually. Maybe there is an Australian-floormats website for your side of the world!
 
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kensbey

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Quick update today:

I had a lot of odd jobs to do around the place today, so while I was doing them I had the little CNC router make me some labels for my electrical work. I decided I should label out which circuits are where while it's all fresh in my mind. Otherwise I'd most definitely forget in a year or two.

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Last coat of varnish on the electronics bench is dry:
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Moved into final position:
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Now I just need to build the drawers for it.
 
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kensbey

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I had a bit of free time today so I undertook a task that I've been putting off for weeks: sorting out my fastener drawer. While I was moving everything into the shed, all my fasteners just got thrown into one of the massive 900mm rack-it drawers. I forgot to take a before photo, so just imagine everything in the photos below in a big pile. I literally had to wade to find the screws I needed.

I spread everything out on the new benchtop and starting sorting into plastic containers.

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And the finished product:

View media item 72744
Not super exciting, I know, but it had to be done.
 
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kensbey

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You won't know yourself now after that, massive time saver.

GB.

That's the plan! I was sick and tired of it taking 5 minutes to find the screw I needed. Thanks GB.

Nice work kensbey, bench looks great!

Thanks Matty! I've seen the woodworking projects in your thread, so I take this as a big compliment! :D
 
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kensbey

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Just had a quick look at your CNC thread. Are you happy with the HM-46 still?

I'd love to get a small mill, although I've nowhere to put it :confused:

GB
Yeah it's great. That said it has been sitting in the rumpus room for the past year while the shed was getting sorted. When I had it running at the old place I was more than happy with it. It's a good size for most jobs and I was taking decent cuts in aluminium manually. I am confident it will be a very capable machine once I get around to finishing the CNC conversion.

From what I've seen you would have to spend twice as much to improve on it much. I have missed it alot since it's been packed away. It's amazing how many little jobs it makes easier.

Being a benchtop machine it doesn't need to take up heaps of space. There are a fair few guys on CNC zone who have built clever enclosures to fit them into standard 2 car garages. Of course they have to back the cars out to use them, but it is doable.

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kensbey

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I work on all kinds of high performance vehicles in the shed:

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:lol_hitti

The one issue I had with the new tool chest is that it has two spinning caster wheels and two fixed ones. There is a couple of spots I wanted to be able to put it that required it to slide straight in backwards, which you can't do with two fixed wheels. The store I got it from was kind enough to get me in two extra spinning casters so I could have 4 fully rotating wheels. I didn't feel like fully emptying all the drawers to swap the wheels, so I channeled my inner mechanic and got the trolley jack under it. Wheels chocks and all (safety first :p).


It's much better now with all spinny wheels.
 
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