Zen and the Art of DIY Car Maintenance #03 …

There’s a stand out section for me in the book Zen and the Art of Motorcycle Maintenance, and it is the part where the author describes making, or proposing to make makeshift ‘shims’ for his friends John and Sylvia Sutherland’s new and exclusively dealer serviced BMW motorcycle. Pirsig tries to explain how shims made from a discarded Coca-Cola can would be perfectly adequate and functionally identical to those fitted by the BMW Dealer’s mechanics at exorbitant costs. John Sutherland could not see this or be convinced, so programmed was he that only the main dealer has the expertise, equipment and materials to carry out such a task.

“In the book, the narrator describes the “romantic” approach to life of his friend, John Sutherland, who chooses not to learn how to maintain his expensive new motorcycle. John simply hopes for the best with his bike, and when problems do occur he often becomes frustrated and is forced to rely on professional mechanics to repair it. In contrast, the “classical” narrator has an older motorcycle which he is usually able to diagnose and repair himself through the use of rational problem-solving skills.”

So, what has this got to do with the 3 old cars in my family you may ask? A short time ago I wrote about the dreaded ‘Engine Fault’ light, cheap DIY diagnostic tools and repairing the EGR Valve. In that post I discovered and pointed out a missing ‘gasket’, missing for several years it turns out, omitted by accident or through lack of care by a ‘reputable’ local garage of self proclaimed ‘Motor Engineers’. At the time, needing the car back on the road and concluding that one more week running minus the gasket while I source a replacement can’t do that much harm, I re-assembled, tested and had the car back on the road.

At the end of that previous post I even screen shot an image of the replacement gasket I’d found and ordered for what I considered quite a hefty price of £9.99! Anyway, gasket arrived but car was busy until this last Sunday when both car was available and weather favourable (yes I’m a wimp and have to work outside) for fitment, 1/2 hour, maybe one hour max? – Wrong! See below;

Spot the problem?
Gasket is the right material, thickness and most importantly – the centre hole diameter is correct. The problem is the pitch of the 2 outside holes which the clamping bolts pass through. In fact this gasket is correct for the other end of the connecting manifold, I ordered wrong, my bad!
I set about improvising a clamping arrangement to locate the gasket in the correct position so that I could use the clear bolt hole as a makeshift ‘jig’ and re-drill the clamping hole.
The gasket is in fact steel with some sort of sealing/fibre coating. Here it is after successfully re-drilling and re-positioning the first bolt clearance hole, 8.5mm diameter.
Using the first re-drilled hole I clamped the gasket to the manifold pipe so as to locate it correctly for the 2nd drilling operation …
… Using my trusty G-Clamp, a work mate bench, scrap wood and battery drill I proceeded to re-drill the 2nd bolt hole, again using the manifold pipe itself as a makeshift ‘jig’.
So here is the successfully modified gasket with bolt clearance holes now at the correct pitch. Not pretty but fully functional. I was hoping to be able to leave it in this form when re-fitting as the excess ‘ears’ would have been useful to hold the gasket in place while positioning the manifold and inserting the clamping bolts – but alas there was insufficient clearance so it was back to the tool shed for another modification …
… Out with the tin snips and OFF with those excess ‘ears’!
And here it is back in place, clamped, but most importantly ‘functional’.

When I was ‘on my tools’ in Heavy Engineering working as a Millwright, we used to say “the art of our trade was not when things went right, but how we overcame and resolved issues when things didn’t go right“. The little episode above reminded of that saying.

Please note: No Green ‘Recycling Wheelie Bins’ were harmed during the execution of this DIY Car Maintenance session 😉

Thank you for reading.

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Baffled Ape

Baffled by much of human behaviour, Life long engineer, Father, Mate, Love #Nature, #Engineering, Saved by #NHS, Stuck with #ChronicPain, Nature can provide #Green Clean #Energy #Politics is broken, we need #Sortition

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