Rear Brakes & Diesel Tanks

December 2013 - 

Renovating the Rear Brakes

 After having the left Rear Brakes open in April 2013, I knew that I needed to rebuild them as they were badly covered in oil. So Starting in December 2013 I removed the rear Shoes from both sides of the rear axle and had new Brake Pads attached. While they were off I cleaned the baking plates, renovated the right hand Rear Wheel Cylinder, painted things that needed it, then cleaned and re-greased the hubs as well as changing the Hub Oil seal.

 Well oiled Brake Shoes

 Waiting for the oily grease to leave the Hub

 Everything was wet with Oil

 The oil fang removed and starting to clean

 Wheel Cylinder well in need of attention!

 Starting the reassembly of the reamed Wheel Cylinder with a coating of brake assembly paste

Oil has been leaking from the Wheel Cylimnder and from the Rear Hub seal to soak into the Shoes.

 Removing the Brake components

 Backing plate clear for cleaning

 The remains of grease collected in the fang

 Crusts of rust

 The Piston, Rubber Seal and Spring

 Very nice weather for doing the job

 The Hand Brake Activating Shaft Bushing Holder after removal

 The Bushing cleaned and about to replace the Bush and new oil seal

 New bush in place

  Before and after sanding rust off the connection pins

  Getting the Shoes in position

  New Shoes and the Hand Brake Shaft with new sealing rubber

 New Grease and Hub Nuts tightened 

 Parts claened, painted and waiting for assembly

 The nylon bush after 47 years was well crumbly

 Starting to reassemble the Brakes

Parts laid out ready for assembly

  In position and with copper paste on all moving parts

 The Hand Brake Shaft held in place with the Bushing

The Axle being slid in

 Diesel Tanks

Due to my original round Diesel Tank being to small with a capacity of only 100 Liter, I decided to add two, 200 Liter tanks, one on each side of the Truck.
First I had to move the Air Tank as it was mounted on the left outside frame of the chassis where I wanted to mount the first new Diesel Tank.

Moving the Air Tank

Mounting the new holders for the Air Tank
on inner side of the Chassis

Cutting the pipes to fit
The tank is mounted and new air pipes are going in

Main air feed and regulator mounted

Mounting the Diesel Tanks


 The two MAN Tanks; 1060mm L
                                   600mm W
                                   360mm H


 Sanding off the rust and flaky paint

 I made a wooden template spacer to get the correct distance away from the chassis to clear the Koffer suspension. Then I had steel spacers made following the template

 My Tank plan for the Fuel feed and return going through 3 way taps

 Tap mounted with fuel hose going through rubber grommets 

 TIG welding on the plates to hold the bolt on Fuel Gauge Sender Unit. Im running the inert exhaust from my car into the tank so there are no explosive gases in the tank

  Lifting the Tank to find the right position that will clear the Koffer and give me the ground clearance that I want           


    Freshly coated with rust inhibiting paint, Owatrol
    Oil. Once dry I painted the Tank with black
     3in1 Brantho-Korrux

 Temporally bolted in place to check clearances

 Cutting the mounting holes for the taps

The Levers mounted on the side of Drivers Seat

Welding almost finished. A small metal plate was put over the hole to keep most of the exhaust fumes out of the welders face

 What it looks like with the left side Tank finally mounted. Plenty of ground clearance. A thick Aluminium plate is going to be mounted under the Tank to protect it from damage when using the Sand Ladders

And the right side Tank is finally on. Im now able to carry a total of 400 Liters of diesel

Wider Rear Rims
I bought new rims for the rear axle to get the wheels sitting in line with the edge of the Koffer.
My new Rims are 8.5V x 20 with an ET of 130mm.
But first I needed to cut out my wheel arches as my wheels were sitting up inside them. It had been on my "To Do" list for a while as changing the rear wheels had always been a struggle to get the wheel in under the arch edge then up over onto the axle hub! Also its going to be much easier to lift into position the 35 kg Snow Chains.

 Starting to cut out the arch

 All cut away. Im going to weld steel strips to close and weather proof the edges

 This is the old Rim. 7.5 x 20

 The Wheel on old Rim

 The front section is free

 I also made this cut out to give more room for filling the Tank

 The newly painted Rims on the way to changing them over

 Now sitting on the new Rim

 As the new Rims didnt have Kugelsenkung on the edge of the wheel bolt holes , I had to build some
rings to center the Rims. So I ground down some of the Lime Rings that were used with the

Kugelsenkung system as they are made of hardened steel.

I used my flex to grind down the edge of the Lime Ring while it was being held on a bolt of the same internal diameter

  Held to my work bench while grinding

 The Newly ground ring in position on the Wheel Bolt and centering the Rim

  A close up of my set up. Ive cut away part of the nut to give me more room to hold the flex flat while grinding. As I grind the Lime Ring spins and I grind evenly around the edge

 Here it can be seen how it is centering the Bolt in the middle of the Rim Bolt Hole

 Now the wheel sits in alignment with the side of the Koffer, making me more stable off road

My Bike now has a place to live while on the road

New Winch Lever Connection

When I mounted the Free Wheel Hubs I had to move the Speedometer cable from the front of the Transfer Box to the Gear Box. Where the speedometer cable screwed in was also screwed the shaft that connected the Lever for operating the Winch.
So I had to build a frame to hold the shaft just behind where it used to be and at the same height. I also needed to shorten and bend the final connection bar to the operating arm on the Winch Gear Box
This is how the Lever used to be mounted

Staring to weld a frame with the offset shaft

The lever with the new frame attached. The
final connection bar has already been cut and
 re welded, but not yet bent

Fitted in position and checking for clearances

I was also able to connect it with a bolt that was on the to the side of the Gear Box, so welded another small tab on my frame
With it mounted in place the Winch is again working. 
The bend in the
final connection bar can now be seen

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