repaired the Excell bi-radial pressure washer

So more than the thermal fuse was leaking on my old pressure washer.  Replaced the thermal fuse and it was still leaking.  Apparently because of the bi-radial piston design it uses a "dead" hose to balance
pressure surges and it had worn a hole after 14 years of use.

It was the first item that popped up on Amazon parts search

new part

worn hole in hose against plastic pump shield

need to remove hose and outlet to remove shield to replace "dead" hose and thermal fuse

reassembled - remember to turn off fuel before laying on back

reassembled and upright

hose connector screws into pump using 3/8" hex drive

Video on the pump function.

So now that the leaks are solved I can make a update on the foam canyon pressure washer switch.

Ford 2N starter replacement

So the Ford 2N backfired when starting and damaged the Bendix drive.  Eventually it failed and I had a new starter on hand.  Good news is the starter motor is fine so I just need to replace the Bendix drive and I'll have a backup around.  Might send it to a starter shop for a refresh vs doing my self.  Right now it is on the shelf.

Watch the video:

Towable Work Bench

The plan:

Make slidable hitch for "free workbench" so it can function a my "yard workbench"

Using 1 5/8 and 5/8 unistrut and assorted unistrut parts plus a hitch (clearance item)

 I wanted to make it so I would not knock my shin so I planned to make it slidable when not in use pulling the workbench.

 Welded the unistrut to the existing frame, the two sides together to make a tongue.

Still functional fully retracted but let turning angle with trailer positioner

 I have a workbench I can tow behind my truck but I would think that a garden tractor would be better.

Cleaning the garage finding all sorts of things to fix:

I have been cleaning the garage so I can get back to work on the car.

After moving lumber I found my headliner with frame that was stashed behind some OSB for safe keeping.

In any case I just have two broken places and I expect to fix it.  My thought was to use fiberglass to reinforce the wood but JB weld and window screen seems like it would work as well.

You all can see the quick photos I snapped with the phone.  I took a close up of the attachment method (staples) as well as the piping that goes along the edge.

The head liner is dirty from use and storage as done it no favors but I always wondered if I should try cleaning and reuse the material (in the spirit of originality).  I figured that even if I should be able to get it clean and white again I would not be able to reattach the channels for the middle support bows neatly so the point it moot unless someone has had any success.  By the time the car is back on the road the $$ in paint and other new stuff will make a small expense like a headliner seem minor.  Now I just have to search out the visor repair place to get them rebuilt...

Slowly making progress again.  It is a '67 so I should try to get it on the road in 2017....

Miata Front Brakes

Time to replace the front calipers, had to replace the rear calipers last year as they were leaking at the parking brake lever seal.

I decided to do the work while still loaded on the trailer for
better ergonomics

Forgot to paint the calipers so I have to
wait for paint to dry...  (also when trying to free a stuck brake piston one can
push fairly hard with loose C clamp to use the hydraulics to free it but once the piston
moves do not pump the pedal one more time just a bit harder...)

Pressure brake bleeder system will make the bleeding process
far easier

A POX on AutoZone - they gave me the wrong rotors (Then again I should have checked...)
so I had time for the paint to dry as I made a trip to town for the correct ones.
http://www.mossmiata.com/sitegraphics/pages/factory_big_brakes.html

All done and bled - ready for the wheels.  Using a lug nut to hold a wobbly rotor
is a handy trick when trying to bolt the caliper bracket back on.  Also install the new brake
line last so you do not need to worry about stressing the hose.  (I do not like the Miata front
hoses - too short to turn the wheel to full lock when the suspension is unloaded - I thought
I got the wrong parts but I checked old to new side by side and they were the same length.) 

Last brake job of the day - replace the rear brake proportioning valve - much easier to get to
than the pair on the 1800ES - nice Subaru part supplier pointed out I only needed one for
this vehicle - the 1800ES needs two for the dual split circuit braking system on pre-ABS
Volvo's with 4 wheel disk brakes. 

Added some stub axles - can roll rotisserie outside

Ok this is a good year late but added some stub axles for a trailer and hubs to the rotisserie.  Now I just need to put some tubes in the old tires so I can return the spare to the camper...

Cross bars for Subaru Outback

I started making a set of cross bars from 3/4 inch EMT - a pool noodle fits over perfectly.  I cut some 1 inch pipe by welding some bolts and nuts to make it easy to adjust.  After making the first one I thought of a better way to make the cross bars using some uni-strut and 1 inch condiut (3/4 inch would have worked but this was going to be a slightly HD version)

I chose to use 1/2 by 2in long carriage bolts that I ground down so it could fit down inside the unistrut.

I may redo the lower brackets but I am quite sure it is plenty sturdy.

Orginal cross bars, unistrut and 1 inch EMT

Orginail mounts

pre fab testing

unistrut with cut/ground down carriage bolts.  The unistrut and EMT was ground down to bare metal for easier weld penetration (less zinc out gassing)

installed

close up of unistrut mounts

front mounts

 

Now I just need to remove the factory cross bars (100 lbs limit - even 1 kayak tied to the bar has broken loose at highway speed)  Note the front and rear bars have different widths between the roof rack mounts.  

Nice thing is the bars do not extend beyond the width of the car mirrors - I cut the 10' EMT in half.  I may make extensions out of 1 1/4 inch conduit.  Next will be to paint the welds and ground off area with high zinc "cold galvanizing compound"  then I will likely paint the bars black.

If you can weld get some unistrut and EMT and make a set of HD cross bars instead of purchasing $100+ sets.