Monday: With respect to the build I worked on the front brakes today and created the first "wall of shame" part. I am sure this will not be the last but it sure was an expensive first.
Attachment 16738 Attachment 16739
Here is the sad tale. I assembled the Wilwood front rotor to the hat. The instruction calls for torquing the screws to 155 in-lb. I misread the setting on the torque wrench and it was set for 1550 or 10 times higher than the max torque allowed. I broke out 2 of the screws before I realized my mistake.
I compounded that error in trying to ease out the remainder of the two bolts when I destroyed a good part of the original threads on the hat. After I searched the forums and Internet I attempted to execute the procedures but had difficulty keeping the hand held drill perfectly perpendicular. I quit for the night in frustration of my lack of skills in getting the broken bolts out.
Tuesday: After attempting some rookie repairs with over sized screws, I decided to be more proper and conservative and order a new hat and bolts. These mistakes cost about $261 in new parts plus shipping and 5-6 days delay in finishing the front brakes. I did get a chance to practice safety wiring!
Lessons Learned:
1. Use the correct range torque wrench;
2. Check the setting on the torque wrench numerous times and under sufficient light to really read the settings (specially true on the digital readings);
3. Use a drill press with a means to hold the working piece vice hand held drill to prepare the broken bolt for removal; and,
4.
Do not work tired!
Since I was essentially stopped on the front brakes I assembled and prepared the parts to mount the IRS components finding all but the bolts and bushings for the front end of the differential. I had planned on ordering the solid bushings from Fortes anyway.
I also gathered all the parts to assemble and mount the Wilwood pedal box. Since purchasing the kit, I have decided to install a hydraulic clutch so I am researching the addition of the third master cylinder to the pedal box but it looks like it will be easier than using the cable system (and all the mods and issues associated with the quadrant).
I have become a devotee to the methodology of mocking up first to make sure all works before doing the final assembly.
Carl "Clutzy" Williams
PS. I will eventually make a nice Wilwood clock for the shop from the hat .