DRB 540 build

[boxhead]

Cheers for that, I got your email, but Chris has a deal with Earls so that is why I was chassing earls part number, thought it was dash 3 but was not 100%

Thanks again.

[boxhead]

This may well be common knowledge? but since no one jumped in, I thought I would let in be known.
The Dash sizings are all reffering to 16th of an inch.
So dash 3 is 3/16
dash 5 is 5/16
dash 6 is 3/8 etc etc.

[boxhead]

Here are some pics of small progress last Saturday.

Stainless steel brake pipes, all straightened out from a roll.
I have added one flared end to each pipe where I know what end they require.


Single flare.


Double flare


Extra legth of wiring in engine bay, not sure what Chris will do, I suspect he will shorten the loom.
He is the sparkie so that is for him to enjoy.


And the R/H inner guard piece, the battery gets located in behind here.


I have ordered the dash 3 brake fittings in steel.
I wanted to do the fuel and emmission pipes in stainless aswell, but can only get the bulkhead fittings in larger sizes in alloy, what are everyones thoughts on the stainless pipe damaging the alloy connectors?
Would the stainless pipe be too "Hard" on the alloy?
I initially thought it might be but then realised I have stainless pipes going into the ABS unit and the Master cylinder?

[G6ETURBO]

I think the two types of metal will be fine but yes you will have to be carful not to strip thread on alloy. A man of your tallent not an issue boxhead. We will have to add your photos into the DRB manual.

[alffie]

Hi Boxhead
AN832-6J,-8J are straight bulkhead fittings and AN837 series are 45Deg bulkhead fittings they come in sizes from -3 to -16. You can get them in steel, stainless and alloy.
The only problem with using SS tube and alloy fittings the flare is a lot stronger than the fitting so if you dont have a perfect flare it will leak.

[boxhead]

Its not so much the thread I was concerned about, more the "gauling" (I think that is the word) that the stainless may do to the alloy, and as Alffie says, if not spot on, they will leak.

[AC-460]

Any updates on the 540 dave...........its been good watching the progress

[boxhead]

Not much worth reporting so far, I will just about run out of things to do after this Saturday till we see some parts.
I have run all brake lines (not secured) and have ordered stainless flex hoses.
I have given Chris a list of items he needs to order (main thing being A/C kit), once A/C is in, I can then fit dash, fit screen frame, fit wipers/washers.
Same with alloy plate under fuel tank, once he has a new one of these (damaged in freight) I can fit fuel tank, fit fuel pipes, fit vapor tank etc.
I should be making fuel pipes this weekend (waiting on flare nuts) and vapour pipe for charcoal canister.
Also making fiting battery box.
If I run out of stuff to do, I may well refit nose panel so I can mount the power steering cooler (but trying to leave bonnet till later)

[Rob. Smith]

Originally Posted by boxhead

Its not so much the thread I was concerned about, more the "gauling" (I think that is the word) that the stainless may do to the alloy, and as Alffie says, if not spot on, they will leak.

Stainless and aluminium does react with each other...something to do with electrolosis.This is relating to sheet and plate metals with a decent surface area. I'm not too sure about threaded fittings. As far as galling, the aluminium will act as a lubricant on the stainless. similar to the zinc/silver based paste stuff ...Goop, nevaseize etc. that you should always use on stainless nuts & bolts. The only downside would be the two different "strengths" of the materials, so if nothing heavy is swinging off the fitting. You shouldn't have a problem.

[boxhead]

A little update, as not much is happening now till parts are ordered and arrive.

Brake pipes bent up, and fitted.








And here is the tool for straightening pipes.


And here is the flared end of fuel pipe, uses factory type filter.

[renovationinnov]

hey the drb 540 is coming along great keep up the good work
question where did you get the pipe straightener from & at what cost

[boxhead]

The pipe straightened is on loan from brake shop, don't know what it is called or it's cost. But it is a fantastic bit of kit.

[Aussie Mike]

Looks like a neat piece of gear. I could have used one when I did my fuel lines as the tube came coiled up.

I've found who makes them.

http://www.brakequip.com/tools_tube_straight.html

Not cheap though @ about US$355

Probably wouldn't be hard to machine something up to do the job though. Are the profiles on the wheels V shaped or U shaped? I reckon they will be V shaped to suit different tube sizes.

Cheers

[boxhead]

I will get some pics of it this arvo.
3 lower rollers and top 2 are spring loaded and adjustable.

[boxhead]

Hey there JayDee, here is the one for sale, it has not gone much further than it is pictured here.

I will ask owner what Dollars he is after.
The only mod so far from factory is that he has had chrome molly roll over hoops made in the same design as the original square sectioned fibreglass ones.

[Jaydee]

The roll over hoops, are they strong enough, is there steel inside them?

[boxhead]

The originals are purely cosmetic made of glass with no internal structure.
This car now has chrome Molly ones that are secured to rear alloy bulkhead.