What's the hardest repair you've ever done (by yourself)?
Discussion
I try to do my own servicing and repairs where possible. I've never done something as involved as a headgasket though.
Hardest job I did by myself (with help from Haynes and Youtube) was the valve clearances on a Suzuki Intruder 800. I had previously done them on easier bikes so I knew what was involved, but the Intruder design left a lot to be desired. I had to fabricate a couple of tools in order to hold the valve adjuster in place while doing up the locknut because the frame just didn't allow access for any hands/fingers.
All in all not particularly 'hard', but you had to know what you were doing and make sure the engine is in the correct position. Plus a couple hours of removing stuff, making sure it's torqued back correctly, double and triple checking the measurements. I think it took me about 6 hours with regular breaks and cleaning every component on reassembly. Luckily it wasn't one of those jobs where you get stuck and have to wait a day or more for extra parts or tools to arrive.
Hardest job I did by myself (with help from Haynes and Youtube) was the valve clearances on a Suzuki Intruder 800. I had previously done them on easier bikes so I knew what was involved, but the Intruder design left a lot to be desired. I had to fabricate a couple of tools in order to hold the valve adjuster in place while doing up the locknut because the frame just didn't allow access for any hands/fingers.
All in all not particularly 'hard', but you had to know what you were doing and make sure the engine is in the correct position. Plus a couple hours of removing stuff, making sure it's torqued back correctly, double and triple checking the measurements. I think it took me about 6 hours with regular breaks and cleaning every component on reassembly. Luckily it wasn't one of those jobs where you get stuck and have to wait a day or more for extra parts or tools to arrive.
Tentatively stripping and rebuilding these on a number of occasions, trying to find the gremlins and getting a bit better at it each time.
Eventually summing up the courage to drill the lead plugs and finally getting to the root of the problem. I'm no mechanic but I love working on carbs.
Weber 40 IDS
Eventually summing up the courage to drill the lead plugs and finally getting to the root of the problem. I'm no mechanic but I love working on carbs.
Weber 40 IDS
Sump gasket on a bmw e39 5 series. Have to support the engine from above and drop the front subframe, steering column joint is a massive pain as no space to get tools in down the side of the exhaust manifold/cats.
About a hundred bolts to undo, have to take dipstick tube out and wiggle the sump around the oil pickup whilst the subframe is in the way of where you need to be. Horrible horrible job, and I’ve done suspension, exhausts, fuel pumps, interiors etc.
About a hundred bolts to undo, have to take dipstick tube out and wiggle the sump around the oil pickup whilst the subframe is in the way of where you need to be. Horrible horrible job, and I’ve done suspension, exhausts, fuel pumps, interiors etc.
Back in the 1970’s. A clutch replacement on an Escort 1100. Lying on my back under the car, on stands, with the transmission on my knees. Never again (but I was younger then, and keener, and poorer). That was the only car I ever needed a clutch changed, even though later cars had done more mileage.
I've done all sorts.
Rebuilt engines
Built a car from (almost) scratch
Currently Restoring another car (from bare rust bucket shell)
By far the most troublesome thing I've done was a front wheel bearing on a 2cv.
There's a lock ring which is M76x2 pitch. It has two little slots to undo it. It's torqued to 400Nm, then peened in two places.
The bearings are pretty robust and the ones I've done have never been done before. So they've been corroded together and painted several times over, which makes removal even more interesting. It's a f
king awful job.
Rebuilt engines
Built a car from (almost) scratch
Currently Restoring another car (from bare rust bucket shell)
By far the most troublesome thing I've done was a front wheel bearing on a 2cv.
There's a lock ring which is M76x2 pitch. It has two little slots to undo it. It's torqued to 400Nm, then peened in two places.
The bearings are pretty robust and the ones I've done have never been done before. So they've been corroded together and painted several times over, which makes removal even more interesting. It's a f
king awful job.End Thread, Honda CBX1000 Carbs, over 400 individual parts, blocked pilot jets which are pressed in not screwed in, fuel passageway O-rings that turn to dust, Fabulous instruments when in good condition, but leave ethanol based fuel in them for a month or two you'll be cursing, I've only ever done two sets
both for other people, never again, I've done plenty of the DOHC Honda fours from that era and they're the same carb but they're in a straight bank
whereas the CBX carbs are in a shallow vee.
This is why the USA's foremost Carb restorer for the DOHC Honda's has an 3 month waiting time on his services, and the cost can be well over $1400
But his work is amazing
https://www.oldschoolcarbs.com/the-carburetors/cbx...
both for other people, never again, I've done plenty of the DOHC Honda fours from that era and they're the same carb but they're in a straight bank
whereas the CBX carbs are in a shallow vee.
This is why the USA's foremost Carb restorer for the DOHC Honda's has an 3 month waiting time on his services, and the cost can be well over $1400
But his work is amazing
https://www.oldschoolcarbs.com/the-carburetors/cbx...
I think for sheer buggeration factor, replacing an E30 gear shift linkage without removing the exhaust or propshaft, and replacing the alternator on an AC-equipped Fiat Panda were some of the most disproportionately awkward jobs I've done for how technically simple they were.
Big stuff such as engine replacement etc isn't actually all that bad. It's the fiddly in-situ repairs with terrible access that ruin your day.
Big stuff such as engine replacement etc isn't actually all that bad. It's the fiddly in-situ repairs with terrible access that ruin your day.
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