Les Henson Posted September 1, 2007 Share Posted September 1, 2007 This type of fork is the same for 2.5 N/A and TD engines, 200 and 300TDi as well. The thin metal construction of the fork and the inability to lubricate it means that the pivot point quickly wears away, causing it to fail - sometimes within just a few thousand miles. The fork can be reinforced by welding a plate over the weak spot - thus extending it's normal life considerably. The steel I have used in this thread is 2.5mm - you can use thicker, but it gets harder to shape the thicker it gets, and other parts of it are likely to fail before it wears through. The plate is 40mm long, 34mm wide at one end, and 26mm wide at the other. Put a curve in it like this. The new fork may be bare metal or primed, clean around the pivot point. Place the new fork in a vice and position the plate like this. And weld. Wide end next - you will probably have to tap it down until it's in contact with the metal. Again, weld. The sides next - these need to be hammered down until they are close to the sides of the fork, and then weld each one in turn. Once all sides are done, allow to cool, clean up with a wire brush and then a coat of paint in your fave colour Les. Quote Link to comment Share on other sites More sharing options...
rtbarton Posted September 1, 2007 Share Posted September 1, 2007 ....Once all sides are done, ........... then a coat of paint in your fave colour Les. Orange. Quote Link to comment Share on other sites More sharing options...
Les Henson Posted September 1, 2007 Author Share Posted September 1, 2007 Pink would my preference Roger Les. Quote Link to comment Share on other sites More sharing options...
Mo Murphy Posted September 1, 2007 Share Posted September 1, 2007 Out with the MIG set these days then, Les, rather than you your trademark gas welding. A splendid piece of work. Mo Quote Link to comment Share on other sites More sharing options...
Les Henson Posted September 1, 2007 Author Share Posted September 1, 2007 trademark gas welding I have to botch carefully repair Mr Beaumonts Disco soon - it's been a while since I set fire carefully repaired a vehicle using gas, so I'm looking forward to it LOADS of pictures will follow Les. Quote Link to comment Share on other sites More sharing options...
BogMonster Posted September 1, 2007 Share Posted September 1, 2007 Nice job Les. I have never seen it done first hand, but apparently folks here used to use one of the bits out of an old drop arm ball joint kit (I think it's the bit that the actual ball of the joint sits in) and weld that over the back of the ball as apparently it's about the right shape. Are you going to post details on the new Extreme Laning forum? Quote Link to comment Share on other sites More sharing options...
Guest diesel_jim Posted September 1, 2007 Share Posted September 1, 2007 Just to hijack this thread a bit, There are one of these clutch arms FREE here for a suitable donation to the forum coffee swindle. Quote Link to comment Share on other sites More sharing options...
geoffbeaumont Posted September 2, 2007 Share Posted September 2, 2007 I have to botch carefully repair Mr Beaumonts Disco soon - it's been a while since I set fire carefully repaired a vehicle using gas, so I'm looking forward to it Sounds like I need to check my insurance Quote Link to comment Share on other sites More sharing options...
tweetyduck Posted August 18, 2010 Share Posted August 18, 2010 I've just done mine. Can honestly say the weld is as ugly as they come but its not going to see the light of day for hopefully a long time....... I daren't even post a pic .... Quote Link to comment Share on other sites More sharing options...
matt bristol Posted August 19, 2010 Share Posted August 19, 2010 well i didn't quite manage to make it as pretty as the one Les did, but here is my repair. Check out the excellent welding!!! Quote Link to comment Share on other sites More sharing options...
bobtail4x4 Posted August 19, 2010 Share Posted August 19, 2010 Rater than messing about cutting the steel, could you use a coreplug? Quote Link to comment Share on other sites More sharing options...
nicks90 Posted August 20, 2010 Share Posted August 20, 2010 i used a big washer to reinforce mine. not pictures i'm afraid and i aint taking the gearbox off to get one. Quote Link to comment Share on other sites More sharing options...
tweetyduck Posted August 20, 2010 Share Posted August 20, 2010 @bobtail4x4.....thats worse than my welding I've be practicing...so much so that my right knee has UV burn. Serves me right for doing it in shorts. I'm now wearing long trousers. I've changed gas to a mix and its amazing how much difference it makes especially on 1mm. Quote Link to comment Share on other sites More sharing options...
simonr Posted August 20, 2010 Share Posted August 20, 2010 i used a big washer to reinforce mine. not pictures i'm afraid and i aint taking the gearbox off to get one. I was just about to post saying that's how I did mine too. The washer was about 3mm thick and didn't need any deforming at all, just weld round the inside & outside. Si Quote Link to comment Share on other sites More sharing options...
ibexman Posted August 20, 2010 Share Posted August 20, 2010 Ok when is someone going to start selling them ;) Quote Link to comment Share on other sites More sharing options...
Mo Murphy Posted August 20, 2010 Share Posted August 20, 2010 Paddocks sell them already here HTH Mo Quote Link to comment Share on other sites More sharing options...
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