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Thread: More fluid leakage repairs and handbrake MOT fail & fix!

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  1. #1 More fluid leakage repairs and handbrake MOT fail & fix! 
    frequent forum contributor Club Member Patrick's Avatar
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    Nov 2011
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    Another week, another new fluid all over the floor! Coolant this time from the rear port on the cylinder head. That’s the pipe that goes to the interior heater core:



    Took it off and cleaned everything up on the head



    New coolant flange gasket fresh from eBay!



    Everything fitted back together (after dropping the bolts…). It’s a little bit fiddly getting this back on with the battery tray in the way. The bolt seen in the follow photo on the left of the image is much higher up than you’d think.





    The nice thing about the Sporters, more room to get behind the engine is just 4 bolts away!




    MOT day, handbrake failure




    So the MOT tester is a beast of a man and ripped both handbrake cables clean off the mounts! Better it failed here than in an emergency though.



    The original handbrake adjusters are bolts with the head of a bolt chopped, the end drilled with the lathe and a recess to capture the shorted handbrake cable with a spot of weld.
    As the handbrake cables were now shorter than before the bolts were too short. These were extended by chopping the machines part off the old bolt and welded on to a new bolt making it longer. The recess needed drilling out again to remove old handbrake cable.

    If this fails again it will need new handbrake cables, the mounts are along as will fit into the handle.



    The torn ends zipped tie down to make them easier to clean up for welding



    Cables welded back on



    Finally mounted back into the handbrake handle and adjusted. Hand brake retested with better results than the rear brakes!

    The car was also failed on emission first time round as the machine was set wrong. HC limit for an 88 engine is 1200, it comes in around 650 - which as been the same for a numbr of years now. They incorrectly wanted to see less than 18 - keep an eye for that one, page 12 of this document is useful if you need paperwork: https://assets.publishing.service.go...th-edition.pdf - I also had several years of prior emissions test results. Retest was done my a more experience tested who set the machine correctly.
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  2. #2 Re: More fluid leakage repairs and handbrake MOT fail & fix! 
    frequent forum contributor Club Member
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    Nov 2016
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    Wouldn't it be stronger and more reliable to have adjusters swaged on to the cable rather than relying on a blob of weld. In twenty plus years of sailing dinghy's I never had or saw a failure in that area.
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  3. #3 Re: More fluid leakage repairs and handbrake MOT fail & fix! 
    frequent forum contributor Club Member Tony Stott's Avatar
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    Nov 2011
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    silver solder? its another solution!
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  4. #4 Re: More fluid leakage repairs and handbrake MOT fail & fix! 
    frequent forum contributor Club Member Patrick's Avatar
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    Good ideas, thanks
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