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On your post #33 you talked about casting your own sway bar rubber parts. Can you elaborate on the process a bit? How did you remove the PVC pipe that formed the hole in the bushing? Was the hole that was left 3/4"?

How have they held up? Thanks

Thanks BigKev. I'm hoping it will 'pass all tests' when the paint goes on!

I am using something similar to the Dura-Block called ChromaBlock, same rubber I think. (The Dura-Blocks are also available here locally). I haven't used their rounds yet, generally have made a rig like the one shown out of PVC pipe which works ok but a rubber one would be better - must get one next time I'm at the shop!

Grabbed a few of the shaping tools that were at hand for a photo in case it's helpful.

Right on about blocking with large blocks, and finishing with a large soft block like the large Dura-Block to avoid the ridges and scratches. And the cross-hatching - totally necessary or you never will get a good finish. Technique is everything, sanding from every direction instead of just one or two.

Last thing before painting I'll do some large flat areas with the random orbital sander with 1200-grit which is supposed to remove blocking lines. Curves and edges will be finished with the 3M foam-backed hand pads ('Superfine and Ultrafine') which are great, leave no edges.

Nothing like running a hand over the surface from several directions to feel the highs and lows, coupled with sighting with a strong light placed at different angles too. Just when you think you have it perfect you see (or feel) another area that needs a few microns off it!

Some Shaping Tools I've Been Using . . . .

Here's a few of them, the basic ones. You can (and should) make your own or buy whatever is required as the more you have at hand the easier it will be to get the job done well and quickly.Add to these a wide selection of wet & Dry papers.

543 Selection of shaping tools including random orbital sander, 17-inch strip sander, 3M Super - and UltraFine foam-backed pads, 'cheese grater' and blades, 1/3rd sheet blocks etc (- each with a different grit paper in it)



551 Body File - used on metal highs



546 Home-made round paper holder up close.



547 Quick-change large block

Hi Bob, just looked back at Post #33 . . . Since I fitted the bushings I have found that they split. This is for two reasons - because the Flexane I used was too soft, and also because the car doesn't have the motor fitted, so there is a lot of extra pressure on the rubbers due to the sway-bar sitting in the wrong position (unloaded) and forcing extra pressure on the rubbers (- for months now).

I'm going to try again, using a harder / tougher Flexane which you can buy, and I'll fit the re-made rubbers after I have put the motor into the car. Hopefully this will be OK.

I think I used 'Flexane 80' which is softer than the 'Flexane 94'. See data at Devcon Flexane 94

and Tech Data Sheet

The release agent I used was just a coating of penetrant - 'WD-40' (sprayed onto the PVC mold surfaces before I poured in the liquid Flexane). The pipe came out quite easily. It was a PVC pipe the same size as the sway bar, from memory 3/4inch. Rubbers slid into place because I used a bit of petroleum jelly on the sway bar to help them along the bar.

Try the hard Flexane - I think it should be OK . . . Others might have a recommendation -? Alternative is to buy the bushes - they're still available from a few places at a cost. Let me know if you need any more info on this.

Quote:


Thanks for the info. I did check with one of the distributers and thought $47.00 for a pair of them was pretty high. Checked with a local NAPA dealer and found they sell a similar bushing for around $18.00 a pair. Was unsuccessful matching anything up. Will keep trying.



I am very interested in how the harder flexane works out.

Larry, another thing you can use is sandpaper wrapped around a piece of hose, Heater or Radiator depending on the radius you need. Cheap and flexible.

Sounds good! The 'real McCoy' blocks are very expensive so thanks for this idea, I'll give it a go.

Larry, are you still counting the railway wagons of the train to China? Would love to hear from you!

G'day Guscha,

I'm still doing a bit of work on the car (mainly small stuff and getting parts) but very disjointed owing to family visits. I just got one of the radios I have working a few days ago, will post on that asap.

We have just been graced with a second grand-daughter, Mila Indiana Rose, who right now is just three weeks old. Beautiful! Our kids (four of them, grown now) are scattered all over the place so it's a bit of a hike to get to see them. Keeps me away from the Packard but what a great distraction, hey!

Also, yesterday I replaced the timing belt on my 'ersatz' car (Nissan Pathfinder - it's the 'Frontiera' over there I think??). That was a full day's work but went well, first V6 belt I've done. Not a hard job, just a long one.

I should be back 'posting' on the blog very soon!

Have a great Christmas won't you!

Pics of our three grandchildren . . . .

Isabella,




Zac. . . .




and baby Mila, just four days old




with her dad -our son Ben

A beautiful crew you have there! I understand the hikes to get to everyone..I see it as part of the fun!
Have a Merry Christmas Larry! Thanks for all of your inspiring posts!