Royale Sabre - Take two!

[Amir Manzoori]

I have been enjoying all your posts. And now, every time I see your move, I can't wait to see the next move you make, all meticulously carried out to perfection. Good on you my friend.

[peterux]

Thanks Molleur, Barber and Amir for your feedback and I'm glad you all enjoying my updates.

However, it appears that my meticulous rebuild overlooked one vital item. It's been highlighted by Mike, (builder of the superb Marlin Cabrio documented in the Marlin section of this forum and BMW e36 aficionado), that I should have replaced the clutch lever pivot pin. These are apparently a common failure point on the e36 and can result in a very difficult clutch engagement position.
It means that I'll have to separate the gearbox from the engine again, but i'd rather do this now while the body tub is not in position.
But more on that next time........

I've only been able to spend about half a day on the car this week and I tackled the clean up and refit of the exhaust manifold. With hindsight it would have been easier to this while the engine was on the engine stand.

First, I had to replace the 24 exhaust manifold studs. They are an unusual size of M7 so you have to get genuine BMW studs.

Exhaust manifold by Sabrebuilder, on Flickr

I then cleaned up the manifolds with a wire brush and scrapped off the old gaskets. They were then refitted with with new copper coated lock nuts and new gaskets. I used a smear of Copper ease on the studs and the nuts were tightened up to the specified torque of 20Nm.

Exhaust manifold by Sabrebuilder, on Flickr

Until next time, enjoy your builds...........

...peter

P.S. I found this interesting report of a Royale Sabre in Russia!!

https://www.retrorf.ru/royalsabre

(You'll have to use your web browser to translate unless your fluent in Russian )

[peterux]

Following a short holiday away I returned to the realisation that the neglected window frames on my cottage had been ignored for long enough and really did need my urgent attention.

Today was my first chance to get back to the Sabre so picking up where I stopped in August.......

Originally Posted by peterux

However, it appears that my meticulous rebuild overlooked one vital item. It's been highlighted by Mike, (builder of the superb Marlin Cabrio documented in the Marlin section of this forum and BMW e36 aficionado), that I should have replaced the clutch lever pivot pin. These are apparently a common failure point on the e36 and can result in a very difficult clutch engagement position.
It means that I'll have to separate the gearbox from the engine again, but i'd rather do this now while the body tub is not in position.
But more on that next time........

.............so out came the gearbox again. Quite easy really with no bodywork in places and with only half a dozen or so bolts to remove it didn't take long.

I then removed the clutch release bearing and lever. Removing the old pivot is easy as you can drift it out from the outside of the gearbox. I hadn't inspected it properly before and was shocked to see how worn it was. I was going to replace it with the standard BMW part (shown on the left) until I bought one. For some reason only known to BMW it has a hole up the centre which leaves only 5mm of solid material at the tip.
Having looked at the new part I decided to get a stainless steel replacement (Hack Engineering). It is a nicely machined part but I polished the tip to prevent any wear on the clutch leaver.
I'm indebted to Mike for highlighting this issue which I had overlooked.
Thanks, Mike

Clutch lever pivot by Sabrebuilder, on Flickr


Refitting the gearbox was quickly done and then I treated it to some nice new oil.

Gearbox Oil replaced by Sabrebuilder, on Flickr

Nice quality oil from Gulf but a stupid shape bottle that slips out your hand and has no filling tube like the old Castrol bottles had.You need about 1.2 litres so you have to buy two bottles!

Following the discovery of perished dust covers on my first handbrake cable I had another one shortened. This one has solid rubber dust covers which will hopefully last longer.

Another handbrake cable by Sabrebuilder, on Flickr

Another handbrake cable by Sabrebuilder, on Flickr

So a few more jobs ticked of my task list......

.....peter

[peterux]

Despite my best intentions holidays, days out and other commitments have prevented much progress being made on the Sabre in the last few weeks.
I have been refitting the exhaust system for the final time with all the brackets painted and with exhaust paste in the joints.(no pictures as it looks pretty much the same as before!)

Still working my way through 'my list of things to do' before fitting the painted body tub but as fast as I complete tasks i keep thinking of more things to do!
I have a thinner front ARB to fit and some new rear springs, but more on that in my next update.

...peter