Handbrake compensator swap from Hell

[HarryM1BYT]

I've just had a member drop in, for a quick exchange of his compensator, for a modified one. He already had the carpet up, cover plate off and console ready to lift, so I was thinking around 10 15 minutes just to swap the compensator. He had also speculatively bought a replacement after market front handbrake cable.

He had already fitted new drums, disks, pads and shoes and all set up and adjusted - he just wanted the play in the handbrake lever sorted due to a stretched compensator.

Easy you might think, but no....

A previous mechanic had cut the adjustment thread off the end of the cable, he had tightened the nut up so much that the square part of the cable end had been jammed tight into its socket in the lever. So the only way forward was to fit the after market new cable.

Then we couldn't get the old cable out, even after releasing the square part - something was still preventing the cable from pulling out, so it had to be cut to get it out from the quadrant channel it runs in as you pull the lever up.

Important this bit - What we eventually worked out, was that there was a tiny strip of metal/ a finger, across the bottom of the square socket retaining the cable into the quadrant groove. Impossible to see and you just would not expect it to be there. You cannot see it at all with the cable in place. A screw driver inserted down the square hole, allows the finger to be bent out of the way and a replacement cable to be fitted.

Next problem....

The after market cable, had a too small hex on the end, to prevent it turning in the square hole of the handbrake lever. With nothing to stop it spinning, you couldn't set the nyloc adjuster nut. We ended up having to MIG weld some metal on the hex, then grind it back to a rough square shape.

A ten minute job, turned into a 5 hour struggle in the dark.

[suzublu]

That's just unbelievable Harry A simple job, turned into a 'mare by inept mechanics

[caravaman0]

Just goes to show how dedicated you are Harry to finishing the job well done and the person will be over the moon with your service.

[FrazzleTC]

Sounds like an absolute nightmare, Harry! Was this Rich's one?

[HarryM1BYT]

Originally Posted by suzublu

That's just unbelievable Harry A simple job, turned into a 'mare by inept mechanics

I was given to understand, it had been maintained by a main dealer all of its life.

It might have been easier taking out the handbrake lever, but the torque bolts fixing that would only undo so far, then they jammed ripping there socket up, So no choice but to try to resolve it in situ..

[Jordan Apex]

Always amazed at how people overcome their mechanical problems by thinking out of the box! I struggle with replace

[suzublu]

Originally Posted by HarryM1BYT

I was given to understand, it had been maintained by a main dealer all of its life.

It might have been easier taking out the handbrake lever, but the torque bolts fixing that would only undo so far, then they jammed ripping there socket up, So no choice but to try to resolve it in situ..

Well congrats on your perseverance

[brook shaw]

yes frazer.
was my 75 connie

many thanks to harry for his enthusiasm and "will not be beaten" attitude towards a problem

it took some head scratching but 2 minds are deffo better than one.

HARRY..a big thank you !!!!
thank your other half for the drinks too

lovely 75 by the way harry!!!!!
looks lovely.nice spec

again.my utmost thanks

[LotusLC]

Well done Harry, this is the part which makes this a great club, helping each other....

[pab]

Originally Posted by lotuslc

Well done Harry, this is the part which makes this a great club, helping each other....

A top guy, just lives round the corner from me too.