'77 Zastava 101 "The Flying Shite"

Beni

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Project Zastava will continue in two weeks time after a little winter break.
In the meantime we got plenty of parts and two more donations by DanROM and MXM so there's about 50€ to be spend.

I had that list two posts up to show which parts are needed and which are bought already, also showing whose money went to which part. Just came here to update it but sadly it seems to have been hacked up with the software upgrade...I'll make a new list in the coming days.

Anyhow, the new donations will buy a regulator for the alternator (10€), a fan belt (2€), a fuel filter (5.50€), Oil (25€) and other small parts I'll have to determine when I'm next in the garage.
The only bigger investments left are new tyres (around 150€) and other parts that still seem to be good enough but would need changing in the foreseeable future (front shocks and top mounts, spark plug wires, sensors and switches, brakes and so on).
 

Beni

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Work has continuned, albeit slowly. The idea was to change the rear suspension bushings and clean the whole thing up.
Whilst the left side was already out of the car and ready to be worked on we sheared a bolt on the other side and it wouldn't move no matter what.
In the end I got the whole thing out, strut, upright and brake, and carefully had to cut the bolt stuck in the bushing without harming the other components. Took much longer than I hoped but it worked in the end.

Here are some pictures, the quality is pretty rubbish as my camera's battery was flat and I had to use the phone!

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[IMG2=JSON]{"data-align":"none","data-size":"full","src":"https:\/\/i.imgur.com\/BjDVi00.jpg"}[/IMG2]

[IMG2=JSON]{"data-align":"none","data-size":"full","src":"https:\/\/i.imgur.com\/CyY8GgC.jpg"}[/IMG2]


Here's the left hand side wishbone. The rear suspension is independent from side to side but connected with a transverse leaf spring.

[IMG2=JSON]{"data-align":"none","data-size":"full","src":"https:\/\/i.imgur.com\/Hgzado3.jpg"}[/IMG2]


The reason for the work, the disintegrating bushings, outside:

[IMG2=JSON]{"data-align":"none","data-size":"full","src":"https:\/\/i.imgur.com\/7rlGX9g.jpg"}[/IMG2]


...and inside:

[IMG2=JSON]{"data-align":"none","data-size":"full","src":"https:\/\/i.imgur.com\/OhL8f8J.jpg"}[/IMG2]


Front bushings were rather easy to push out with a big vice and a makeshift tool made from a brake piston:

[IMG2=JSON]{"data-align":"none","data-size":"full","src":"https:\/\/i.imgur.com\/ZwUwmlY.jpg"}[/IMG2]


For the rear I had to get a bit more creative because of the shape of the fastening rod:

[IMG2=JSON]{"data-align":"none","data-size":"full","src":"https:\/\/i.imgur.com\/lo9iPNJ.jpg"}[/IMG2]


Gave the left hand side a good clean:

[IMG2=JSON]{"data-align":"none","data-size":"full","src":"https:\/\/i.imgur.com\/BHRymQa.jpg"}[/IMG2]


...and then some paint:

[IMG2=JSON]{"data-align":"none","data-size":"full","src":"https:\/\/i.imgur.com\/wjgT62w.jpg"}[/IMG2]


Whilst the other side will be done next time around:

[IMG2=JSON]{"data-align":"none","data-size":"full","src":"https:\/\/i.imgur.com\/7AdHRe1.jpg"}[/IMG2]


Next time the bushings will be pressed in, the rear suspension reassembled, the welding done and possibly the engine reinstalled...there'll be a few days reserved for that.


Most parts are covered by now, major things missing are the tyres now. I'll repost the list of donations and parts ASAP, if you still feel like throwing money at the car, please visit the moneypool or send it directly to zastava.restauration@gmail.com!
 
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Beni

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So, work will continue next week, we'll be at loose_unit's place on the 24th - 25th of March if anyone wants to come along and help/sit around/do nothing!

More updates then.
 

loose_unit

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Germany, 57.7km from The Ring
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Zastava, MX-5, M140i, Pluriel, Equus
Some happenings!

On the way from my place to Limburg in the truck:



Sitting in the Zastava on our first attempt at loading it up: (We later moved the truck to a steeper downhill to give us a shallower run-up where it actually worked)



Here it is in the truck ready to be tied down a bit better and all of the rest of the bits need to be added:



On the way back to my place:



Unloading was very easy as expected:



Aaand parked for the evening:



THE NEXT DAY:


The workshop was in quite a mess, so more shelving was aquired:



Tidying up and re-organising things:



The Zastava waiting for it's turn in the sun:



And we have light above the desk!



A new cambelt and tensioner are installed:



A new gasket was installed after Adamar honed the cam cover and was quite pleased with himself:



A stand was built for the 60" plasma TV I scored from work (It has massive burn in, but it's fine for the barn and outside) Then we sat down and enjoyed the moment:



​​​​​THE NEXT DAY:


New clutch installed and then the gearbox get's fixed to the engine:



This is the first attempt:



The second attempt, we needed more angle:



IT FITS!!!



Even the engine mounts line up. Some tweaking was needed with the new bottom mount as we installed it after the engine was dropped in, but that fit eventually after Mikko built a nice extension combination with screwdrivers and sockets and whatnot:



IN:



​​​​​THE NEXT DAY:

No photos from today so far, I did very little, DaBoom has been putting in lots of effort to get things tidied up while I have been forced to work so I can pay for things like the Zastava :) I am sure Beni and DaBoom will post more photos and information of the happenings!
 

public

Has been known to shou emousshiöns
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Oysterbottom
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So this is the 85hp performance engine?
 

loose_unit

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So, tonight I have ordered some parts, a few bits that might fit the throttle system (I cannot tell but they are only €2,50 each) and a new throttle cable.

Let's see what arrives and what I can do with it!
 

MWF

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MX-5 1.8i Indiana SE, update pending
I'm confused. Whose car is it now, technically? And are there any plans for sorting out the body rust and giving it a respray?
 

Beni

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To clear a few things up, I still own half of it and the other half is somewhere in transition between Adrian and loose_unit I guess.
We decided to bring it to loose_unit's place since he's got all of 10 metres to walk from his front door to the workshop whilst it is about 560 kms for me.

Body rust has been mostly repaired already, a few places couldn't be finished since my welder played up before we shifted the car. All the structural and visible rust needs to be repaired for TÜV anyways.
We've got paint and we'll touch it up in places, the old paintjob is rubbish anyways and loose_unit and I strongly agree that the patina needs to stay and is essential to the car's story. So the idea is to tidy it up but not fully respray it.

I'd post some more pics if only I had any!
 

DaBoom

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So, I had a nice fly&wrench holiday in Germany last week. I was planning on heading there anyway, to play with my Benelli that Joe is kindly storing for me. But this coinsided nicely with plans to move the Zastava about, so I adjusted my schedule to match. Solved some transport issues at the same time as well, as I have a licence to drive fitting equipment for the move.


Getting started at the garage, Z rolled to the working area.
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Beni working on the other rear suspension arm, while I got to saw some bushings to make them fit the car.
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Professional lighting setup.
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Then it was time to attack the other rear shock, that had ever so slightly stuck bolt in it.
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A bit more effort needed to remove the hub from the shock.
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Meanwhile, a bit of weather cover sprayed on the suspension arm. With a heat gun, as it was rather cool spring weather still.
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After that had dried off the next day, it was time to press in some bushings. Extraction tool Beni had made previously worked the other way as well.
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At the other end a bit more modification was needed though.
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Finished!
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Back to attacking remnants of the stuck bolt again then.
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Quite a bit of extra work needed..
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Since there was no hydraulic press around..
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As has become customary, shocks needed a bit of adjustment to fit as well
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Some beautiful welding to finish the other shock tower.
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Covered up for now
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We also found out that the rear suspension arm needs to be assembled in specific order, or things wont fit. :lol:
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Too bad these wheels won't fit (centre hole mismatch). I think they look great on the Z. And would ease the process of getting new tyres. Also, racing lightness!
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Vacuuming, before filling the back with.. Well, rest of the car
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A bit more rust was found from the front. This process got halfway done, before the welder put up a protest.
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All blacked up and ready to go.
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Important bits assembled and ready.
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Waiting..
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At this point it was time to go pick up a Joe
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And this thing
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This looks safe and sensible. Not that surprisingly two people weren't enough for that uphill.
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Ready to go.
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As is the driver
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Unloading at around midnight at the other end.
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Two slightly different Joecars
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Next morning the rental place had set a beginner a nice reversing challenge.
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Back at the new base, it was time to start clear out space for the new inhabitant.
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Err..
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Works with a bit of added force.
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After we got the space cleared out we got distracted with other side projects a bit.
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New day, yet more sunshine.
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After previous days work servicing the engine, it was time to put the gearbox in. Went reasonably well, before some extra plates that should go in between there appeared.
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Joe involving his other power tool.
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Carbs..
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After a bit of faffing, the engine went back to its place.
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Some extra bits left over.
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