Flapper Box Refurb

[Jonny Hart]

Hey budgeteers,

 

Here's my recent budget refurb of the the flapper boxes. Mine weren't too bad. A bit of surface rust, but the mechanism was stiff and the butterfly seal melted.

 

I started by taking everything apart, and sent the housings and wheel of for blast and powder coat (£30) then started with the butterflies themselves.

 

Drill out the six rivets in the butterfly and separate the two halves - the black stuff is the hardened melted seal:

 

 

I got some 2mm silicone rubber sheet for a fiver off ebay, make template:

 

 

Cut oversize and remove centre strip for control rod, add holes (use leather punch)

 

 

Re rivet

 

 

Offer up to flapper and trim curve

 

 

I recently acquired a 1930's Myford lathe (£50) so remade the cracked and brittle swivels out of PTFE bar:

 

 

Once these were made I reassembled the unit, with new swivels and spring:

 

 

On the end of the flapper cables there is an aluminium end that had completely crumbled away. Made these replacements from 10mm ally bar:

 

 

 

Old versus new:

 

 

On the car:

 

 

Final result:

 

 

As you can see there was a small hole after blasting but that isn't really going to effect the heat output so I can live with that. Levers in the car now silky smooth.

[semprini27]

Nice work ! You can do mine !!

[Lesworth]

[MrPerkles]

best fresh flap joke wins a lifetime supply of toffee crisps...

[Jonny Hart]

best fresh flap joke wins a lifetime supply of toffee crisps...

 

 

Don't. I spent the morning speaking to a wheel manufacturer about how to test for "abnormal flange distortion".

[Beaky]

"abnormal flange distortion".

 

I know just the girl that fits this description.............Lol

[Jonny Hart]

"abnormal flange distortion".

I know just the girl that fits this description.............Lol

Radial or lateral run out?

[Beaky]

Radial or lateral run out?

 

Either depending on position...............................................