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A bit too obvious really wasn't it.. :D
 
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Discussion Starter #664
Salvaged my charging cable from the old mount earlier, some images to show how distorted the mount became:





Fair to say, not recoverable!
 

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My phone no longer fits in my holder without removing the case. Must be down to the material used in the digital printer!
 

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Discussion Starter #666
Certainly seems to be the case (no pun intended), at least the CD slot mount seems to work for now
 

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Just come across your thread as I don’t make it onto the forums very often. Looks like you’ll have transformed that car by the time you’re finished.

The red calipers on my car are going to need tidying at some point. They’re a bit scruffy when you look at them very closely. It’s probably just my OCD kicking in if I’m being honest though.

David.
 
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Discussion Starter #668
Cheers David, yeah I already started on the prep work to replace them, unsure as to what i will do with the ones currently on the car as of yet...
 

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Discussion Starter #669
Forgot to post this when they arrived, some new brake hardware, although the shims aren't what I thought they were...



Just waiting for the call from the blasting company to say the calipers can be collected...
 

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Discussion Starter #670
Got the message that my bumpers are ready! Wahoooooo!.

Will have them fitted on the weekend, next weekend I am back up there and they'll be flat and polished on the car whilst I do other things
 

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Discussion Starter #671
Bear with me as I am awaiting dinner and this is going to be a split post so may be a big gap..

Yesterday after the TT work mentioned in the members section, we went to the bodyshop to collect the bumpers, 250 for front and rear bumper and the 2 diffuser pieces, exceptional deal!

Front bumper and rear diffuser:



Rear bumper:



Started removing the front bumper:



The old sensor bracket was exceptionally bent! This may have been a big problem that wasn't picked up by the JLR dealer:



Evidence that this has been in for front end work before, this is a slam panel bolt in the slam panel recess, but no missing bolts:



Slam panel off to make it easier to remove the bracket, which was also rusty:



Front end stripped:



Started drilling out the old steel (stupid) rivets:



Looked at the setup for the front bumper behind:



Really struggled with the remaining rivets:



Even after changing bits, but more later...

Glued the magents on the rear of the front bumper:



The acc bracket grille was deformed from the bumper damage:



Nothing a little heat couldn't sort:



Went and got some cobalt drill bits, they made the rivets look like cheese and came off a dream! Bracket removed:





Used the threaded nut tool, failure on first attempt:





Bummer...
 

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Discussion Starter #672
Old bracket matched new one:





Made the holes ever so slightly larger, upped the size of the insert, et voila!



Little tab for the bracket goes in this hole:



Bracket attached correctly:



Slam panel refitted and bracket nice and straight:



Fitted my old sensor as I was still convinced the previous diagnosis have been wrong:




Rear bumper came off, so did the lights to clean them:



Front bumper on:



Acc grille nicely aligned now:



Magnetic sheet held in place:



Attached it to the number plate, but no good, wouldn't hold at all!

Luckily I bought extra magnets, wrapped them in felt tape:



Adhered to the number plate:



Holds nice and firm:



Fitted the towing cover, front end complete:



Took the car for a drive and got some pictures:







Then as I was driving along, wondrous things happened!



No fault light anymore! Cruise activated and stayed on...

Success!
 

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Nice one Jordan, you're dedicated work is paying off handsomely.


I see someone knows about removing old mushroom head rivets. Filing the top off to get an easier flat section to drill.
(Nb, they're not silly, nor stupid, but are far stronger than blind rivets, which is why they are still used mainly in aerospace structural components, also probably made from hiduminium, or mono metal rather than steel)

Advice if you want it - or for anyone else, regarding the rivets.
Lightly centre punch the new flat section on the rivet, to help get your drill bit cutting.
As you get more experienced, you'll find you don't need to centre punch anymore.
Don't drill at high speed, you'll find that drilling at a slower speed lets the drill bit work more effectively.
It also gives you more control and you won't snap as many bits either.
You only need to drill as deep as the rivet head itself, not all the way though - that increases the risk of damaging the material the rivet is holding together.

Do not, really - do not use high speeds with Cobalt drill bits. They have a very real tendency to shatter at high rpm.

It's why we call dullards 'Cobalt' - slow boring tool.
 
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Discussion Starter #674
Cheers! It was a steep learning curve but got there quickly, it was very slow on a nice drill with a decent trigger for speed control that did it.

Also use spray 3in1 to lubricate, although we went to slow that you could hold the cobalt bit after all rivets drilled between your finger tips. It was stone cold, just watching the metal swarf come off in strands showed how easy it was. The drill bits I got had a review where someone used them for 28mm steel beams, so knew it was a safe bet for 3 simple rivets.

With the use they'll get they're likely a tool for life too, so a good investment
 

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Cheers! It was a steep learning curve but got there quickly, it was very slow on a nice drill with a decent trigger for speed control that did it.

Also use spray 3in1 to lubricate, although we went to slow that you could hold the cobalt bit after all rivets drilled between your finger tips. It was stone cold, just watching the metal swarf come off in strands showed how easy it was. The drill bits I got had a review where someone used them for 28mm steel beams, so knew it was a safe bet for 3 simple rivets.

With the use they'll get they're likely a tool for life too, so a good investment
A good investment, eh?

I've plenty of HSS drills in my garage. Not got any Cobalt though. I've used them plenty when I was working aerospace, but personally I doubt I'll ever need them for home use.

If you get really tough metal, then have a look at carbide drills. Very specialist, very easy to bend (rather than snap) - and very expensive.
But if you thought Cobalt makes easy work of drilling, carbide goes through it like butter.
 

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Discussion Starter #676
I have a big set of Makita bits, HSS, wood, masonry, hole saws and the like...

If I ever have any form of metal to drill I will use the cobalt, will be much easier than the standard HSS bits I have, can use them on plastic and other dulling materials... the cobalt set was double the price for a small set of bits than a triple figure volume of makita bits.

If I ever have anything serious enough to require stronger than cobalt, likelihood is i am well out of my depth. As much as I like doing things myself, I have no training in anything manual. A lot of DIY and car things can be done with logic, a half decent tool space, organisation and time.

There are limitations when you start entering into where a lot of experience or an engineering mind/experience/ability is required. That is the point where the money comes out and the kettle goes on
 

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Don't use cobalt on stainless bud. HSS is good enough to drill that.

I'd also stick to HSS for the majority of metalwork jobs, leaving cobalt until it's really needed.

Key to drills isn't pressure behind the drill, but rotational speed.

Too much pressure can blunt a drill in no time.
 
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Discussion Starter #678
On my way home when I started the car, was greeted by this:



After about 100 yards it went and worked faultlessly all the way home! I am thinking it may be where the code is stored perhaps, or maybe it really does need calibrating! Will try a code clear with the carsoft first...

When i arrived home I had parcels, no surprise, one of which was this:



Currently have no need, but future proofed in case I do need it, I am hoping that I do :lol: gated driveway would be lovely!
 

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Discussion Starter #680
Collected the blasted brakes:





That is the selection I took to them after doing the other bits myself, so all parts are blasted now!

Need to rebuild and paint now...should be fun!
 
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