Dave's "S200KYS" Jimny 'laner Build...

Back to the MOT repairs today...

Track rod ball joint has excessive play Offside Front (from steering box drop arm)



Indeed it did. so I whipped it off and used it to copy the set length against a new one from JimnyBits..



Jacked up tight, with the jack at full stretch it still wouldn't reach so I used a 3" aluminium bodylift block to reach it...

Driver's seat insecure (Bolts loose in frame)

I was going to question this, but indeed when I tried it the bolts had indeed rattled a little bit loose...



Just finished doing that and the missus called me in for breakfast

Soon back out again, and...



An eBay purchase is called into play...

Windscreen damaged but not adversely affecting driver;s view



Cutting polish and a pad for the drill... hmm? "snake oil" ?!



There's the bad scuff, some 7" long and half an inch wide... a branch on the last 'lane of the Lakes Day Trip, in the dark...



A few minutes of polishing...



And blimey! It's soon gone!

Next... gulp!...

Suspension arm attachment bracket / mounting likely to fail Offside Rear (Bracket / mount broken on rear axle)



I used a spare rear axle casing in the corner of the garage...



To make a cardboard template...



Which were then transferred to 5mm steel plate



That'll do!



Then the axle was cleaned up and they were welded in place...

Shock absorber missing Offside Rear



tools and spares, digging tools, spare wheel...
The mount was welded back on, and a 2" square tab welded over the join to strengthen everything back up, the flap in the floor was then welded up and the back of the Jimny refilled - tote box sliders, totes containing

Suspension component attachment bracket / mounting likely to fail Nearside Rear (Panhard rod mount fractured)

The crack was cut into using a slitting disk and then the mount re-welded inside and out, and then painted with black hammerite...



That should be it then? Time to book the re-test this coming week...



I then packed my tools away using the gold Jimny mobile floodlights

A few beers and roast beef dinner...

I worked late as I've lost my day off on Wednesday this coming week, so I needed to get everything done today to be within the two week dedline for a free re-test

And we're out greenlaning again on the 10th of November!...!

Looks like the man should be happy with all that. The screen kit, was it actually cut into the glass or just a hard smear on the outside? Only I get probably 3/4 of the bramble rash you do including occasionally branches up the screen and so far they have always lifted with autoglym glass polish and a cloth.

Damn! It didn't pass it's re-test today...

I welded the crack in the corner of the top of the panhard rod mount on the rear axle... the tester says he was referring to a different crack underneath which he has now highlighted with chalk...

And the SuperPro "heavy duty adjustable" £100-ish anti-roll-bar drop links are indeed goosed I'll be replacing them with some 'disposable' cheap ones and sending them back for their comments... :evil:

Apart from that... everything else was fine :lol:

So the work falls to this coming Sunday for a lst-chance at a free re-test on Monday then... :blink:

How annoying. How long have you had those drop links on for doesn't seem like ten minutes since you were installing them?

Just had a search back trought the forum...

April 2017 -

www.bigjimny.com/index.php/forum/18-buil...ild?start=864#180507



I'll include those details when I send them back

I know my off roading isn't as extreme as you do and my car is noticeably lighter but I do off road every single day and my standard drop links are absolutely free of play after 5 odd years. I think you are right in asking questions of the manufacturer.