DS23 Safari Restoration

[Maximillian]

Howdy all,

Thought I would have a general thread for my restoration rather than one thread per question I have for the collective hive mind.

Current question - is there a spring or something else missing from my clutch pedal system? (See photo). It pushes to the ground but doesn’t return without being pulled back up. There doesn’t seem to be any noticeable friction in the cable.

Any advice would be appreciated!

Cheers,

 

[Maximillian]

Here are some photos from the journey thus far.

 

[Maximillian]

Engine back in after some serious adventures.

 

[bleudanube]

Howdy all,

Thought I would have a general thread for my restoration rather than one thread per question I have for the collective hive mind.

Current question - is there a spring or something else missing from my clutch pedal system? (See photo). It pushes to the ground but doesn’t return without being pulled back up. There doesn’t seem to be any noticeable friction in the cable.

Any advice would be appreciated!

Cheers,

G'day from Australia - and welcome to the forum!

And even better: another Safari resto! Keep the photos coming…. My 1964 Safari Resto is somewhere in the bowels of Aussiefrogs by now. As is my DSuper one from years ago.

Re the clutch pedal - it’s certainly not right that the pedal doesn’t return - I don’t recall the setup from my DSuper and my early Safari has a different setup. I am sure someone here will chip in with a photo of how the springs should be. The horizontal one is certainly correct. The big one on the left looks like the one that should push the pedal back out, the little one looks odd…

I found a photo in manual 814 - maybe it helps.

Here a photo of my Safari - before and after ! They are good fun!

Sven

 

[Maximillian]

Hi Sven,

Your Safari resto thread was part of the inspiration to take on this project. What a journey that was.
Great work!

I haven’t worked out what is the matter with this clutch pedal, mainly because it’s such an uncomfortable place to work in the footwell!

 

[Maximillian]

My current challenge is cutting out the correct fittings for the dash, which were welded up by the previous owner.

 

[forumnoreason]

VHT wrinkle paint works really well on dashes. Better on primed surface though I reckon and give it good even coats. I think 2 or 3 does the job.

 

[Greenpeace]

With the VHT wrinkle paint you are meant to apply the paint in three directions for best results.
Spray one coat vertically, one coat horizontally and one coat diagonally.
10 minutes between coats.

 

[faulksy]

It looks more like they elongated the clock hole to take up the 2 switches and choke cable holes. I've got a spare dash to take some measurements from if you like. Not sure what shipping to SA would be but given it's size I'm thinking it won't be cheap. Let me know if you want it.

 

[Maximillian]

Hi Faulksy, measurements would be fantastic.

Thankyou for the offer of your dash. If I totally bodge the holes on this one I’ll take up your offer.

 

[Phill]

A picture of the clutch on my Safari 1970 hope this helps

 

[DoubleChevron]

If the clutch isn't returning, my first though is broken cable ....... or throwout bearing has punched through the pressure plate (or possibly the throwout fork has broken ).

 

[Phill]

The pedal should return with a broken cable as it has a spring on it to assisit as per the photo

 

[Maximillian]

In the process of refreshing the LHM supply hose and return hoses. My LHM supply hose from the tank to the pump has this filter in it. Does anyone else have one of these installed? Thoughts on if I should keep it?

Re the clutch pedal. With the cable removed from the gearbox, the pedal still doesn’t return. The cable seems to move smoothly through its sheath. So my thought is that there must be a lot of friction in the pedals pivot assembly.

 

[fritzelhund]

Your clutch pedal shot shows a single horizontal coil spring on the "pivot shaft". They are known to snap and therefore no return up action is available. If the spring has broken it will still in situ and difficult to see the break as it will all stay in place.
Later versions of the pedal include a vertical spring as well that serves to return the pedal to its top of stroke position.
The clutch pedal shown in the #1 post has a cobbled up look to it. .. two springs in the same plane .... I am pretty sure someone has made a modification ( without success ).
Phil's shot in post # 11 lacks the vertical return spring I mentioned earlier.
I have never seen a filter in line on the intake suction line. There is a very fine nylon mesh filter that sits in the big tank.

 

[Phill]

My Safari never had the vertical spring
I’ve seen a few and I’ve been working od ds since the late sixties

 

[Ramaling]

Here are some photos from the journey thus far.

When you removed the engine, did you undo all the nuts that link the axles to the side of the disc brakes - I think there are six each side
They are 17mm nuts.
I am looking to do this soon. Did you use a simple ring spanner because on the later cars its to tight to fit a socket in there

 

[Maximillian]

If I recall to remove those triaxe housings I used a mixture of long extension bars and a spanner. Needed a decent bit of leverage to get them undone.

When I did them back up, I used a 3/8th inch ratchet, on a long extension bar. Then to torque them up, I used the 1/2 inch torque wrench ( as that’s all i have!) It was all pretty tight and uncomfortable!

 

[Maximillian]

Your clutch pedal shot shows a single horizontal coil spring on the "pivot shaft". They are known to snap and therefore no return up action is available. If the spring has broken it will still in situ and difficult to see the break as it will all stay in place.
Later versions of the pedal include a vertical spring as well that serves to return the pedal to its top of stroke position.
The clutch pedal shown in the #1 post has a cobbled up look to it. .. two springs in the same plane .... I am pretty sure someone has made a modification ( without success ).
Phil's shot in post # 11 lacks the vertical return spring I mentioned earlier.
I have never seen a filter in line on the intake suction line. There is a very fine nylon mesh filter that sits in the big tank.

The second small vertical spring certainly is a recent addition. Held in by a cable tie so certainly a bodge after my own heart.

I’ll investigate the horizontal spring and see it it’s broken. To me that makes the most sense.

 

[SuppleC]

When you removed the engine, did you undo all the nuts that link the axles to the side of the disc brakes - I think there are six each side
They are 17mm nuts.
I am looking to do this soon. Did you use a simple ring spanner because on the later cars its to tight to fit a socket in there

You have to “double nut” the studs in tightly before fitting the driveshafts.