I turned my hacksaw blade upside down and cut through the inner bush sleeve, rubber, and carefully through the outer sleeve without scoring the chassis itself. I was then able to knock the inside parts out, but was left with the outer sleeve still stuck in place. Having removed a 1mm strip from its perimeter I was confident I'd knock it out in no time when I returned the next evening (it's still waiting for me).
When I tried to remove the first spring bush, I had an even harder time. I've heard all the hints and tips about a screwdriver or shim either side to release the grip leaf enough to knock the bush out - but I could not get this approach to work.
So I set about making a tool I could use to remove bushes. With limited free time, my mind was starting to add up the weekends it would take to get through the 12 bushes that are on the vehicle in total..
I took some threaded rod from an old scissor jack and some other bits of scrap. A couple of failed attempts (where some piece of the tool would give way before the bush moved) saw me enlist the help of a friend with a lathe (thanks, Jacob!). He machined me a cap of the right dimensions to push the bush from one side, out and into a receiving cup (a very big socket in this case, but sturdy pipe would do the same job).
With this, I was able to get the other chassis bush moving:
I will cover this tool in detail once we've machined the final piece, a steel cylinder of the right size and strength to lock in place behind the push cap and follow the bush all the way through. We need to bore the centre out a few thou. I've used some scrap tubing in place of this stronger piece but it always crumples before the bush moves, such is the force needed to push past the corrosion and tight fit. More soon..
In other news I got the two front springs apart; a big hammer, cold chisel, sweat, blood, and tears being the main ingredients. There is also a knack to it, but it's hopeless to explain. Take one apart with some pain and swearing, and you will learn enough to take the second apart in almost no time at all. Often the way!
Initial estimates of "they don't look too bad" have proved correct, but they will still benefit from the clean-up they're getting and the grease I'll pack them with and a light spray of Chassis-in-One once they're back together.
Hopefully, the next couple of updates will detail the bush extractor tool and show a pair of refurbished leaf springs ready to go back on the front!
