Security Lug Defeated

 

This week’s challenge was a flat tire; I switched to the spare relatively quickly and uneventfully except that when I was tightening the security lug bolt the security key slipped out a bit. When it slipped it broke a little chunk off of the security key and warped the security pattern on the lug bolt. I ordered a new key and lug right away but since I didn’t want to risk the warped lug bolt breaking the new key, I had to come up with some other way to remove it.

First I tried a broken lug extractor – these are cheap and readily available at the local car parts place. They’re basically a regular impact socket with a reverse thread on the inside rather than the usual hex pattern. The theory is that as you loosen the lug the socket’s threads bite into and turn the lug bolt. This actually would have worked great if it weren’t for a collar that’s integrated into the security bolt – the socket only bit into this collar and it spun on the lug bolt without turning the bolt body. It’s almost like they thought of this scenario when the security lug was designed…

Next I tried to cut some small grooves in the bolt head and deform the collar into these grooves so that the collar would be able to drive the bolt out. I think this was an OK idea, but since the collar was glass-hard steel it chipped instead of deforming.

Running out of options, I decided just to weld a nut to the security lug bolt and unbolt it. I had held off on this ‘nuclear option’ because there is a level of risk – the ground current could actually weld the bolt into the hub somewhat or damage bearings/electronics – I chose the ground clamp location carefully and also cleaned it carefully to avoid this. It was a messy weld (prioritizing not damaging the spare) but worked great. I think the heat from welding may also have helped by expanding the bolt and relieving some of the pressure against the spare.

With the lug bolt out the spare was swapped to the (now repaired) wheel and tire. Not sure how a dealer/mechanic would handle this scenario, but I’m guessing it means the welder has now paid for itself for at least the 3rd or 4th time.

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Adding Auto-Refill to Keurig

It’s not that manually refilling a Keurig tank is hard, it’s just unnecessary. Commercial Keurigs (and some of the high-end home versions) are built with this in mind and can be directly plumbed for water. Our Keurig, however, is a ‘normal’ home machine without provisions for direct plumbing; so some creativity was involved in adapting it for this feature. Altogether this was a fairly simple 3-step process:

#1 – Make bracket from scrap piece of PVC pipe.

#2 – Install miniature float valve ($3 w/ free shipping) and bracket into tank.

#3 – Plumb float valve to existing water filter under sink.

All plumbing is nicely concealed behind the microwave/cabinets, so the only evidence of anything different is the float visible in the tank. Before anyone freaks out about the evil toxic plastic floating in the water, I should point out that the tank itself is plastic anyways, as is much of the tubing that supplies water to the faucet when filling the old-fashioned way. Total project cost was well under $10.

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The Bungee Shifter Device

I’ve been driving the bus quite a bit this week and so far all is well. It seems happier/smoother/quieter with each trip. If first gear is selected it works for a foot or two then pops out; if it’s held in first it works for a foot or two then grinds. Although I did clean and reseal the trans I didn’t do anything with the internals and I think they’re just too far gone. Luckily the 1600 has plenty of torque to just start in second all the time; it’s a little tougher on the clutch but I’ll replace it when I replace the trans. Replacing the trans has been part of the plan anyhow, the stock trans requires 4500RPM (redline) in 4th gear to go 65MPH; the replacement will have taller gearing to both allow higher speed and lower the revs at normal speeds.

It pops out of 4th too, which is apparently a very common problem. Since it stays in 4th if held, I’ve solved this by deploying a strategically placed bungee cord anytime it’s in 4th for longer than I feel like holding onto the shifter.

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