peaking of efficiency, Penrite has revamped its manufacturing operation in Victoria. The renowned Australian oils and lubricants brand has made some massive additions to its production process, making its output more efficient and ultimately benefitting its end users.
Why get yourself worked up by working harder than you need to?
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n old colleague used to tell me –on a near daily basis – to work smarter, not harder.
There were times when I thought this was a catch phrase for laziness, but as I’ve aged it’s become more relevant than ever.
Take the constant innovations in software and technology – it’s all aimed at making aspects of our work easier … right?
Sometimes, it might feel like learning new services for hybrids and EVs, or even just implementing an online booking form for customers, is just another spanner in the works.
However, once you see technology as a way of making your life easy, you’ll be working smarter, not harder before you know it.
In this edition of Australian Car
Mechanic, we touch upon this notion in a variety of ways.
Some brands – such as Supercheap and GMB – showcase the way new online tools specifically geared towards making mechanics’ lives easier.
In terms of EVs, contributing writer Iain Curry takes us to Moreton Island, where a crafty local has built an electric Baha Beetle built to avoid dependence on fuel drops off the mainland.
No matter where you look in the workshop, there’s ways to make life easier without overtly cutting corners.
Some things take time, but if you can set yourself up for working smarter in certain areas, you can make the day-to-day so much easier, and less stressful.
Harry Murtough – Editor
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Penrite Oil, a proud Australianmade and family-owned company, continues to set the benchmark in the automotive lubricants industry with recent manufacturing upgrades to its main production facility in Melbourne, Victoria. These enhancements, pivotal to Penrite’s ongoing commitment to excellence, underscore the company’s dedication to efficiency, quality, and the local workforce. For Australian automotive mechanics and professionals, understanding these advancements offers a glimpse into how Penrite’s products are crafted to meet the highest standards.
Penrite’s latest investment in stateof-the-art production machinery has transformed its manufacturing process into a model of modern efficiency and precision. With the addition of seven blenders, seventeen base oil tanks, twelve additive tanks (and six more on the way), and eleven production lines. Penrite now has the capacity to hold 1.2 million litres of base oil and 500,000 litres of additives with a further 300,000 litres to be installed. Penrite has introduced further automation to the manual handling stages of its production lines with a focus staff safety, minimising potential hazards and allowing redeployment of trained technical staff to key areas of the production process. This automation spans from unloading bottles to applying labels, filling oil, capping, packing and palletising, all managed under the vigilant supervision of skilled production employees.
Penrite’s Head of Information
The latest developments to Penrite’s manufacturing process reinforce its commitment to remaining Australian-owned and made.
Technology & Automation Biren Patel (image far right) said “the implementation of our new depalletising and palletising automation project has been a major milestone for Penrite.
“This project, which has been in development for the past 18 months, represents our commitment to continuous improvement and innovation. “We have invested heavily in state-of-the-art technology to fully automate our production lines, from unloading bottles to palletising finished products. These advancements have significantly increased our production capacity and efficiency, allowing us to meet the growing demands of our customers.
“Looking ahead, we plan to focus on further upgrades and digital transformation to maintain our competitive edge.”
The automation of Penrite’s production lines has brought several key benefits:
• Improved efficiency and consistency: automation ensures that each step of the production process is executed with precision, resulting in consistent product quality. The automation of loading containers in and out of the production line has significantly increased production speed and capacity. This allows Penrite to meet higher demand and reduce lead times, ensuring that products are delivered to customers more quickly than ever before.
• Increased production output: prior to the upgrades, Penrite was capable of producing approximately 1,500 units per hour. With the new machinery, production output has increased by Images: Penrite.
20 per cent, with further optimisations expected to boost this even further. This increased capacity means that Penrite can now pack approximately 5.6 million units annually in Victoria alone, translating to 40 million litres produced across its two Australian facilities.
• Reduced error rate and minimised waste: Enhanced precision in the production process has reduced the error rate, leading to less waste and more efficient use of resources. This not only benefits our Australian environment along with Penrite’s extensive implementation of recycled and locally sourced packaging material but also ensures that customers receive the highest quality products.
• Injury prevention and improved staff morale: By automating key ‘at risk’ areas of lifting and twisting where possible repetitive strain can occur the personnel can now oversee the automated process. Penrite Oil CEO Toby Dymond is proud of the latest upgrades. “As a family-owned business, we’ve always focused on meeting the needs of our customers and ensuring we deliver the best possible products we can,” he said.
“These upgrades are not just about advanced machinery—they’re about giving our team the power to ensure that every bottle that leaves our production line reflects the quality Penrite is renowned for. This is a significant investment for Penrite
as a business which will not only benefit our staff and customers but the wider Australian manufacturing industry and I’m genuinely excited about how these advancements will enhance our ability to continue delivering excellence, right here in Australia.”
Ensuring the quality of each product is paramount at Penrite. The new production lines are equipped with advanced quality control measures:
• Weight scales: each bottle is checked for correct weight, a critical step given that different oils and lubricants measure differently by volume and weight.
• Batch printing machine: this machine prints
the batch code on each bottle, ensuring traceability and quality assurance.
• Carton over product (COP) machine: automating the packing of bottles into cartons, the COP machine performs a weight check to ensure the correct number of bottles per carton, eliminating the risk of workplace injuries associated with manual handling of heavy products.
• Palletising robots: these robots pick up cartons and place them on pallets, ensuring consistent and secure packing for shipment.
• Automated wrapper machine: packed pallets are wrapped precisely for transport, protecting against weather conditions and ensuring that all Penrite products arrive in perfect condition.
Penrite Oil’s commitment to Australian manufacturing is unwavering. The company’s production process is 100 per cent Australian-owned and made, employing close to 200 Australians across the country. This not only supports the local economy but also ensures that Penrite products are tailored to meet the specific demands of Australian conditions.
For Australian automotive mechanics and professionals, these upgrades mean access to products that are not only high-quality but also reliably produced with cutting-edge technology. Penrite’s trusted range of engine oils, coolants, gear oils, fork oils and more continues to evolve with several new products introduced this year to meet the demands of Australian applications. Formulated, tested and made here in Australia, the growing range is crafted with the same meticulous attention to detail and commitment to excellence that has defined the brand for decades.
As Penrite continues to innovate and optimise its production processes, the future looks promising. The company’s dedication to efficiency, quality, and the local workforce positions it as a leader in the automotive lubricants industry. With these advancements Penrite is wellequipped to meet the evolving needs of its workshops and customers, ensuring that no matter what or how you drive, Penrite has got you covered.
MB has developed a useful new tool to help identify universal joints by size and type.
With so many Universal Joint varieties available, it can be tough to get the right one for the right application. Not with GMB.
The Universal Joint Lookup Tool is an online platform aimed at assisting users in selecting the right Universal Joint by size and type.
Simply visit: gmb-oceania.com and scroll down to the Universal Joint lookup tool. From there, users need only input their Universal Joint type and size. Metric or Imperial measurements can be selected to view which Universal Joints are right for them.
GMB’s Universal Joints offer high-quality smoothness and reliability across a wide array of applications. Designed to efficiently transmit torque from one shaft to another within rotating assemblies, these top-tier joints ensure seamless power transfer. Available in a variety of sizes and styles, GMB Universal Joints cater to diverse industries, including automotive, agricultural, and industrial sectors.
Crafted from premium materials and subjected to rigorous testing, GMB
“GMB’s Universal Joints offer high-quality smoothness and reliability across a wide array of applications”
Universal Joints are built to endure the harshest conditions of heavy usage. Their robust design guarantees reliable performance over time, making them a dependable choice for OEM’s, professionals and DIY enthusiasts. The ease of installation and maintenance further enhances their appeal, ensuring hassle-free operation and longevity.
Unlike inferior, low-grade rubber products that use fillers and impurities, GMB’s nitrile rubber is engineered for superior integrity and performance. This high-quality rubber
is resistant to a wide range of oils and chemicals and can withstand extreme temperatures from -40°C to +120°C, ensuring that functionality and integrity remain uncompromised. GMB Universal Joints made with nitrile rubber are designed to resist prolonged exposure and prevent grease loss, which is the leading cause of universal joint failure.
The use of low-grade steel in universal joints can lead to cracking and shearing, causing vibrations and potentially severe vehicle control issues. GMB addresses these risks by utilising the highestgrade Chrome-Molybdenum steel, which offers superior strength, durability, and corrosion protection. This premium material surpasses the standard-grade 1020 steel, providing longer life and enhanced safety for your applications.
For Universal Joints that have a reputation for quality and reliability which is recognised world-wide from our OEM and Aftermarket customers, you can’t go wrong with GMB Universal Joints.
GMB Universal Joints are part of the GMB product range that includes: Water pumps, Drive Belts, Timing kits and components, Fan clutch, Suspension components, Wheel hubs and bearings.
Contact GMB for further information: Web: gmb-oceania.com Tel: 1300 007 132 Email: oceania-sales@gmb.jp
Mechanics needing comprehensive calibration for passenger cars can look to Launch to deliver the goods for them and their customers.
Introducing the ADAS RADAR 3-IN-1 Kit: a total radar system calibration solution. This advanced kit is engineered to meet the rigorous calibration requirements of various systems, including adaptive cruise control, blind spot monitoring, lane change assist, and front corner radar.
The ADAS RADAR 3-IN-1 Kit supports calibration for a wide range of radar systems, ensuring optimal performance across all functionalities without requiring an ADAS equipment main frame. This makes the calibration process more streamlined and cost-effective. It also provides step-by-step visual guides to simplify the calibration process, ensuring accuracy and ease of use. Additionally,
For comprehensive servicing across a vast selection of vehicles, the ADAS RADAR 3-IN-1 Kit has mechanics sorted.
it offers both pre-and-post calibration reports, giving you a clear overview of the calibration results
The ADAS RADAR 3-IN-1 Kit supports calibration for the following functions:
• ACC (Adaptive Cruise Control): Ensures your vehicle maintains a safe following distance and adapts to the flow of traffic.
• BSM (Blind Spot Monitoring): Enhances safety by detecting vehicles in your blind spot and alerting you accordingly.
• LCA (Lane Change Assist): Aids in safe lane changes by monitoring the surrounding environment and providing alerts.
• FCR (Front Corner Radar): Enhances front corner detection capabilities for improved manoeuvring and collision avoidance.
For more information about the ADAS RADAR 3-IN-1 Kit, check out launchtech.com.au or call 1300 369 788
• LAM05-02 ACC Radar Target – ACC – Mercedes-Benz, BMW, Audi, VW, Porsche, Skoda, Seat, Romeo, MINI, Bentley, Rolls-Royce, Maserati, Fiat, Jeep, Nissan, Mitsubishi, Suzuki, Inifiniti, Hyundai, Kia, BYD, Geely, Chery etc.
• LAC05-03 Corner Reflector – ACC/ BSM – Toyota, Lexus, Honda Acura, Mazda, Subaru, Mitsubishi, Hyundai etc
• LAC05-04 – LCA/FCR – VW, Audi, Seat, Mazda etc
Trico’s Authorised Wiper Expert program is not only a recognised network, but it also delivers benefits to workshops as well.
Trico, one of the world’s leading manufacturers and innovators of automotive windscreen wiper products, is extending an invitation to all of its trade customers to become a part of the company’s Trico Authorised Wiper Expert program.
This program enables automotive repairers or re-sellers to become a part of nationwide group of wiper experts, with
the product and technical support of a global leader in this important, fast moving and road safety enhancing automotive product sector.
Every Trico trade customer who becomes a Trico Authorised Wiper Expert will earn one reward point for every dollar spent on all products across the quality Trico windscreen wiper range.
The points earned will be redeemable on a
range of prizes at the end of the year.
Trico Australia will also place Trico Authorised Wiper Experts into a draw to win tickets to exciting Trico Trans Am Series or Supercar race events located in their home states.
Every Trico Authorised Wiper Expert workshop will be provided with Trico merchandise, including hats, t-shirts and two free sets of wiper blades for their own cars accompanied by attention-focussing Trico Authorised Wiper Expert signage.
All Trico Authorised Wiper Experts will also gain priority access to new Trico windscreen wiper products as they are released and they will also take part in exclusive Trico Authorised Wiper Expert promotions.
“The Trico Authorised Wiper Expert program rewards our trade customers for their loyalty, while also serving as a reminder to customers that frequent windscreen wiper checking and replacements are an important part of each service or repair job,“ Trico Asia-Pacific Sales Manager Adam Rickard stated.
“There is no cost to be involved and there are prizes to be redeemed from points earned at the end of the year. There are no downsides to becoming a Trico Authorised Wiper Expert,” He added.
Becoming a Trico Authorised Wiper Expert is easy - advise your Trico distributor who can arrange for a member of the Trico team to visit your business, or you can register your interest using the contact section of the Trico website at tricoproducts.com.au
Supercheap Auto Trade has made trade super with the launch of a brand-new purpose-built website designed exclusively for automotive workshops and other businesses involved in the automotive trade.
Among some of the new and substantial improvements to the Supercheap Auto Trade website is a full Account Management section that allows workshops to control purchases and purchase limits, view past invoices and apply for or increase limits on 30-day credit accounts. Particularly impressive is the ability for Trade Account Holders to manage their whole account including giving authorised access to all employees and even apprentices. This means that all authorised users gain the benefit of exclusive trade pricing and the Trade Account Holder or Account Manager still has full control to customise the level of access for each employee and manage areas like spend limits.
In what is believed to be the first of its kind for the automotive industry, the Supercheap Auto Trade website will offer a Barcode Scanner facility where customers can scan any product, whether in store or at their workshop and it will provide full product information, including the tailored trade price. From there, customers can add products directly to the shopping cart and have them delivered or use the rapid 30-minute Click & Collect now available at Supercheap Auto locations.
The Parts Guide has been improved with the addition of trade pricing now integrated into the section. For the serious workshop, service schedule and repair time modules can be enabled. The Log Book Service Screen allows you to select a car, choose the required service, and view a comprehensive list of all necessary products, conveniently displayed on the side for easy reference. In the Repair Times tab, after selecting a car and the specific category of repair, you’ll be provided with precise repair durations in minutes or hours along with a calculated cost based on the applicable labour rate.
There’s plenty of smarts behind the new e-commerce platform that integrates with all the key attributes of the website. Repeat orders and larger items have become super easy and fast with a dedicated area to order bulk products and a re-ordering system for those items that are purchased on a regular basis. This means that customers can quickly reorder from a previous invoice
or utilise the new Quick Order Form that’s designed to save time when placing a large order or stocking up on common items.
In total, there’s access to over one million products online from trusted brands like Bendix, Bosch, Brembo, Castrol, Century, Gates, Kincrome, Mobil, Penrite, Ryco and ToolPro, to name just a few and Supercheap Auto Trade have ensured that pricing is not only super competitive but is now listed on the website clearly and accurately. A whole team behind the scenes are dedicated to making sure all the products listed are
available to Trade Account Holders at the very best price, 24 hours a day, seven days a week.
Speaking of 24/7, a massive benefit to trade customers is that they can shop online anytime and anywhere. Whether they are under the bonnet or at the beach, shopping for the best brands and products can be done whenever a customer wants. And of course, during business hours, products can be delivered or the 30-minute Click and
Collect is available through all Supercheap Auto Stores across the country. When it comes to payments, there’s a host of new improvements in this area too.
Bearings: A subject that can be overlooked but can have a devastating outcome if not maintained or serviced correctly
There are several different configurations of Wheel Bearings used in light vehicles, trucks, 4WD’s and trailers depending on what type of application is required. There are primarily two styles of wheel bearings commonly used:
The most common type of wheel bearings used in vehicles consists of small metal balls that rotate between two smooth rings or races. Ball bearings are known for their efficiency and ability to handle both radial and axial loads.
Designed to handle heavier loads and
provide better resistance to shock and impact compared to ball bearings. They consist of tapered rollers held in place by a cage between two outer races.
Additionally, within these two broad categories, there are variations and specific designs depending on the vehicle’s requirements and design considerations. Some vehicles may also use specialized bearings, such as double-row ball bearings or sealed bearings, to enhance durability and performance in specific conditions.
It’s worth noting that modern vehicles often use sealed bearings, which integrate the bearing and hub into a single unit. This design reduces maintenance requirements and simplifies replacement but may necessitate replacing the entire hub
assembly if the bearing fails. When used in the area or attached to an axle, for example, attached to a rear-wheel-drive axle, some bearings can be replaced and purchased in a kit form, but some late vehicles can require a complete axle replacement.
It is critical in checking, maintaining and servicing wheel bearings especially a Tapered wheel Bearing at the correct intervals. This can vary, depending on the type of driving conditions experienced.
Maintaining wheel bearings on Light vehicles, Trucks, 4WD drives and Trailers is crucial for several reasons. Proper maintenance of wheel bearings enhances vehicle performance, safety, and longevity.
Key benefits
Enhanced safety:
• Preventing wheel detachment: wellmaintained bearings prevent the risk of wheel detachment, which can be catastrophic at high speeds or during heavy loads especially on trailers. If disc brakes are fitted and if the wheel bearing hub is running out of line because of a wheel bearing collapsing it will push the brake caliper piston away from the brake disc causing an excessive downward movement of the brake pedal when the brakes are applied causing extended braking time for the vehicle to stop. The brake pedal may need to be pumped to stop the vehicle completely as this could cause a serious accident if you’re not stopping in time or at all.
• Stable handling: properly functioning bearings ensure stable and predictable handling of the vehicle, especially during cornering and off-road driving.
Improved vehicle performance:
• Smooth ride: well-lubricated and correctly adjusted bearings reduce friction, leading to a smoother and quieter ride.
• Efficient operation: properly maintained bearings minimize rolling resistance, which can improve fuel efficiency and overall vehicle performance.
Extended component life:
• Preventing premature wear: regular maintenance helps avoid excessive wear and tear on wheel bearings, which can otherwise lead to costly repairs or replacements.
• Protecting other parts: by ensuring bearings are in good condition, you also protect associated components such as the wheel hub, suspension, and drivetrain.
Cost savings:
• Avoiding expensive repairs: regular maintenance helps catch issues early before they lead to more expensive repairs or replacements.
• Reducing downtime: keeping bearings in good shape minimizes unexpected breakdowns and downtime, which can be particularly important for commercial vehicles.
Optimal load handling:
• Handling heavy loads: for trucks especially trailers and 4WD vehicles, which often carry heavy loads or tackle rough terrains, well-maintained bearings are crucial for handling and distributing loads effectively.
Enhanced off-road capability:
• Durability in harsh conditions: off-road vehicles benefit from properly maintained bearings as they endure more challenging conditions, including dirt, mud, and water. Regular maintenance ensures that the
bearings continue to perform well under these stresses.
Prevention of alignment issues:
• Maintaining wheel alignment: good wheel bearings help maintain proper wheel alignment, which is important for even tire wear and overall vehicle stability. Reduced noise:
• Quieter operation: Worn or damaged bearings can create noise that indicates an issue. Regular maintenance helps keep the vehicle operating quietly.
Maintaining wheel bearings is essential for vehicle safety, performance, and costefficiency. Regular inspections and timely replacements or adjustments help ensure that your truck/trailers or 4WD continues to operate smoothly and reliably.
Fitting and servicing wheel bearings involves a series of precise steps to ensure that the bearings are installed correctly and function optimally. Here is a detailed procedure for fitting and servicing wheel bearings: Preparation:
• Tools and equipment: gather necessary tools such as a jack, jack stands, wheel wrench, socket set, bearing puller, press, and new bearings. You may also need bearing grease, a torque wrench, and a dial indicator for measuring runout.
• Safety: ensure the vehicle is on a stable surface and engage the parking brake. Use wheel chocks to prevent the vehicle from rolling.
Remove the wheel:
• Loosen the wheel nuts slightly while the vehicle is still on the ground.
• Lift the vehicle using a jack and secure it with jack stands.
• Remove the wheel and set it aside.
Remove the brake components:
• Caliper: unbolt and remove the brake caliper. Support it with a hanger or a piece of wire to avoid stress on the brake line.
• Brake rotor: remove the brake rotor. If it’s stuck, tap it gently with a rubber mallet to free it.
Remove the hub assembly.
• Outer nut/cap: remove any dust cap or nut covering the hub assembly.
• Locking nut: if present, remove the locking nut (it could be a castle nut with a cotter pin or in a front hub in a 4WD can have a flat plate with a serious of holes which contain two or three tapered screws attaching it to the stud hub spindle stopping it from turning).
• Hub: remove the hub assembly. This might require a hub puller if it’s tightly fitted.
Remove the old tapered bearings:
• Outer bearing: remove the outer bearing from the hub assembly.
• Inner bearing: remove the inner bearing, usually requiring a bearing puller or similar tool.
Clean and inspect components:
• Clean: thoroughly clean the hub assembly, spindle, and all related components. Remove any old grease and debris.
• Inspect: check for any damage or excessive wear on the hub assembly, spindle, and other related parts. Replace any damaged components.
Install New Bearings if it is a ball race to Hub assembly mentioned in the two dot points below, normally the ball race comes pre-greased.
• Pressing bearings: using a press, carefully press the new bearings into the hub assembly. Make sure to follow the manufacturer’s specifications regarding the installation depth and orientation.
• Bearing race: ensure that the bearing races are properly seated in the hub. You may need a bearing race driver or appropriate tool for this.
Either fitting new or reusing the old Tapered Roller Bearings. Regreasing of the bearings needs to be performed as described or click on any of the internet addresses listed below.
Properly applying the correct type of grease to a tapered wheel bearing is crucial for its longevity and performance. Here’s a step-by-step guide on how to do it: Clean your hands: thoroughly clean your hands or wear a new pair of latex gloves. Grease placement: place a golf-ball sized amount of grease, (which requires to be the correct type of grease) into your palm. Apply grease: using your opposite hand,
push the large end of the bearing cone assembly into the grease. This forces grease between the rollers, cage, and cone. Remember, proper lubrication significantly increases bearing life, especially in adverse conditions. So, follow these steps diligently to ensure optimal performance. For more detailed instructions, you can refer to below sites:
• blog.slsbearings.com
• timken.com
• forconstructionpros.com
Rotate Assembly: while pushing grease into the large end, rotate the entire cone assembly until the grease is evenly distributed around the small end.
Reassemble the hub: place the re-greased inner tapered bearing and dust seal into the Hub.
Reinstall the hub: the inner bearing & seal has already been installed in the hub. Install the hub assembly onto the spindle and ensure they are properly seated. Install the outer bearing: place the outer bearing on the spindle.
Torque the nut or flat plate:
• Preload the bearings: tighten the spindle nut or the flat plate to seat the bearings properly.
This is often done in two steps:
- Initial torque: tighten the nut or flat plate to a specific initial torque value to seat the bearings.
This value is typically around 15-25 ft-lbs (20-34 Nm) for many vehicles, but you should refer to the specific vehicle’s service manual for the exact specification.
- Adjust the preload
• Back off and re-tighten:
- Back off: after the initial torque, back off (loosen) the nut by approximately 1/4 to 1/2 turn. This step is crucial to avoid overloading the bearings.
- Re-tighten: re-torque the nut or flat plate to a lower, specified preload setting. This is often around 10-15 ft-lbs (14-20 Nm) but varies by vehicle.
• Final Assembly
- Locking mechanism: if the vehicle has a locking mechanism, such as a cotter pin or locking washer with three tapered screws, install it to prevent the spindle nut from loosening.
- Reinstall dust cap: place the dust cap over the spindle nut to protect the bearing from contaminants.
• Reinstall the brake components:
- Brake rotor: reinstall the brake rotor. Make sure it sits flush against the hub.
- Caliper: reattach the brake caliper and secure it with bolts. Ensure the caliper is correctly aligned with the rotor.
• Check and test then reinstall the wheel:
- Place the wheel back onto the hub.
- Hand-tighten the wheel nuts initially.
- Manually spin the wheel to ensure it rotates smoothly and quietly.
- Lower the vehicle from the jack stands and do a final tightening of the wheel nuts to the manufacturer’s torque specifications using a torque wrench.
- If applicable, check the wheel alignment or have it checked by a professional.
- Conduct a test drive to ensure that everything functions correctly and listen for any unusual noises.
• Manufacturer’s specifications: always follow the vehicle manufacturer’s specifications and recommendations for torque settings and installation procedures.
• Use quality parts: use high-quality bearings and components to ensure longevity and reliability.
• Use proper tools: use a calibrated torque wrench and a dial indicator for accurate measurements.
By following the above steps, you can ensure that your wheel bearings are fitted and serviced correctly, contributing to the safe and efficient operation of your vehicle.
It has been alleged that there have been at times where trucks are catching fire on the side of major highways, because of major failure with wheel bearings subjected to lack of maintenance.
It has been noted where there has been a real concern about trucks catching fire due to wheel bearings failing, though such incidents are relatively rare compared to other causes of vehicle fires. Here’s how a failing wheel bearing can potentially lead to a fire: Heat generation and friction:
• Excessive heat: when a wheel bearing begins to fail, it can generate excessive heat due to increased friction. This friction heat can be significant, especially if the bearing is severely worn or damaged.
• Grease degradation: wheel bearings are typically lubricated with grease. As
a bearing fails and generates more heat, the grease can break down, potentially leading to a loss of lubrication and further increasing friction and heat.
Fire hazard mechanisms:
• Combustion of grease: if the temperature of the wheel bearing and surrounding components becomes high enough, it could cause the bearing grease to ignite. Although wheel bearing grease is generally formulated to withstand high temperatures, prolonged overheating can lead to the grease becoming flammable.
• Contact with flammable materials: in some cases, if the vehicle is carrying flammable materials or debris accumulates near the wheel area, the risk of a fire increases if there’s sufficient heat generated by a failing bearing.
Heat transfer to other components:
• Heat transfer: excessive heat from a failed bearing can transfer to other nearby components, such as brake lines, tires, and even fuel lines in extreme cases. This can potentially lead to fires if the heat reaches flammable materials or components.
Signs of failing wheel bearings:
• Unusual noises: grinding or squealing noises can indicate a failing bearing.
• Vibration: excessive vibration in the wheel or steering wheel can be a sign of bearing problems.
• Heat: overheating of the wheel hub area
can indicate issues with the bearing. Prevention and maintenance:
• Regular inspections: regularly inspect and maintain wheel bearings as part of routine vehicle maintenance. This includes checking for signs of wear, proper lubrication, and replacing bearings as needed.
• Proper installation: ensure that wheel bearings are installed correctly and to the manufacturer’s specifications to avoid premature failure.
• Immediate attention to symptoms: address any symptoms of bearing failure immediately to prevent further damage and reduce the risk of overheating or fire. While it is not common, the failure of wheel bearings can potentially contribute to a fire hazard due to excessive heat and friction.
Proper maintenance is the key to everything and timely inspection and or replacement of wheel bearings are essential to minimizing this risk and ensuring vehicle safety.
If you suspect issues with your wheel bearings, it’s important to have them inspected and repaired by a professional to prevent potential hazards.
Please be advised that the information provided in this article is only a guideline and you should always seek expert advice and have ensure all work is carried out by a licenced professional
allergens, virus*, bacteria, and noxious odours from the air flow. Filtering down to 0.3 microns or greater in size, it prevents
Upgrade Performance Brake
Elevate your 4x4 performance
For those who frequently tow, offroad, or haul heavy loads with their 4x4s, Disc Brakes Australia’s (DBA) new Upgrade Performance Brake Kits are a game-changer. This latest offering includes larger calipers, steel braided hoses, XP level friction brake pads, and DBA’s patented 4000 Series T3 rotor with Kangaroo Paw vane ventilation. These Upgrade Kits are designed to enhance performance, safety, and reliability. Injected with DBA’s patented technology, they are perfect for off-road enthusiasts and heavy-duty users alike.
Enhanced safety and performance
Standard brake systems often fail under the intense demands of towing, off-roading, and carrying heavy loads. DBA’s Upgrade Performance Brake Kits are designed to tackle these challenges head-on:
• Upgrade Calipers: ensure effective stopping under heavy stress.
• 4000 Series T3 Rotor: unique Kangaroo Paw vane ventilation with 144 diamond and teardrop-patterned pillars enhances heat dissipation and stability. The patented T3 slot design provides more exit points for dust and gases, resulting in a quieter, more responsive, and smoother brake pedal feel.
• XP Friction Level Brake Pads: deliver exceptional stopping power with high initial bite and increased surface friction, ensuring consistent performance from low to high temperatures.
• Steel braided hoses: offer a tougher barrier against the elements and increase peak performance longevity.
These kits guarantee efficient braking even under the heaviest loads or toughest terrains, significantly reducing the risk of
accidents and improving vehicle control.
• Superior towing capabilities: Towing places significant strain on a vehicle’s brakes, often leading to faster brake fade and increased stopping distances with standard systems.
DBA’s upgrade kits are engineered to handle this extra load effortlessly:
• Enhanced heat management: Crucial for descending steep grades with a heavy trailer. DBA’s patented Kangaroo Paw vane ventilation ensures up to 20% better heat dissipation compared to conventional rotor ventilation systems, allowing you to tow with greater confidence and ensuring your brakes are less likely to overheat and fail.
Off-roading demands a reliable braking system in unpredictable conditions. DBA’s upgraded brake kits excel by offering improved modulation and response:
• Consistent performance: whether navigating steep inclines or muddy trails, these brakes provide safer and more controlled driving.
• Durable hoses: OE rubber hoses can become soft over time, causing a loss of force applied to the brake pistons. DBA’s steel braided hoses resist debris and mud, reducing premature wear and ensuring long-lasting reliability.
For 4x4 owners who use their vehicles for work or expeditions, carrying heavy loads is a common challenge. DBA’s upgraded brake kits are designed to handle heavier loads more effectively:
• Reduced pedal effort: larger calipers
reduce pedal effort by up to 60 per cent, providing more force and surface area for the brake pads to push against the rotor. This results in shorter stopping distances and greater stability, crucial for maintaining control during sudden stops or emergency maneuvers.
While the initial investment in DBA’s upgraded brake kits might seem substantial, it proves cost-effective in the long run:
• Longer lifespan: high-performance components typically last longer compared to standard parts, especially in demanding conditions.
• Lower maintenance costs: fewer replacements and improved braking efficiency reduce wear on other vehicle parts, such as tires and suspension, further cutting down overall maintenance expenses.
DBA’s Upgrade Performance Brake Kits for 4x4 vehicles offer numerous benefits, especially if you regularly tow, off-road, or carry heavy loads. Enhanced safety, superior towing capabilities, improved offroading performance, better handling of heavy loads, and long-term cost savings make this upgrade a smart investment for any 4x4 enthusiast or professional. DBA’s upgraded brake kits not only boost performance but also provide peace of mind, allowing you to tackle any adventure or task with confidence.
For more information, visit DBA.com.au and follow our social channels to stay updated on everything DBA
ack in 1974, a group of 17 Western Australian Golden Fleece service station owners came together to develop a plan to gain better value for their automotive parts purchases and to improve their business profitability. Little would these forward-thinking small business owners realised that in doing this, they had planted the seeds of what would become Capricorn – Australia and New Zealand’s largest automotive cooperative.
There have been many defining moments in the history of the Capricorn Society, ranging from its humble establishment in the 1970s, to becoming a bi-nation cooperative organisation that reached $500 million in sales at the dawn of the new millennium, to becoming one of the world’s leading cooperative organisations with sales of over $1 billion in Australia and New Zealand by its fourth decade.
This year marks the 50th Anniversary of Capricorn, which has continued to grow from strength to strength reaching over 28,000 automotive service Member businesses and including more than 2,000 Preferred Suppliers. Working together, they generated an astounding $3.4 billion in sales last year alone, making Capricorn one of Australia’s most outstanding business success stories.
The first Capricorn General Manager and one of the original Golden Fleece service station owners who established this cooperative, Frank O’Connor, said that everything that Capricorn does is purpose driven for the continued success of its Members.
“As service station owners in the early days, we attended a training session about building a better business and one of the topics was called ‘how to buy better’,” he said. “So a group of us discussed how much we were paying for certain automotive parts and we quickly established that by working together we could gain far better value for the parts that we were frequently purchasing. “Soon some of us became specialised in certain auto parts, I became the sealed beam headlight person. We continued this with more auto parts and it was the former lighting company Lucas that was the first to approach us, offering a five per cent discount if we established a single point for our group orders and invoicing.
“That is how it all started and from that point it became all about finding more suppliers and more members, a process that continues to this day, 50 years later.”
The growth of Capricorn’s membership continued at a steady pace through to the new millennium, when accelerated growth took place.
Now Capricorn is proud to offer its Members a range of competitive financial services products, as well as access to risk protection, exclusive industry events and a generous Capricorn Rewards Program.
This 50th Anniversary year also coincides with the conclusion of the highly successful career of long-term Capricorn Group Chief Executive Officer David Fraser. David’s 18 years at Capricorn started with his appointment as General Manager – Automotive, working together with former Group CEO Greg Wall, the duo largely responsible for Capricorn’s incredible growth over the past decade.
David became Group CEO in 2019 and
ends his highly successful tenure at Capricorn at the end of the year.
“Capricorn has created a community within the automotive industry that extends beyond business relationships,” David said.
“There have been many good times along with several challenges that our community has faced over the years and throughout it all, Capricorn has never lost sight of our purpose - to help and support our Members to become stronger businesses.
“The vision of the original 17 remains as Capricorn’s purpose today, a commitment to working together and understanding the benefits of strength in numbers.”
Visit cap.coop/50 and keep an eye on our Facebook and LinkedIn to meet those who make up the Capricorn community and help us celebrate 50 Years Strong
ACM Parts’ range of quality assured aftermarket parts guarantee material, fitment, and functionality, offering peace of mind when selecting an aftermarket part. This range includes collision parts, lighting, and cooling components to suit a large range of major makes and models.
ACM’s Aftermarket range is focused on quality and reliability. You can rely on every part to meet all the OEM lifecycle performance standards — offering repairers an easy, fast, and cost-effective solution for sourcing parts.
Quality, hard work and family are the keys to business success according to Zarate Mechanics owner John Zarate.
The popular family-run workshop from Arndell Park in Sydney is preparing for a major upgrade and relocation to keep up with growing demand.
“The new shop is going to be a clinic. So clean. Customers will see how well we take care of our shop, and they know we will do the same with their vehicle,” John said.
“We’re really growing through word of mouth.”
The Zarate Mechanics team received an extra marketing boost with surprise branding on the Castrol Racing Tickford Ford Mustang at Sydney SuperNight – it was all part of Castrol’s 125-year celebrations designed to highlight its loyal independent workshop customers.
“It is an honour to be a part of the Castrol family...I’m speechless,” John said.
He said choosing the right partners with the best expertise, support and solutions was important to stay ahead of the game.
“We need to provide the right advice and the right products to our customers, and the suppliers we choose help us do that,” he said.
“When I choose suppliers, I’m looking for quality, respectful communication, and consistent and on-time delivery – if I can’t use a hoist I’m losing money, I’m losing
business. Efficiency is key.”
With the industry facing faster-than-ever changes, John said he stayed up to date by accessing the latest training courses, certification, supplier conferences, and trade shows.
“Every day is a school day,” he said.
“We have to keep up with the changes and learn. I’m always learning. Even the smallest things matter.”
Practice makes perfect
Having taken stages one and two through the Motor Traders’ Association, John encouraged other mechanics to get up to speed on Electric Vehicles.
“It’s important to do it for our industry because we need more expertise across the board in independent workshops,” he said.
“You can take advantage of the government grants as well so it’s not expensive to do it.
“I’d advise anyone starting out in apprenticeships to do EV courses.“
While John said he was good with his hands as a mechanic, he admitted the biggest challenge he’d had to overcome as a business owner was communicating well with customers.
“For many years I was behind the scenes and fi xed the cars. I hadn’t really had the chance to speak to customers directly, so it was a big challenge when I opened my own workshop,” he said.
“Practice makes perfect, so dealing with
customers on a daily basis has helped a lot.
“I’ll often go for a drive with them before doing the work to chat and build trust.”
John said customers wanted to make sure their cars were safe and reliable and confirmed his team was well-equipped to support their evolving needs.
“You name it we do it all,” he said.
“When I say I use Castrol the look I get is like ‘ah’. They’re content, everyone knows Castrol.
“Quality always comes first, especially the lubricants that we use…I’ve never used any other oil when Castrol could do it.”
John said building trust and providing greater value than the dealers was vital, and it’s clearly paying off, with Zarate Mechanics booked out a month in advance.
“It’s a new generation and the trend is swinging back to workshops like us,” he said.
“I really like seeing what other independent workshops are up to.
“Particularly building engines and engine swaps. I love that stuff.”
Running his own business has been John’s dream since first arriving in Australia from the Philippines in 1998, inspired by his mechanic father, Johnny.
“Working with my dad is really awesome because he teaches me a lot [and] at the same time I teach him a lot. Because he is old school, I’m new school...we make a good team.”
“Quality
He said he was also supported by his wife and fellow Director, Erin.
“This business would not be where it is without my wife. There is so much paperwork behind the scenes that people wouldn’t understand. It’s crazy.”
John spoke highly of his wider team and said they are a quality bunch.
“They work very hard and I treat them as family.”
John’s advice to other mechanics who wanted to open their own workshop was simple: “Don’t cut corners…if you do the right thing, you will never go wrong, just work hard.”
“If you’re honest, do quality work and use quality products, people will always come back.”
hat started as a childhood passion for all things fast has led to Dane Mckay in the fast lane to long-term success as a mechanic.
His love for the auto world went up a gear in high school, however, when he began to seriously consider working on vehicles fulltime.
“Through school, I was always tinkering with motorbikes and other stuff. My uncle is a diesel mechanic as well, so I thought I’d get into it,” the 22-year-old said.
Dane first got connected to his apprenticeship through the Clontarf Foundation – a non-for-profit which helps equip Aboriginal or Torres Strait Islander men with the tools to complete school and beyond.
From there, Dane was able to secure employment at Veolia’s Wetherill Park depot. For his apprenticeship, Dane said he decided on Apprenticeships Are Us over others because of their tailor-made approach to helping his studies.
“Apprenticeships Are Us said they could come to me, so I went with them,” he said.
“I saw them at Parramatta and they were really helpful, they sat me down and explained everything pretty thoroughly. The classes were really small at the start so I got a lot of one-on-one time.
“Now I’m even helping out more of their apprentices because there’s three mechanics and four apprentices, I’m helping show them the ropes.”
Apprenticeships Are Us is a not-for-profit organisation dedicated to empowering automotive apprentices across Australia. Its mission is to ensure that aspiring automotive professionals can pursue their dreams, regardless of financial or socio-economic background, education level, or other social disadvantages. The organisation provides comprehensive support to apprentices, including the provision of proper PPE (personal protective equipment), training in employability and life skills, and on-the-job support.
Dane completed his apprenticeship in Cert III in Heavy Diesel Mechanics in 2023. Since then, he’s been getting to grips as a part of Veolia’s repair crew at Wetherill Park.
“We repair things like all the suspension brakes and a bit of engine maintenance as well.
It’s mostly repair work,” he said.
“I do work with garbage trucks so it can smell sometimes, but the pay’s pretty decent.
“Two weeks per month I’m on-call which is really good work.”
Dane’s eager to take his heavy machinery talents to the Outback soon, however, with plans to work at a mine.
“I’d love to get into restoring old cars or working on trucks as a mobile mechanic at some point. [But] In the next year or so, I’d love to head to a mine and save money for a house.
“If I did three years doing my work at a mine I’d have enough to buy a house.”
When he’s not on the tools, Dane can still be caught playing with his own rides.
Whether it’s taking out the bikes (road and dirt), or even a bit of drifting, Dane’s an adrenaline junky through and through.
“It definitely helps knowing what to do with fi xing cars and bikes yourself, rather than paying someone else that’s for sure,” Dane added.
“No one loves you more than we do” – that’s the message Burson Auto Parts wants its customers to know. The
team at
Australia’s preferred automotive trade supplier is here with an opportunity to provide unmatched value to mechanics and workshop owners.
Knowledge, service, solutions and having a vast range of products is in Burson Auto Parts’ DNA, servicing the trade for over 50 years. Across more than 210 stores nation-wide, Burson has the ability to deliver immediate and longterm support to its customers. Continuing this tradition, Burson Auto Parts’ latest promotion shows its love for the automotive trade community by giving back to loyal mechanics.
What’s on offer?
Burson Auto Parts is excited to return the love to trade customers through its Burson Tools and Equipment WIN Campaign, live during September and October 2024.
To enter, Burson Auto Parts trade account holders will need to spend at least $1,000 (excl. GST) by October 31 to receive one entry into a draw. Every additional $1,000 purchase gives one extra entry. Entries are allocated to five state groups.
Winners of draws in WA, QLD, SA/NT and NSW/ACT will each receive a prize pack containing a Milwaukee 218 Piece
“No one loves you more than we do. We’re here to provide a solution to multiple challenges”
Automotive Starter Toolkit A1 (MTK218A1S) and an Ecotechnics Fully Automatic R134A Service Machine (ECK4012).
The winner of the VIC/TAS draw will receive a Milwaukee 218 Piece Automotive Starter Toolkit A1 (MTK218A1S) as well as a Rotary 3D Wheel Balancer (R155).
This promotion aligns with Burson Auto Parts drive to help mechanics deliver as much quality and efficiency to their customers as possible. Sitting down with Burson Auto Parts Marketing Manager
Joseph Ottobre proved this. “We see ourselves as an extension of workshops, and we wanted to build a promotion that shows our appreciation for how much they mean to us.”
“No one loves you more than we do – we’re here to provide a solution to multiple challenges that are brought into workshops,” said Joseph.
In keeping with Burson Auto Parts drive to provide long-term support to workshop owners and mechanics, the Burson Equipment team will be there to support winners with training on using their new tools.
“Our winners will be able to continually use their prizes to drive more profit into their workshop and provide a new service offering to their customers,” said Joseph.
Being a trusted, automotive trade supplier since 1971, Burson Auto Parts knows a fair bit about long-term value.
That’s why prizes were chosen that delivered a helping hand and significant
Simple to use; the Rotary 3D Wheel Balancer adds tones of value for little work for mechanics.
returns to workshop owners and mechanics.
Burson Equipment National Sales Manager Adrian Butler is eager to be offering customers the Ecotechnics Fully Automatic R134A Service Machine.
With summer on its way, mechanics will be wanting to support customer vehicles with efficient AC servicing.
“The idea behind an AC service machine is that it pulls out the existing gas that’s in your vehicle,” Adrian explained. “It cleans it, it recycles it, and more often than not, most vehicles will have low amounts of gas in them.” The ease of use and potential returns are something Adrian thinks customers will be excited about.
“This machine will generate substantial revenue every year for very little user input,” he said. “If someone told me I could earn a significant income stream for plugging a machine into a vehicle, I’d be thrilled to get an Ecotechnics Service Machine.”
“In those warmer states, these things are going to be in high demand.”
For the VIC/TAS winner, the Rotary 3D Wheel Balancer is another stellar product that mechanics can offer their customers
while doing a check-up. There is significant return on investment and earning potential for this piece of equipment.
“In a workshop, you’ll find a high percentage of vehicles that will have wheel and tyre combinations that aren’t balanced correctly. Unbalanced wheels can cause premature wear of your suspension and steering components,” said Adrian.
“If you have 10 vehicles coming into your workshop, you could have about a 70 per cent hit rate of people that you offer wheel balance and rotation.”
Just like the Ecotechnics Service Machine, the Rotary 3D Wheel Balancer is simple to use, while also delivering massive returns to the operator’s bottom line.
Adrian also highlighted that workshops
could potentially be missing out on this $210 per day of revenue per vehicle, before tyres and wheels are fitted.
“It’s not a hard or long process, so pretty quickly you’re generating more than $1,000 of revenue for your shop each week with vehicles that are already coming in”, Adrian added.
For Burson, it’s all about making sure the customer has the right product to get the job done, and ultimately make their day-today job smoother and easier.
No matter where they are in Australia, mechanics and workshop owners are frontof-mind for Burson Auto Parts.
With this latest promotion, Burson demonstrates its passion for improving long-term relationships with their customers and its continued focus on being where the trade turns.
“Burson wanted to bring something fun with this giveaway,” Joseph said. “We want to show our appreciation to our hard working and loyal mechanics.”
For more information about Burson Auto Parts Tools and Equipment giveaway, please visit burson.com.au/giveaway
Maintaining a fleet of veteran, vintage and classic cars could be the ultimate retirement hobby – if you have the skills
WORDS AND IMAGES: IAIN CURRY
We all have different ideas of paradise, but for the mechanicallyminded car enthusiast, Colin Kiel’s setup feels heaven-sent. His Sunshine Coast home looks out over an expansive lawn, bordered by a giant aircraft hangarlike workshop and two freshly-built ‘show sheds’ housing cars and memorabilia.
With the shed roller doors raised, and the eclectic pieces of motoring history on proud display, it must feel like being a king surveying his kingdom. The subjects just happen to be beautifully restored and maintained vehicles, from a 1908 twincylinder Sears Motor Buggy, to a 1926 Panhard et Levassor X-46 Torpedo and bright red 1957 Chevrolet Corvette.
Most of us fantasise about owning a car collection, but there’s the inconvenient reality of having to maintain them.
Mechanics have an obvious advantage here, and Colin’s life working with cars and deep understanding of these now ancient mechanicals means he can keep his fleet in running order.
Colin and wife Maxine have recently relocated from Victoria to Queensland, moving their ‘4C’s Motor Museum’ with them. Colin’s Chair of the Australian Motor Museums Association (AMMA), and is strong advocate for maintaining historical vehicles and educating current and future generations about their significance.
And as anyone working in the restoration and classic car maintenance business knows, the old skills required for this are dying off, and there aren’t enough youngsters coming through to fill the void. For mechanics with a passion for older vehicles, there’s opportunity aplenty if you’ve got the required patience.
An electromechanical engineer by trade, Colin has a longstanding love of old vehicles. His first was a 1960 MG A Mk1, bought when he was 21 years old, which he reveals was roughly half a century ago. He won his class at an MG concours event, firing him up to continue his hobby.
“You could buy MGs for about $300
back then, and there were loads of spare parts,” he said. “The parts boys would know me well as I’d be in almost every Saturday morning; could see I was young and enthusiastic and would look after me. My father and grandfather were very hands-on people, so restoration made sense to me.”
His working life included designing and manufacturing the hanging speakers for cars at drive-in theatres (remember them?), but his workmates were also into old cars, so “it was always something to talk about at lunchtime.”
Colin bought one of the very earliest Land Rovers – a 1948 pre-Series 1 – which his mate found on a farm with a tree growing through its middle. Once restored and enjoyed it moved on (it’s the car he misses
most, apparently), and now having children, he was into a Series 1 Jaguar. But most of his other car projects were put on ice due to business and family focus.
When his youngest graduated, Colin got busy making up for lost time. “We decided we’d go back and start playing again,” he said, soon buying an elegant Jaguar Mark V and gorgeous 1934 S.S. open four-seater sports. The S.S. brand morphed into Jaguar after World War 2 – those two letters were a bit tarnished after Hitler’s efforts.
“Grace and pace; that’s Jaguar,” Colin said. “They’re just beautiful, and even today, very few cars have the same ride and comfort that Jaguar suspension provides.”
Bright red 1957 Chevrolet Corvette was one of the first in Australia, coming here in 1959 and given a right-hand-drive conversion.
His targets were restored cars without the tough mechanical work completed, allowing him to put his skills to best use. “I buy cars with the beautification done like the body and paint, then I rebuild the engines and more or less do all the mechanicals,” he explained. “For me, it’s a lot easier to repair the engine than it is to have a body repainted.”
The really vintage stuff doesn’t daunt Colin, helping his museum display vehicles almost from the dawn of motoring. The horseless carriage Sears Motor Buggy is the eldest; this 1908 twin-cylinder automobile with tiller rather than round steering wheel was bought via mail order for $395 back in the day. A roof was an extra $5.
Colin bought it as a wreck and has completed a superb full restoration, with 1895 Melbourne-manufactured coach lamps – picked up at a swap meet – looking resplendent on the front. Ready to drive (slowly) on Australian roads, Colin said he’s waiting for the right rally to debut it at.
Alongside is a 1922 Citroen Boattail Doctor’s Coupe – head gasket needs fi xed on that one – and then a grand 1912 Star Tourer with a Colin-rebuilt drivetrain. The defunct Star Motor Company brand
was apparently the UK’s biggest car manufacturer that year, and this 2.5-litre 16 H.P. open-top is poshly appointed with rear passenger glass screen and drinks cabinet. Its external timber is Australian blackwood, and is one of just four examples remaining in the world.
As you’d expect, parts aren’t easy to come by. Colin’s more about repairing and rebuilding bits, as often that’s the only option. But he has resources. The ’34 S.S. now uses as 1936 Jaguar 2.5-litre engine, making life a bit easier. “With a mate I bought a collection of 12 Mark V Jaguars, so I’ve got lots of spares there,” he explained. His massive workshop houses neatly labelled boxes of old car parts in the rafters, while ground level features a hoist, pulleys to lift heavy oily bits and even a Coventry Climax forklift with Jaguar badges (Bill Lyons of Jaguar fame bought the company in 1962).
There’s the rolling chassis of a 1949 Mark V Jaguar drophead coupe – its body is away for repair – while a lifetime of tools fill the walls alongside a heavy-duty drill and small lathe for polishing and refurbing
generators, starter motors and the like. “I’m in here seven days a week,” Colin said. “It’s a hobby that keeps me going, and keeps the grey matter ticking over.”
Despite passion for all his cars, Colin has a particular soft spot for his French 1926 Panhard et Lavassor X46 16CV Torpedo. It’s been in Australia for almost a century, features a 3.2-litre twin sleeve valved engine and seven-seat Aussie-built Martin and King (Victoria) body. The original car burned in 1939 bushfires, leaving little but the chassis and parts of bodywork. Colin has painstakingly restored it over 20 years, even travelling to Paris to source parts. Good excuse for a Euro holiday.
“It has two crankshafts, eight sensor valves, four separate heads, eight sets of rings and 12 conrods,” he said. “Engineeringwise they’re a delight to work on; just absolutely beautiful,” showing me one of the silky smooth-operating sleeve valves. “These engines were good for 650,000 miles.” Not many French cars have a reputation to match that in recent decades.
His American section includes a 1937 Studebaker President with South Australian T.J. Richards body and 250 cu in straight eight, and a 164 cu in 1951 Studebaker
Bullet with distinctive pointy nose. Then there’s the Rock ‘n Roll toy. A bright red 1957 Chevrolet Corvette, this one with ‘Fuel Injection’ written down its flanks, which has been in Australia and in right-hand-drive since 1959.
Sadly, when it was converted in Sydney, the linkages for the fuel injection were now on the wrong side of the engine, and try finding an Aussie mechanic who knew much about fuel injection in the 1950s. A singlebarrel Holley was put on instead, but Colin got busy upgrading to twin Webers. No more fuel injection, but good grief that V8 sounds good on carbies.
There’s another 1949 Mark V Jaguar saloon, this parked beside a 1950 Lagonda LB6 Drophead Coupe. The latter has an aluminium body and six-cylinder twin OHC designed by W.O Bentley, and was originally owned by Winston Churchill’s grandniece. Solid English history there. Absent from the British section was Colin’s 2005 Bentley Flying Spur – his modern luxury choice which was away for body work.
Speaking about his collection, Colin said he uses each car on rotation. “You’ve got to properly run them. We take them on long drives and really enjoy club rallies. Sometimes they drive like crap for a few days, then they suddenly run beautifully. You must use them.”
But he’s concerned about the longterm prospects of older vehicles, and “the future of motor museums across the world is pretty glum,” he said. Museums like his aren’t eligible for grant funds, making them hard to stay open unless self-funded. “But we don’t mind that,” he said. “It’s all about the camaraderie and keeping the history alive.”
Colin also compels younger mechanics to consider a career working with classic vehicles. “They’re so rewarding and often easy to work on,” he said. “It can be hard finding parts and frustrating repairing things, but there are no electronics to worry about, and as you’re in demand, it can be lucrative and very satisfying too.”
is a great tool for every toolbox.
We’ve all been in those frustrating spots where your hand can’t quite reach or having to wait for a hot muffler or radiator to cool before you can reinstall a bolt. The Extension
Part no: 385105
The clamp’s jaws open 3mm (1/8”) to 28mm (1.125”) wide giving you the ability to hold a ¾” nut or bolt. It’s vice-like design also ensures you won’t drop the part it’s holding until you loosen the tension nut. This means unlike a pliers you do not need to maintain tension to keep what you’re holding in place, this is very valuable when you’re in a difficult spot where if you drop what is clamped it will be gone. The extension clamp has been used in everything from auto body to airline maintenance and is a great option for anyone’s toolbox. See it in action
Clamp will also save you time by not having to remove other parts on your equipment to get into a tight spot. USE CODE “ACM” FOR 10% DISCOUNT
ver the past few years, JB Weld has been concentrating on developing a total exhaust repair collection with pastes and repair wraps that are long lasting and easy to use for both the home handyman and the professional repair shop.
All together, JB Weld has a range of seven products that can be used to repair just about any problem with a vehicle exhaust. Each product has specific attributes in terms of maximum temperatures, curing time and application. There are three wrapping products and three pastes in the line-up.
The pastes feature high temperature ratings, high torque loads and can seal as well as fill, the wraps feature fibreglass technology and they seal, insulate and structurally repair the system. No mixing is required with the wraps.
JB Weld Tiger Patch and the Tiger Patch Kit contain a fibreglass wrap coated in epoxy
that can withstand temperatures of up to 260 ºC. This product is a temperatureresistant epoxy combined with a fibreglass wrap that cures with heat to permanently patch holes and cracks in mufflers and tailpipes. The Tiger Patch Kit includes aluminium tape for sealing and securing the product while it cures, whereas the JB Weld Tiger Patch product pack does not.
JB Weld ExhaustWeld is a very versatile wrap that can be used on any part of an exhaust system to perform high strength repairs, sealing and insulation on breakages, holes and cracks. It is formulated to resist temperatures of up to 593ºC and cures in 20 minutes with heat. This product package includes protective gloves and aluminium tape to secure the product while curing.
JB Weld ExtremeHeat is a temperature resistant metallic paste which sets in one hour and is fully cured in 24 hours. It dries machine grey and withstands continuous
heat of up to 538 ºC. It is ideal for filling holes and cracks in metal surfaces and can be used on exhaust manifolds, heat exchangers, mufflers, engine blocks as well as on household items such as outdoor BBQs and fireplaces.
MufflerSeal is for use on mufflers and tailpipes for sealing cracks and can resist temperatures of up to 371ºC with a curing time of two hours.
JB Weld Exhaust System Sealant is a product that seals and fills gaps on tailpipes and catalytic converters and is ideal for seam and connector sealing. It cures in two hours and can withstand temperatures of up to 982ºC.
With this range of JB Weld exhaust repair products, you can fi x an entire exhaust from the manifold through the catalytic converter, down the exhaust pipe and even the muffler itself.
NTK has more than 40 years of expertise in the sensor industry and stands as Australia’s leading ignition and sensor supplier.
NTK’s premier status in the industry is driven by its dedication to four competitive advantages – range, availability, tech support, OE standards.
The latest addition to NTK’s sensor range highlight its unique offerings to the Australian aftermarket, quickly gaining popularity among distributors, workshops, and end-users.
Following success in Europe and the North America, NTK expanded its comprehensive catalogue of sensors which already included Oxygen Sensors, Exhaust Gas Temperature Sensors, Air Fuel Ratio Monitors, Engine Camshaft Position Sensor, Engine Crankshaft Position Sensor, Manifold Absolute Pressure Sensor, Mass Air Flow Sensor and ABS Wheel Speed Sensors. In October 2023, NTK Released a new emissions category:
• Exhaust Gas Recirculation Valve (EGR Valve) –EGR Valves reduce the amount of nitrogen oxides (NOx) that are produced during combustion by reintroducing exhaust gases into the intake manifold. Available in ‘pneumatic’, ‘electric’ and ‘electric with cooler’ variants, EGR Valves
are equipped in all diesel vehicles and 30 per cent of petrol cars.
Plugged in
Building on years of leadership in sensor technology for both vehicle manufacturers and the aftermarket, NTK’s addition of EGR Valves compliments its portfolio of antipollution products.
“Our range, availability, technical support and OE quality makes NTK sensors the most trusted brand for mechanical workshops Niterra Australia NTK Product Manager James Henson said.
“NTK have always been the sensor specialists you can count on, and our expanded range only reinforces this. With
The introduction of our new NTK product which enhances coverage for vehicles in Australia and New Zealand and expands OE replacement opportunities for aftermarket customer, we have further solidified our position as a leading global manufacturer of ignition systems and sensors”
To support this new range, NTK has released educational marketing materials, including an informative YouTube video and complementary advertising artwork, to spread awareness about these exciting new products.
“Modern vehicles require greater efficiency, optimised fuel consumption, and maintained performance while ensuring
safety, pollution control, reliability, and long service life,” James explained. “All these functions depend on the ECU, which processes inputs from sensors throughout the vehicle. Quality sensors are crucial for ensuring that vehicles operate as intended by the manufacturer.”
“Our new marketing materials aim to educate consumers on the importance of using quality sensors to ensure their vehicles ECU operates with the best and most reliable inputs, resulting in faster diagnostics, less downtime, lower costs and happier customers.”
“The last thing those working on customer vehicles should be worrying about is if the replacement sensor they have chosen is going to stand the test of time. As the sensor specialist, NTK applies its engineering expertise and goes the extra mile to test its full line of technical sensors beyond OE specifications so our customers can focus on moving onto the next job, rather than worrying about comebacks.”
“With the release of our informative videos and advertising resources in support of our sensor ranges, we look forward to speaking with more and more automotive professionals across Australia and New Zealand about what we can do for them.”
For more information, call Niterra Australia on 1300 55 40 59 or visit ngk.com.au
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beneficiaries) into and completing an apprenticeship in the automotive industry. Our unique group training organisation consists of automotive apprenticeship specialists working with the automotive industry to source apprenticeship opportunities for our beneficiaries. This means we can be more hands-on by regularly working with our Apprentices and their Host Businesses to ensure the satisfaction and well-being of both. You will find us at careers fairs, trade expos, State and Federal Government forums, vocational education and training working groups, and regular meetings with interested
Apprenticeships Are Us Ltd is dedicated to developing sustainable career paths for our beneficiaries so that they may have a strong start to their career. Throughout the apprenticeship journey we provide mentoring, on-the-job support, life skills training and employability training whilst the apprentice undertakes employment and formalised training at a Registered Training Organisation of their choice.
Spare Parts Interpreter
As a business owner and/or manager are you struggling to employ apprentices, enroll apprentices in training and register their apprenticeship? Applicants not turning up for interviews? Do you also struggle to find time to complete weekly payroll? Are you concerned your insurance premiums with relation to employment are increasing? Apprenticeships Are Us have these services covered.
Payroll: Your organisation will receive a weekly invoice that includes all associated costs.
HR: All apprentice-related matters will be handled in collaboration with your organisation.
Baseline audiometric testing will be arranged within the first three months of employment.
ARU will participate in the latest industry group meeting and keep your organization informed of any changes affecting apprentices.
With hay-fever season in full swing, Ryco wants to remind mechanics there’s no reason your customers need to breathe pollen and allergens in a vehicle’s cabin.
According to a study by the Royal Society of Chemistry on Environment Science, pollution inside a car stuck in heavy traffic is as much as 40 per cent higher than when the car is moving.
Ryco’s N99 MicroShield Cabin Air Filters will protect drivers and passengers with its medical grade media technology to filter out H1N1/H3N2 virus, bacteria, harmful exhaust gases and noxious odours from the air flow down to 0.3 microns or greater in size.
Importantly at this time of year, they will also filter out pollen and allergens, meaning that when your customers use an N99 MicroShield Cabin Air Filter, they are breathing the best quality air possible inside the cabin and preventing those dreaded sneezing fits while driving.
In addition to being great in the spring, Ryco’s N99 MicroShield Cabin Air Filters are flame retardant, making them the perfect addition heading into the summer bushfire season. They inhibit combustion when exposed to embers, sparks, or open flames as the media is impregnated with non-toxic fire-retardant resin, reducing the ability of the media to support combustion. The activated charcoal layer will stop chemical pollutants and smells which many cause nausea, fatigue, and headaches, from ever entering the cabin.
Tested in Australia’s only dedicated filtration laboratory to meet the harshest Australian conditions, Ryco’s N99 MicroShield Cabin Filter is the perfect filter to prevent contaminants from penetrating a driver’s or passenger’s respiratory system. So, when your drivers want peace of mind, be Ryco Ready
*Not all Ryco Cabin Air Filters come with flame retardant media. Check the ‘Tech Specs’ on the Ryco website to verify.
“Ryco’s N99 MicroShield Cabin Air Filters will protect drivers and passengers with its medical grade media technology”
Kangaroo Paw rotor vane for enhanced cooling properties
T3 bi-directional rotor slot design for improved brake dust discharge
High-performance ceramic friction material
Stainless steel braided hoses for enhanced heat and pressure resistance
Caliper mounting brackets supplied
where applicable
Fully ADR approved
f you’ve recently inherited an old Warren and Brown torque wrench, such as the model 3220 deflector beam, you may find yourself wondering if it requires calibration. Renowned for their durability and accuracy, these tools are often passed down through generations. However, the question arises: does age impact their precision?
The legacy of Warren and Brown Warren and Brown torque wrenches, particularly those from the 70s and 80s, have established a reputation as some of the finest tools available. These wrenches were essential for tasks such as tightening head bolts, harmonic balancer bolts, and flywheel pulley bolts. Despite their exceptional quality, even the best tools need occasional attention to maintain their performance.
Do they need calibrating?
Generally, Warren and Brown deflecting beam torque wrenches are designed to retain their accuracy over time, provided they are well-maintained. Proper storage, such as keeping them in their original boxes and ensuring they are not left under tension,
plays a significant role in preserving their precision. However, if the tool has been mishandled or stored improperly, it might require calibration.
If you are comfortable performing a basic calibration check at home, here are some steps you can follow:
1. Comparison Test: utilize a modern ratchettype torque wrench for comparison. Secure a large bolt in a vice and test both wrenches at various torque settings (e.g., 3-5 different settings). This will give you a good indication of whether your Warren and Brown wrench is still accurate.
2. Torque Test Rig: a bolt in a vice can serve as a makeshift torque test rig. This setup allows you to apply known torque values and compare the readings from your old wrench to those of a calibrated tool.
For those who prefer a professional touch, seeking out a specialist for calibration services is a prudent choice. In regions like East NSW/ACT, services such as Torque Calibrations offer NATA-certified and
traceable calibrations. While the cost varies depending on certification requirements, professional calibration is highly recommended if you are undertaking critical tasks, such as assembling an engine.
For personal use, especially if you are confident in the tool’s history and condition, a simple comparison test might suffice to verify its accuracy. However, for critical tasks or for complete peace of mind, professional calibration is the best option. With proper storage and maintenance, your Warren and Brown torque wrench can continue to be a reliable and precise tool for many years to come.
In summary, while old Warren and Brown torque wrenches are built to last and typically maintain their accuracy, it is always wise to check their calibration status, especially if they have been subjected to rough handling or improper storage. Whether you opt for a DIY approach or seek professional services, ensuring your torque wrench is accurately calibrated will guarantee its reliability and effectiveness in all your tasks.
Head over to wbtools.com.au to check out our latest products
Scan the QR code to find out more.
Whether it’s supercars, antique or classic cars this is your one-stop-shop for buying, selling and hiring a variety of cars from both dealers and private sellers.
Advertise on Australian Car Mechanic Marketplace to reach the right buyer.
EX continues a relentless customer focus to solve common design and application challenges. A recent improvement was upgrading the brush holder on 79 and 200 series LandCruiser alternators to avoid premature failure. A particularly compromised component given how low the alternator sits in the engine bay.
When the engine is running, air flows from the rear of the alternator to cool down the rectifier, rotor, and stator.
In wet, dusty, muddy or off-road driving conditions, water, dust, and mud can easily enter the brush assembly with the airflow, leading to brush, brush spring, and slip ring failure.
OEX’s innovative and problem-solving thinking is evident in its design of an alternator with semi-sealed brush holders,
“OEX’s innovative and problem-solving thinking is evident in its design of an alternator with semisealed brush holders”
which minimise the entry of water, dust, and mud into the brush assembly, preventing premature failure.
Additionally, OEX offer two high-output alternators for these applications, with a custom-made upgrade cable, fuse, and fuse holder included in the box.
Mechanics can find further information about OEX parts and other NAPA Auto Parts products by visiting napaparts.com.au and repcotrade.com.au
pecialist Tools Australia’s Extensive Range of specialised automotive professional tools which includes engine timing tools for a diverse range of vehicles and applications.
Specialist Tools Australia only supplies quality tools; it may not be the cheapest, but you have the backup of trained automotive technicians who know what you are trying to achieve and how to get there. You won’t get this when you purchase cheaper mass produced products. You can’t afford to spend hours working out how to use the tools without instructions in a professional setting.
All Specialist Tools Australia products are of exceptional quality (trialed by its team), and they are available for immediate pick-up or delivery from its Canberra Warehouse.
Specialist Tools Australia is a family-owned small Australian business with a lifetime of trade experience in automotive repair and diesel fuel injection repair industry in Canberra, and throughout New South Wales and Australasia.
Timing tools maintain the correct alignment of the engine drive gears to facilitate timing belt replacement, injection fuel pump removal or cylinder head removal. Using these tools ensures the correct operation of components. Often these tools are
SA-8214A Timing Tool set for Diesel Engines - Zexel, Bosch EP/VE Rotary, Kikki and Nippon Denso pumps found in Toyota, Nissan Patrol, Mitsubishi, Mazda, CAV Roto diesel in Alfa Romeo, Audi, BMW, Daihatsu, Fiat, Ford, Isuzu, Iveco, Lancia, Land Rover, Mazda, Mitsubishi, Nissan, Renault, Rover And Volkswagen.
quite necessary; the procedure cannot be performed without them for the accurate placement of replacement parts.
The precise positioning of camshafts, valves, pistons and crankshafts being integral to the internal combustion process, there really is no room for error considering the rate and load at which these components interact with each other.
Often the removal of a supply pump will require the positioning of gears, retaining of the timing belt and holding of the supply pump gear all in one operation.
This is true of the engine timing and supply pump removal tool for the Ford/Mazda Duratorq 2.0L/ 2.2L/ 2.4L and 3.2 litre engines
combination kit (SA-8033 & SA-8033A) which is often teamed up with the Toledo Timing Tool Kit (SA-8113) and the Diesel pump sprocket puller (SA-3757). All these tools suit the Ford/Mazda group and are used depending on the vehicle you are working on.
The Timing kit in the red case is used on both Petrol and Diesel Mazda (1-6 as well as other models), Ford Fiesta, Focus, Mondeo, Transit etc for engine setting and locking. This kit (SA-8199) will also fit similar engines fitted in other vehicles.
Some timing tool sets are very comprehensive and versatile such as the Govoni Timing Kit for the VAG engine group (G310232015) which includes Audi, Skoda, Seat and VW. This kit contains 32 tools that will lock and align the camshafts, crankshaft, tensioner pulleys, chain and pinion etc during the removal and installation of the engine timing belt, chain and other engine servicing and repairs facilitating the removal and replacement of components.
Diesel vehicles with mechanical fuel systems require the injection timing point to be set related to crankshaft position.
When the engine is fitted with VE type rotary fuel pump the setting is expressed as plunger lift measurement in mm at a specified point, usually ATDC (At top dead centre).
Measurements can also be checked and set with dedicated tooling containing a dial indicator and specific adaptors like those found in the Diesel Fuel Pump Timing Set (SA8214A) which is designed for many earlier, pre common rail diesel vehicles in Australia such as Toyota, Nissan, Mitsubishi, Mazda, VW, Audi and Ford.
This tool screws into the fuel injection pump to measure the plunger lift at a given specified position, which is often Top Dead
Centre. This kit contains the dial indicator, DTI bracket and probe with adaptors, Injection pump locking pin and camshaft alignment pin and locking bracket
The Specialised Govoni range has many different tools for most vehicles found in the Australasian market. These superior quality tools made in Italy are specifically designed for vehicle industry OEM tools and Specialist Tools Australia has kits in stock for most aspects of automotive repair.
There are often times when it is difficult to ascertain “Top Dead Centre” where the engine needs to be before dismantling as this will be critical for all other timing operations. The “Top Dead Centre” tool (SA-5193) is a pneumatic indicator for finding top dead centre. The indicator is located into the spark plug/glow plug hole and when the engine
is rotated it clearly shows when the piston has achieved Top Dead Centre by visible movement of the indicator float. Adaptors for 8mm, 10mm, 12mm, 14mm & 18mm sparkplug holes and glow plug holes.
These timing adjustments are very important in achieving a correctly assembled and a well running engine. Incorrect installation of new components (belts, chains, fuel pumps etc) can have devastating
results, both to the new component and to existing gears and the engine.
There are many more timing tools, as well as other quality tools for the automotive professional available at specialisttools.com.au or if you would like any assistance in finding the right tool call Specialist Tools Australia’s helpful team on 02-62804334 in Canberra
Guilt-free, silent sand driving in a Baja Bug is made possible with one of Australia’s finest EV conversions
WORDS AND IMAGES: IAIN CURRY
When a lifted, bull-barred VW Beetle with underbody bash plates and mud terrain tyres starts barrelling towards you, you always – always – expect it to be accompanied by the metallic, rattly beat of an air-cooled four-cylinder.
Yet this fascinating Baja Bug approaches me in utter silence. I eventually detect some feint whirring, which turns into cosmic zooming as it launches past at serious pace. From a distance you’d naturally expect this mad Volkswagen was going to be a fuel-sucking carbon-emitting funster. But get closer and the truth emerges. The old flat-four’s long gone, replaced by a single electric motor and Tesla battery pack to
create one of Australia’s finest electromods. The electromod movement has snowballed in recent years, with numerous businesses and backyard mechanics converting classic cars to run only on electrons. It’s a polarising game. Some insist classic cars should retain their original heart, but others point out the benefits – environmental and reliability-wise – of utilising the latest EV technology.
Electric boogaloo
Working mechanics have little choice but to accept that electrification – hybrid and
full electric - is part and parcel of most new cars today. If you’re new to the trade or mid-career, there’s little choice to upskill or be damned. Being able to work with high voltage and understand the nuances of electric drivetrains appears unavoidable. Tragically, we may need to say a prayer for the Ferrari V12, Mercedes-AMG V8, BMW straight-six and even a VW’s classic aircooled four-pot.
Best bet’s to embrace it, as Brisbanebased David Elliott’s done in creating his electric VW Baja. Here’s a man renowned for meticulous attention-to-detail, as is
required to succeed in his 40-year career as a marine trimmer. His work’s won numerous national and international awards, and states his goal “is always perfection.” Peer over this Baja Bug and you soon believe it.
His apprenticeship was in Coach and Motor Body Trimming, and he soon found customers from Mercedes-Benz, Jaguar and BMW car clubs. As you’d imagine, such owners are a particular lot. David was running the workshop in his final year, and started his own business a week before graduation.
This was the early 1980s, and cheap
Beetles were ideal test beds, especially for David’s family’s holiday home on Moreton Island – the world’s third largest sand island a short ferry ride off Brisbane’s coast.
“You could buy them (VWs) for $60-100 out of Saturday’s paper back then,” he said. “I’d just buy one, get a gas axe, cut the guards and bonnet off and take it over to Moreton. When they rusted out with no floor left, we’d drive them to the tip, park up with keys left inside, then buy another one and do the same. They’re just so easy to work on and not rough to ride in.”
You sense younger David and his fellow
A meticulous attention to detail has held David in good stead his whole life, and gave him the confidence to build his beautiful Baja Beetle.
islanders had a pretty wild time modifying and enjoying these throwaway VWs in their sandy element back in those carefree days. But he was also learning.
German electric
David was a founding member of the VW Drivers Club of Queensland, and has built numerous high standard custom specials, including street and beach-bound Volkswagens. He and his wife currently keep two Baja Beetles at their home on the southern end of Moreton Island.
A negative is having to boat over drums of fuel to feed these old air-cooled Bajas, so an electrified version tickled David’s creative
fancy. “I started this thought process as our house batteries are fully charged by eight in the morning, and that’s running full solar on the house,” he explained. “So why not build a Baja I can plug in?
“Most of the time we’re travelling within 10 kilometres, and more than likely just two kilometres. We head out, have a bit of a fish, then plugging it in it’ll only take an hour to charge.”
The EV Baja’s soon setting sail for island duties, but I first sampled it at David’s Brisbane home workshop, where he’s basically crafted it single-handedly. Under the custom tray back (there for the fishing catch and garden mulch) is a 170hp (127kW)/230Nm NetGain HyPer 9HV electric motor driving the rear wheels. It’s been sourced from Queensland EV converter Traction EV, which provided parts, advice and final motor programming.
The floor pan’s a 1971 VW Beetle, and the project started with extending the suspension arms to give longer travel. The front features VW’s Country Buggy spindles, which are a 75mm raise, giving much better articulation with the height.
There are adjustable torsion bars front and rear, and current ground clearance is a soft sand-friendly 300mm, helped by monstrous 305/70x16 Kumho Road Venture off-road rubber.
Any electromod presents the challenge of getting hold of batteries, and where to place them. You’re ditching the weight of a combustion engine and its oily bit accoutrements, but lithium-ion batteries have serious mass. Ideally, they’re placed low down and evenly spread for best weight distribution.
David bought a wrecked Tesla Model X at auction, and despite being told he’d need a four-post lift and a scissor lift to get underneath and pull out the batteries, he worked his own plan.
“If someone says to me ‘you can’t do something,’ I say: ‘watch me,’” he explained. “In the backyard I had the whole thing pulled apart in four days. I ended up sliding the body off.” He measured the batteries and crafted an alloy floor with triangulation side impact protection.
The Beetle’s skin was fully stripped
While Moreton Island’s beauty can’t be denied, getting day-to-day necessities can be a logistical challenge, making the switch to EV a tantalising prospect.
ahead of significant custom work, not least adding a fibreglass bonnet (cut in half and widened by 40mm) and crafting the hefty front guards and nose cone by hand. Paint is Audi Nardo grey.
The rear section has been taken from the back end of a 1937 Dodge, which had been in David’s garden for 35 years. “I did some measurements, cut it off and grafted it on,” he said, as if it’s as simple as you or I putting on a shoe. It creates a cabin with a rear dicky seat (for David’s dogs), which lifts to reveal the high voltage electric work.
“The side steps and bull bar are powder coated 6.7mm alloy,” said David. “Everything else is 2-pac painted, with each part prepared and primed properly. All welds have been ground out clean.”
Black and orange wheels are 16x7-inch up front and fatter 16x8-inch at rear. He runs tubes in the tyres let down to just 6psi. “The tubes mean you don’t roll them off the rims, and it’s just like a big bit of jelly, but the footprint is more than double like that.”
There are disc brakes all round, Toyota Prius electric power steering, a Toyota HiLux steering wheel and modified Suzuki Vitara front seats. A custom padded dash mixes old (VW speedo and switches) with the new, such as an LCD readout for electric vitals, plus a digital GPS speedometer.
The vehicle tips the scales at 1230kg, which is roughly 150kg over David’s petrolpowered Bajas. “I’ve over-engineered with thicker components than necessary,” he explained.
You’ll notice the proper licence plates on this EV VW, which landed after securing an engineer’s approval. This involved welding inspections using ultrasound, a torsional twist test and a lane change test, performed by a professional driver in NSW. A manual gearbox remains – it’s a 1976 Beetle four-speed – with a 200mm Stage2 pressure plate and 6-puck solid centre disc. Fourth and reverse gears have been removed, the latter being resolved by fitting a reverse switch on the dashboard.
“With the gearing, at 110km/h in second, we’re doing 5500 revs,” he explained, “and
in third about 3000rpm. You really only need to use first if you want to do someone at the lights. Normally I’m just cruising away in second gear, and you can go up to 120km/ h+ and pop it into third gear if you need to.”
The giant tyres impact the EV range of this VW, as will sand driving. “But even if I only get 100km range after softening the tyres, that will definitely get me around Moreton Island,” he said. “It’s got plenty of range for what it needs to do.”
David’s adapted quickly to everyday EV driving. “I’m taking it everywhere because it’s just so easy and quiet,” he said. “I’ve stopped driving my normal (combustion) VW van. And I’m noticing at a set of traffic lights all the other cars’ fumes. I never really had before.”
The EV Baja project’s taken two and a half years from start to finish, but there could be more. David’s wife’s taken a shine to EV life, and fancies a street Beetle with electric conversion.
“I believe classic car EV conversions will be a bigger movement in future,” he said. “I’d advise those interested to be as meticulous as you can. Google has a lot of information, but you must filter out the correct from the false and get multiple opinions.”
This electric Baja Bug has wowed locals and the ever-enthusiastic Volkswagen
