Post Photobucket reboot from April 2010: Continued.........Busy day today, so not much done to the Morgan. I did manage to take that Series1 specific nut & bolt out. It's unusual in having a 13mm bolt head and a 17mm nyloc nut.
This shows the sump flange with the bolt out, and you can see that the casting has been thickened up for the extra hole. You can also see that the bolt has chased some threads in the alloy. I'm guessing that the hole was drilled after the engine & gearbox were mated (from the rear). The hole is slightly undersize for that size bolt.
Here I'm using metal foil from a wine bottle to make a template for when I drill the extra hole in a spare sump. This foil is just right for keeping shape, so it can be moulded round the holes to transfer the location.
Well, I've prepped the spare sump for emergency use, and drilled the extra hole using the template.
Round the back it needs strengthening, and I've taken the easy route with JB Weld. This is so that when the nut is tightened, the filler will not compress, and stop the flange cracking.
Finished off........compare this with the photo in the first post.
Now the question of the sump bolt. There are two sizes, 21mm & 28mm - and I really can't see what difference it makes.......3051079 is the 28mm version, which comes in this large box. Look carefully at the integral neoprene washer and you'll see a small raised lip. This is what makes the seal, so providing it's undamaged, the bolt will be OK to re-use.
Next the gasket. Two were listed for the ST220, and I went for the post 2003. The part number for this is 4763355, BUT there's a big but............
I hope it's obvious in this photo. The gasket is a composite alloy/neoprene (and is over £40.........). The thickness is at least 2mm and if this were fitted to my Mog it would be visible as a sandwich plate. No gasket is visible. I therefore conclude that in order to increase clearance, a paper gasket is used on the Morgan.
FRANK - next time you visit the dealer, can you ask them about the sump gasket please. I bet it's paper, which means that we can make our own.
More to follow>>>>>>>>>>>>>>>>>>
