Gallery

A small selection of projects completed by Styx Worx Garage and details of how we saved significant cost by addressing the root-cause.

2007 BMW Z4 - Bumper Cover & ABS Module

This vehicle experienced cosmetic front-end damage. A local body shop was unable to repair it because a new bumper-cover could not be located. Instead of replacing it, Styx Worx Garage plastic-welded the broken seam, refinished, and repainted the damaged area. We also addressed a faulty ABS module, an issue that a different shop attempted - and failed - to repair at a cost of more than $2000. Rather than replace entire $2950 module, we located and addressed the root-cause: stuck carbon brushes inside the ABS pump motor, a repair that cost nothing in parts. After flushing and re-calibrating the module, the ABS and DSC systems were once again fully operational - a repair that saved the owner thousands.

Pre-work: Front-end damage

Pre-Work: Crack in lower bumper cover

Step 1 - Remove all damaged parts

Step 2 - Plastic-weld cracked / broken components

Step 3 - Remove ABS/DSC module

Step 4 - Refurbish and clean carbon motor brushes

Step 5 - Reassemble body panels

Step 6 - Clean and wax body panels, clean convertible top

2006 Lexus GS300 - Transmission Computer

This is a vehicle encountered a transmission computer failure. The dealer wanted around $1600 for a new computer, and another $2300 in labor and programming. Instead of replacing the entire ECM, Styx Worx Garage opened the unit to locate and and replace the faulty component on the printed circuit board. A new SMD capacitor kit for $23 was enough to get this one back on the road. We also replaced the engine wiring plugs, seat leather, shocks, brakes, and a number of other components to get it back to near-original condition.

This is the PCB that needed to be repaired

Replacing the fragile connectors

Replacing seat leather

New seat leather

2013 Toyota Avalon - Head Gasket

These photos show a customer's vehicle that was diagnosed by a dealer with low cylinder compression. Their solution was to replace the entire engine, at a cost of over $3500. Instead of replacing the engine, Styx Worx Garage was able to replace only the broken component for around $220 in parts, saving the customer thousands on the repair bill.

Step 1 - Remove valve train and heads

Step 2 - Inspect heads for warping

Step 3 - Clean and prep heads

Removed parts - cataloged

Step 4 - Reinstall heads and valve train with new seals

Step 5 - Vacuum fill coolant

Step 6 - Perform compression test to ensure proper sealing

2014 Chevy Silverado - Turbo Rebuild

These photos show the rebuilding of the unison ring on the turbocharger of a 2014 Chevy Silverado 3500 HD 6.6L Duramax V-8 diesel. A different repair shop's solution was to replace the entire turbocharger with a remanufactured unit at a cost of over $1,500 for the turbo and more than $2000 in labor. Instead of replacing the entire unit Styx Worx Garage sourced a $50 overhaul kit that would replace the seals & bearings. We then cleaned the stuck unison ring while the turbocharger itself was disassembled.

Step 1 - Remove Cab

Cab removed

Step 2 - Remove exhaust

Step 3 - Remove piping

Step 4 - Remove turbo

Turbo removed

Step 5 - Disassemble turbo

Step 6 - replace shaft seals

Step 7 - Clean and rebuild unison ring

Step 8 - Reassemble turbo

Step 9 - Install turbo on engine

Step 10 - Reattach cab

2009 Polaris RZR800 - Transmission Shift-Arm & Lift Kit

This is one of many side-projects that Styx Worx Garage's owner completed for personal use. This started as a nearly stock RZR 800 with a broken shift-arm inside the transmission. The Polaris dealer's recommendation was to replace the entire transmission and quoted several thousands of dollars for the service. Instead, I decided to simply weld the broken component, a repair that cost around $100 for seals and gaskets. After repairing the broken part I started adding many more pieces and ended up with a buggy that was 6" wider, 8" taller, and 6" longer than original.

Original configuration

Step 1 - Remove body

Step 2 - Remove engine & transmission

Step 3 - Disassemble transmission

Step 4 - Repair shift fork

Step 5 - Replace seals

Step 6 - Reassemble

Step 7 - Remove suspension

Step 8 - Replace shocks

Step 9 - Replace wheels and tires

Project complete

2001 BMW 525iT - Engine Rebuild

This project started after the engine lost all power while driving. A compression test indicated loss of compression on cylinders 5 and 6. After disassembling the engine, pre-detonation was found to have caused 'nibbling' of the piston edges, eventually eating past the rings and through the piston surface. Unable to afford a new engine, I sourced 3 pistons and rebuilt the short-block.

Step 1 - Remove valve cover

Step 2 - Remove heads

Step 3 - Remove short block

Step 4 - Disassemble and clean

Damaged piston

'Nibbled' edges

Step 5 - Install new parts and rebuild short block

Short block complete

Step 6 - Reinstall bock and heads

Step 7 - Re-drill and tap head bolts

Step 8 - Reinstall valve covers and VANOS system

Project Complete

2002 PT Cruiser - Timing Belt

This project started after my wife's car died on the interstate. After towing it home, we found that it had thrown the timing belt. The dealership wanted thousands to remove the entire engine and replace the belt. Instead of removing the engine, we found a way to save time by removing the belt in steps, with the engine in place. Parts were a few hundred dollars and it was back on the road in about a week.

Step 1 - Remove headlight, engine covers, fender liner

Step 2 - Remove timing cover and pulleys

Removed parts

Step 3 - Lower engine to replace covers

Step 4 - Raise engine to replace upper components

Step 5 - Replace covers and reassemble

Page updated

Google Sites

Report abuse