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No point in cutting out rust on an common Toyota.
Even grinding back and treating is going to cost a bit if labour. Given you have a snapped drive shaft and that is part that is worth going oem for your bill is going to be fairly substantial. I dont know how much a 10 year avensis is worth but you may not see much change from £1000. I don:t know if your wheel bearing has to be changed for this job but you might as well while everything is apart.
Going to breakers yards can be worth it but for cars you are attached too.
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I would not risk 1x heads in lacing. The benefit is small and the flange is at greater risk. With a forged shell it might be o. K the other risk is the bends on the spokes does cause a weakness. It is a small weakness but for the tiny improvement it is not worth it.
I have done 45mm carbon disc brake rims I use with cx rays 24h and a son deluxe disc brake and the flange spacing is rubbish. There is not a huge ammount of flex but if it was a rim brake wheel it would not be acceptable. Being disc brake though and it's for a light lady it is an non issue. She rode tcr on them.
I would replace the spokes with plain gauge or sapim race if that is all the rim can take. I would also ignore lb spoke recommendation. It is a front wheel and under lower tension. Use washers to help protect the rim and limit tension to 900n and all will be well. What lb are worried about is the spoke being stronger than the rim. If you don't snag it the rim won't fail. No other good solution if you don't want a higher drilling rim.
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To change the topic this morning commute was possibly more horrid than yesterdays MTB race which was awful. cold wet rubbish ran down my tights into my nice water proof and rather warm shoes. needless to say after a 45 minutes my feet were no longer dry and warm. They were yesterday in the race.
Jwestland - this is why i just sayno to any cyclepath that is mixed with pedestrians unless i am on a plod. yoou just cant make progress and pedestrians are truely oblivious. best avoid them at all costs.
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Yes it will select gears with the engine off without effort so the gearbox selector works. The clutch plate must not be moving. I would have though if the trust whatever it is that connects to the slave cylinder was broken the pedal would feel light. It feels normal.