137 replies to this topic

[Mito]

A few photos of my handy work.

 

 

 

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Edited by Mito, 16 January 2022 - 06:34 PM.

[Mito]

duplicate post

Edited by Mito, 16 January 2022 - 06:32 PM.

[Mito]

While I'm waiting for the suspension parts and wheels to come back from the powder coaters, I thought I would make a start refurbing some of the other parts.

 

I started with removing the heater matrix from the heater.

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It looks like this may have had a bit of a leak, which was probably contributing to the water in the passenger foot well and the rusty floor pan. 

I've now replaced this with a new heater matrix but it didn't come with any foam which I'm guessing is required to prevent it from rubbing on the sides of the case and rupturing or just making an annoying noise. 

 

I stripped the clutch master cylinder and put it in some deox-c as the bottom bracket was quite rusty. Once it had been left, it was rinsed, polished and rebuilt.

 

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The tower bolts also had a bit of rust on them, so these went into the same deox-c bath. I've applied some acf-50 to them to help keep the rust at bay.

 

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I then heard that the London to Brighton run is on in May and now need to step things up a gear.

 

The head came off the engine so that I could see the extent of the work required. The gearbox was fine and the engine was running, albeit very rich, before it was taken out of the car. There is a lip in the bore, so time to strip it and re-work the block.

 

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Carbony! I'll strip the engine next month before I take it in to be bored and deck refaced.

 

On with the carb. I've fully stripped the carb and left it in some surfex overnight.

 

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I'll carry on cleaning and rebuild it tomorrow.

 

 

[johnR]

Deox C is great stuff isn't it? that's one grubby carb!

[Mito]

Deox C is great stuff isn't it? that's one grubby carb!

Yeah, the only time it has failed to shift the rust is in an old petrol tank I have. I may give it another go at some point. It has been great on all of the other parts I've used it on though.

 

The carb is looking better already, just some stubborn bits that I thought might shift after an overnight soak. There's probably 30 years worth of dirt and grime on it in the pic.

[Mito]

After an overnight soak in Surfex, the carb parts have come out pretty clean.

 

Main body

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Parts ready to be assembled.

 

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Fully rebuilt with new jet, gaskets, and a MiniSpares superflow float needle.

 

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It could do with a good polish, but it looks a lot better and cleaner than it was. Hopefully it won't over-fuel when it goes back on the engine.

 

The slave cylinder was also looking a bit crusty, so I disassembled it and put it in some deox-c.

 

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It's come out looking like new, the only thing is I bought the wrong rebuild kit for it. Damn! So this will have to wait until the next parts run.

 

The re-assembled clutch master.

 

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[Mito]

Back in 2017 when the car was taken off the road, it was running very rich and in addition to all of the body work issues also failed on emissions. It wasn't worth even a cursory look at this at the time.

 

CO 9.56%

HC 1418

 

I'm convinced that this was due to it over fuelling and that this was due to an issue with the carb, likely the float bowl overflowing as there was a very strong smell of petrol if you round the front windows down.

 

 

The float needle seat on the carb didn't have a washer under it, so possibly wasn't sealing and allowing the petrol to continue flowing?

 

As time is tight to get it back on the road for the London to Brighton run in May, I've decided to give the engine an ebay refurb, clean and paint, and then drop it in the car, and take it for MOT asap in April in the hope that it runs okay and passes. If it doesn't, then it will have to be rebuilt which I think will push me beyond my deadline.

 

So, new head gasket delivered today.

 

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This weekends plan...

1. Collect parts from shot blasters
2. Paint rear radius arms and a few other parts
3. Assemble as much of the front and rear subframes as possible

 

[Mito]

I didn't quite finish what I had planned for this weekend.

 

Picked up the refurbished alloy wheels. They're finished in metallic black.

 

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Sprayed a few of the suspension components that I had forgotten to take to the powder coaters in matt black

 

Tie bars, throttle pedal, servo bracket, front subframe mounts, and the plate behind the carb.

 

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Close ups

 

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The new donuts where in bare metal, so they were painted as well along with the rear radius arms.

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All looking much better.

 

Picked up some more parts from the powder coaters, just the rear subframe to pick up now.

 

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[Mito]

Another pic of the painted rear suspension parts.

 

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The rear subframe back from shot blasting and powder coating.

 

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During the assembly of the subframe, pushing the rear radius arm pin through its mounting hole, the bracket for the brake line became detached. It appears that the spot welds holding the bracket in place where not done properly.

 

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I cleaned up the area and welded the bracket back on.

 

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The rear subframe is now pretty much assembled baring one brake line which I kinked, so I'm not quite ready to put it back on the car yet.

 

The front subframe is now assembled barring the hubs and brake calipers.

 

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And now the subframe is back on the car.

 

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It appears that the spot welds holding the bracket in place where not done properly.

[Mito]

Rebuilt the clutch slave cylinder.

 

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Built up one of the front hubs with new Timken bearings. I'm still waiting for the new ball joints to arrive.

 

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Finished off building the rear subframe and installed in the car.

 

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Started assembling the rear brakes. 

 

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After this I put on the rear shocks. However, they don't extend far enough to be able to fit them to the wheel arch.

 

Then I rebuilt the brake calliper's with new seals and new bolts with Loctite 270. Bolts torqued to 60lbft. They have been shot blasted but have some surface rust on them, so just put them in a bath of Deox-C to remove it before paint.

 

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Edited by Mito, 18 March 2022 - 07:04 AM.

[Mito]

The new "no shims" required ball joints arrived which meant the front hubs could be finished off.

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nice. Easy to fit as well, so this didn't take long at all.

 

Rear drums painted red and on the car.

 

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It has a steering wheel!

 

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Loosely assembled the front suspension ready for the wheels to be fitted. They'll have to come off again when the engine and drive shafts are being fitted, so thought I'd make my life a bit easier.

 

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Went to have fitted the new Yokohama A539's. Now on the car.

 

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Cleaned the engine and gave it a coat of yellow paint.

 

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Getting there. 4 weeks remaining to get it road worthy.

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[johnR]

loads of time - if you spend every waking hour on it!

[Mito]

loads of time - if you spend every waking hour on it!

it will be done

[johnR]

I got my bodyshell back in June 2015 and it was ready to drive to Monte Carlo in the September, but I had been renovating parts while the welding was being done. it was the customised parts that took the time rather than just bolting on standard stuff. 

[Mito]

Engine painted using por15. So much for it only requiring one coat. This took 3 costs for it to cover.

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Dropped in the half engine.

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Put in the wiring loom, put the grommets in the bulk head, and glued the foam to the bulk head.

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Put the drive shafts in.

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Installed the cylinder head last night.

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