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'91 Mayfair Restoration/upgarde


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#466 M44K TS

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Posted 16 August 2010 - 09:20 PM

Ah well, I got impatient :thumbsup:

triggerwheels.com are closed from tomorrow until the 23rd, so bought the SC kit as I want to try and start the megajolt conversion this weekend if I can as I'll be away in a couple of weeks with work. It worked out a little bit more expensive but it looks a more comprehensive kit and the sensor bracket look better quality.

#467 M44K TS

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Posted 17 August 2010 - 01:05 PM

Megajolt kit has arrived from Autosport Labs...

The whole kit
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Megajolt unit
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LED Shift light, (I hopefully have unique plans for it)
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Serial cable for connecting to the laptop, (need to buy a serial to USB cable)
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Megajolt wiring plug and terminals
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Hard Rev Limiter which needs installed inside the main unit
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6 way fusebox to replace the current 4 way as I need a couple of ignition live fuses
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And lastly a fuel filter, nothing to do with the Megajolt but doesnt hurt to fit one!
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So, now that I have a decent stock of cable, electrical terminals etc, I'll just be waiting on the trigger wheel kit then I can get cracking with it!

#468 MiniLandy

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Posted 17 August 2010 - 02:51 PM

Good to see you've got the megajolt bug! :)

Looking forward to seeing how the triggerwheels kit mounts up, i went for the cheaper option of fabbing my own.

Also interested to see whether the megajolt box connects to your PC, as mine still won't connect to my laptop...

Good luck!

#469 M44K TS

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Posted 17 August 2010 - 03:07 PM

Cheers dude, I'll be taking pics and videos throughout as usual.

#470 mighty mini jack

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Posted 17 August 2010 - 03:43 PM

Loving this as usual dude, look forward to seeing more!

#471 M44K TS

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Posted 17 August 2010 - 08:45 PM

Cheers Jack, I'm excited to say the least! I love stuff like this.

First part of the Megajolt project underway, soldering the hard rev limiter to the main MJ unit...

First 2 wires on..
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Everything connected
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And sloted inside the MJ casing
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Part 2 should follow tomorrow!

#472 M44K TS

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Posted 18 August 2010 - 08:59 AM

Trigger wheel kit came this morning, it looks like a very well made setup too.

Crank position sensor
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36-1 trigger wheel
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Brackets for CPS
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Some big heavy duty tool? I guess it's for aligning the trigger wheel with TDC?
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I think that's everything I need now, so will make a start at the weekend! :)

#473 M44K TS

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Posted 21 August 2010 - 09:30 PM

Started on the Megajolt installation tonight, only had about an hour or so, got the radiator & cowling out, n/s engine mount off and the coil out of the way.

Work halted when I realised I didn't have a socket big enough to fit the crank pulley, anyone know what size it is? 34mm or 36mm or the imperial equivilant?

Anyway, took a couple of pics

Quick shot of the rad and cowling out the way, loads more room to work
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Engine mount off
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Moved the battery cable bracket down to give more room for the coilpack if I decide to mount it there. I'm thinking about mounting it on the bulkhead between the wiper motor and the airbox as there's enough length on the HT lead I bought, (Halfords set for a 1993 1.3 CVH Fiesta if anyone's interested?)
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Wilst taking the rad out, the side bracket which is usually atattched fell off, and the general condition of the radiator core is looking a bit shabby, so I'll either paint it up or buy a new one price depending
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Going to clean the fan cowling up a bit as it's pretty ropey
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The hopefully redundant coil
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Tomorrows job with be to allign the engine up to TDC, whip the crank pulley bolt out if I can find the right socket and fit the trigger wheel and crank position sensor bracket.

#474 M44K TS

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Posted 22 August 2010 - 06:49 PM

Today's update.

Started off with a quick trip to Halfords for a breaker bar, (didn't fancy my 1/2 drive ratchet and the usual trolley jack handle trick) and a socket as close as 1-5/16" as I could get, closest they had was a 34mm which did the job nicely.

So first things first, whipped the fan off for better access, I painted it properly too so 2 birds, 1 stone etc.
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Starter motor out to get access to the flywheel to lock it when removing the pulley bolt
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Crank pulley bolt
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Interesting holes in the flywheel, are they for a crank position sensor on another car?
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With the timing marks set for TDC, got on with removing the bolt
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With the aid of these
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Next to be removed was the distributor which will be for sale shortly, in 100% working condition too!
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Distributor drive thing removed too, Thanks mini_mad69 and Jordie for the heads up, I wouldn;t have noticed it otherwise lol
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Now I'm left with a hole in the engine block
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Luckily I bought the blanking plug
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And with some gentle persuasion with a hammer, fitted.
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Decided where and how to mount the coilpack too
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And my mounting brackets, you might recognise them as seat extender brackets, going to chop them about so they will fit if I can find the bench grinder in the garage. 2 holes line up perfectly with the holes on the coilpack which was a stroke of luck
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Rough idea of how they fit
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After searching round for a longer bolt bottom fixing for the crank position sensor, I eventually found one and with the aid of a few washers, got the bracket and CPS fitted
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It says in the instruction to have between 0.8mm and 1mm clearance between the trigger wheel and CPS, this is as close as I can get it, looks more than 1mm, if I turn the bracket over, it looks like it sits too close and could catch. Any ideas?
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At this point I realised that I didn't have the longer crank pulley bolt that's supposed to come with the trigger wheel kit so I was unable to get the trigger wheel fitted properly and alligned. I've taken the alternator off too so I can clean it all up and get it painted black as it's only half done.

#475 M44K TS

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Posted 26 August 2010 - 09:19 PM

Extended crank pulley bolt arrived Tuesday morning just before I set off for Aylesbury, so I can get the trigger wheel bolted back up tomorrow night, then start fitting everything back up...

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And I my eBay impulse buy, gonna have it in the boot just for oncourse points :D

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Not very interesting I know :)

#476 nev_payne

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Posted 27 August 2010 - 08:19 PM

Can you push us the part number on that ebay find Mark?

#477 M44K TS

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Posted 28 August 2010 - 09:26 AM

For the first aid kit?

If so, there's no part number as such on it, this is the only sticker that's on it...

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#478 bamby

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Posted 28 August 2010 - 11:05 AM

Here you go

http://www.franzkalff.de/

(decided to google the label !)

#479 nev_payne

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Posted 28 August 2010 - 06:44 PM

Cheers muchly :)

#480 M44K TS

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Posted 29 August 2010 - 01:19 AM

No problem mate.

Tiny update tonight.

Got the new extended crank pulley bolt in and torqued up to 150ft/lb after a quick trip to Halfords for a 12mm allen socket, trigger wheel lined up, starter wiring tidied a bit, starter motor fitted back in and the engine mount almost on, one bolt doesn't want to line up, but it was getting late so called it a night.

Starter motor in and wiring tidied, (the looms have been wrapped in cloth tape after I took the pics so they look a bit neater.
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Trigger wheel on and lined up, (engine not at TDC on pic)
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Cheeky shot of the new crank pulley bolt
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Multimeter ready for checking the crank sensor is working
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The keen eyed will have spotted the EDIS module is also fixed down, means I can run the wiring under the scuttle across to the coilpack then into the car
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A quick video of the crank sensor working. Setting the meter to AC and turning the engine over with the multimeter probes on the sensor wires...


Also started to clean up the fan cowling, alternator and radiator.

Fan cowling before
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Cleaned up a bit, still needs some of the tight spots doing that I could get the flap wheel into.
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Alternator flattened back a bit, again, needs going over with some wet and dry tomorrow.
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Radiator end tanks flattened back, again, needs going over with some wet and dry, I'm also going to try and straighten out as many of the fins as I can.
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Tomorrows job will be to finish off stripping the paint off the above, kurust where needed, then etch prime then paint satin black.




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