Mikeb's Builds Thread

[MikeB]

Well I thought i'd better start with the build thread.
Think its been 3 months since I got my chassis pack from Handy.
The chassis is nearlly there, need to finish fully welding and add suspension brackets.

http://i555.photobucket.com/albums/jj473/mjb22001/mikechassismk2.jpg

Picked up donor parts at the weekend and have some shiney wishbones from talon so rolling chassis soon... well heres hoping

[shh120m]

Looking good mate, getting the suspension brackets on is a massive milestone.

[MikeB]

well not lots done but started tacking the rear suspesion mounts on, and there was a nice delivery of shiney shocks!
Added the metal panels in the drivers footwell, started fully welding parts of the chassis. Welder decided to start cutting out a lot thought this was the cold or the fact the welders getting on a bit. End up the connections in the plug had come loose, I guess the plug gets thrown around a lot as I only have two sockets in the garage.

http://i555.photobucket.com/albums/jj473/mjb22001/rearsuspensionmockupjpeg.jpg

[Spikehaus]

Hey Dude, your TVR has the same engine that I have installed into the Roadster, (with a degree of difficulty)! What engine are you planning to use?

[MikeB]

Small update on the build hopefully a bit more progress as I think I may have a couple of days in the garage coming up!

I've tacked on one side of the front suspension brackets and trial fitted everything. Thanks to Andy for getting my mushrooms modified (note anyone with 3ge mushies they will probably need modifying to get a full nyloc on the thread of the drag link).
Theres also a bit of gap at the front edge (the back edge it touching) of the upper front wishbone mount where it sit against the front frame, from recollection this is to be expected.

http://i555.photobucket.com/albums/jj473/mjb22001/FrontSuspension.jpg
http://i555.photobucket.com/albums/jj473/mjb22001/sus.jpg

So with a bit of a push the chassis should be finished soon. Can't wait to get it painted and panelled so I can start to actually build the car.

So after starting this build in September I'm nearlly back to where I was with my firts build, moral of the story if you sell up keep your chassis somewhere you don't get much for them anyhow!

[adrianreeve]

Mike

Glad you're building again! If you look in my photobucket photos below, you can see that I put all the bits from your last build to good use! Nearly finished now, so thanks!

Actually, I need an exhaust for my Zetec install, so can you change your engine plans to Zetec. That way when you give up this time, I can get a bargain exhaust!!:p :p :p :p

Good luck with the build!

Cheers

Adrian

[twinturbo]

I think it's funny how we all tackle stuff in different orders.

My chassis is floored and tunneled, and the engine mocked up before I do the suspension :)

That's next on the cards..

TT

[MikeB]

First wheel on, never managed that with my last build

http://i555.photobucket.com/albums/jj473/mjb22001/firstwheel.jpg

Also mocked up the engine and box, gearbox mounts are in engine mounts nearlly there will finish that tomorrow.
http://i555.photobucket.com/albums/jj473/mjb22001/engineandboxin.jpg

Its then finishing welding a few bits and bobs, cutting some ali panel and painting, not to far our of order twin! I use the actual suspension components and cut down jig to put the brackets on.

Glad the builds going well Adrian, can't find a pre 95 zetec for love nor money so sticking with the boat anchor for IVA then swap back to zetec.
Heh those wheels look just the job, wish I still had them and a load of other bits now!!! but heh I'll catch up soon enough, does the engine run always wondered if it was a good one? (maybe I shoudn't ask!)

Like the seats are they westie ones?

[adrianreeve]

Mike

No idea if the engine runs, only just wired the megasquirt up, and still waiting for an exhaust, but if it's a duffer, I know where you live!!! Sure it'll be fine, it's unusual for them to wear out. Hope so, cos like you said, trying to find a pre 95 one is getting really hard!

[MikeB]

Did some more welding on the chassis including tacking the the steering rack frame mounts on. I'm sure there is a dimension wrong in the book for the steering rack mount spacing

Got bored with welding so made some interior panels out of the ally I had knocking around the garage, it will be more difficult to cut once the build table has gone so a good job out of the way just need to order a new peice for the floor and bulkhead. I used a jig saw with a ali blade in it (I think wood blades work ok to) this seems to give a nice neat cut and a lot better than the angry grinder or aviation sheers.

http://i555.photobucket.com/albums/jj473/mjb22001/chassisinternalpanels.jpg

I found this picture of my old chassis just after I sold it, a lesson to all if you have to sell up keep your chassis somewhere for the amount of cash you get for it you might want to build again. The good news is I'm nearlly back to where I was!
http://i555.photobucket.com/albums/jj473/mjb22001/000_0263.jpg

[MarkB]

Wood blades in a jig saw work well on ali, fine blades just clog up that's why angle grinders and cuttings discs are no good. Pendennis use what look like small woodsaw blades in 4" angle grinders, now they are scary things to use:eek:

[ozzy1]

I'm sure there is a dimension wrong in the book for the steering rack mount spacing

I think there is an amendment from the book angle to 108' i recall.

[MikeB]

its not the angle, your right there is a mod for that, its the spacing between holes, .

[MikeB]

Chassis chassis, oh chassis, hope your happy now that you nearlly b*****y finished.
Well there we have it, chassis number 2 finished. A massive milestone. Really looking forward to the next phase of the build, a lot less angle grinding and welding. I'm proud having done the chassis but its a long slog!

Painted it with epoxy mastic from rustbuster, just used the cheapy spray gun that came with my compressor, it looks good. The standard finish is a gloss black, I bought the starter pack but will need another to do underneath and a second coat. I used some wet and dry/wire wool to rub down the chassis finished with a wiper over of thinners, note to self don't leave a big roll of wire wool around when grinding, well that is if you value your garage!!!!

http://farm4.static.flickr.com/3487/5780853338_0bc6801b52.jpg (http://www.flickr.com/photos/62740914@N04/5780853338/)
IMAG0224 (http://www.flickr.com/photos/62740914@N04/5780853338/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr
http://farm6.static.flickr.com/5028/5780838938_c102cbe9c0.jpg (http://www.flickr.com/photos/62740914@N04/5780838938/)
IMAG0218 (http://www.flickr.com/photos/62740914@N04/5780838938/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr
http://farm6.static.flickr.com/5185/5780299087_d4fe0149e5.jpg (http://www.flickr.com/photos/62740914@N04/5780299087/)
IMAG0219 (http://www.flickr.com/photos/62740914@N04/5780299087/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr
I've also added a second plate for the zetec engine install after IVA from recollection its in the right place so should save me welding come upgrade.
I notched the top rail to clear the cvh thermo housing and added a 25mm rail behind the notched one to add the strength back into the chassis.
I've also left off two of the diaganols at the rear to fit a bigger fuel tank, the roll bar rails will add the necessary support in this area, its pretty tough as is!

[MikeB]

Talking about carbon wings, forgot to say I have got these beauties.

http://farm4.static.flickr.com/3074/5780425847_56137bc2cb.jpg (http://www.flickr.com/photos/62740914@N04/5780425847/)
IMAG0225.jpg (http://www.flickr.com/photos/62740914@N04/5780425847/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

They are very very light (not that FG weighs much) and they look niceeeeeeee.
There's a guy on locostbuilders that makes them.
I believe they retail around £170- £200 for fronts.

[MarkB]

OOO pervy wings aye:)

[baz-r]

Wood blades in a jig saw work well on ali

i use cutting fluid for drilling and jigsawing ali works wounders and cuts like lighting :D

cooling with duck oil/wd40 also works as when the blade gets hot the alli welds its self to the blade keep the blade cool and the sh1t dont stick simples

i got air shears tho :cool:

[MarkB]

Another neat trick is a dry bar of soap rubbed on the blade...:D works on grinding discs too so ali doesn't clog the disc..:D

[John.W]

Another neat trick is to buy a cutting disc for aluminium.

[MikeB]

A bit of an update for you.

Finally started to attach something to the chassis, this time brake lines.
I've ran the the front to rear brake line in the chassis, its looking really good
I also got hold of a ebay manifold from a westfield, its a well made stainless number for a 1.8 cvh so it will suit my zetec upgrade later.

http://farm6.static.flickr.com/5319/5900658698_5ebe325444.jpg (http://www.flickr.com/photos/62740914@N04/5900658698/)
IMAG0233 (http://www.flickr.com/photos/62740914@N04/5900658698/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

It will foul against the diaganol though, where it exits the side of the car,
The picture shows the manifold but it needs to move to teh right inline with the current central engine mount.
Raising the angle of the diaganol should give it the clearance and not affect the chassis stiffness much. I also need to mod the engine mount, on the exhaust side of the cvh there are two possible positions for the engine mount, a central one (fouls this exhaust manifold) and a forward one off the old alternator bracket. If I use the alternator bracket this will be identifical to what is needed for the zetec to so may as well do the mod now. I 'd already put the plates on the chassis so not a big job.

[twinturbo]

looking good.


But running the brake line in the chassis may be an IVA fail :)

TT

[MikeB]

Now you have me worried! best take it all out again!

[AshG]

brake and fuel lines in chassis rails is a big no no.

[MikeB]

Woooooaaaa guys, does my pic looks like I have put them IN the chassis rails!
Same as everyone elses so don't panic! :)

[MarkB]

Nope I saw them running down the tunnel.....just like witches at black masses...:D

[MikeB]

Right hoping to make some progress on my build this weekend.
If my sheet of ali turns up I want to try and get the floor in!
With a good run at it I could even have it on its wheels! but lets not get carried away!

[MikeB]

Well i finally got my floor cut, ordered the ali from aluminium warehouse which I liked as its all on line, uk delivery no messing and i think the price was reasonable £70 delivered for a large sheet, it came on a wooden pallet and was coated both sides with plastic.

Laid the sheet on my build table, placed the chassis on top and marked out the floor. 15 minutes with the jigsaw job done.

I got some sikaflex from screwfix and ordered some countersunk pop rivets, some people have reported the glass fibre side panels need a lot of work to fit so I think countersinking the rivets will make this a lot easier.

50 rivets later and I have RSI in my hand and the drills flat! should finish the job tonight.

Then, there might be a slight chance of getting it on its wheels and the engine and box in! Can't wait, that will be a massive milestone for me!

[deezee]

Well i finally got my floor cut, ordered the ali from aluminium warehouse which I liked as its all on line, uk delivery no messing and i think the price was reasonable £70 delivered for a large sheet, it came on a wooden pallet and was coated both sides with plastic.

2500mm x 1500mm 2mm 5251 H22 (210MPa Tensile Strength) grade aluminium cost me around £35 from Aalco in Liverpool. I had to collect it though.

[MikeB]

It was 49 less VAT, a bit hard to collect without a van though! lol
Still thats a good price you got.

[MikeB]

The floor is in!
It only took about 150 pop rivets with a standard hand tool!

So surely it is time to get my chassis rolling??
I need to weld up the diff brackets
Cut slits in the handbrake bracket.
Other than that I think she is good to go.
Getting excited, dont want to be in work just at home working on the car!!

[HandyAndy]

Nice one Mike , soon be rolling it in and out of the garage :cool:

I remember the pop rivets too ....160 of the blighters :eek: had biceps like Popeye afterwards :D

get some pics up of the day she rolling :cool:

cheers
andy

[MikeB]

hopefully at the weekend, not sure I have all the nuts and bolts I need but we'll see!

[twinturbo]

Mine Rolls, and steers (just) but when it comes out of the garage it will be to allow the Old Mondeo in finaly for it to be broken up. But I can't do that in my current condition so will potter on doing little bits and bobs. Need to take the passenger side panel off to do the exhaust.

Will be good to see yours out in the open :)

TT

[MikeB]

Can't believe it nearlly a year to this day my chassis kit arrived and she rolled out of the garage!
Manage to get the gf to help get the chassis out of the garage and spend saturday morning building it up.
Managed to get the engine and box in as well.
Other than being completed knackered I'm well chuffed massive milestone, it actually looks a bit like a car now when people come round!

Big question what next, get the engine running (need megajolt, carbs manifold and some wiring) sort the brakes, bodywork???

http://farm7.static.flickr.com/6202/6066114927_93e81cc6d1.jpg (http://www.flickr.com/photos/62740914@N04/6066114927/)
IMAG0269 (http://www.flickr.com/photos/62740914@N04/6066114927/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

http://farm7.static.flickr.com/6201/6066112677_03eccd8637.jpg (http://www.flickr.com/photos/62740914@N04/6066112677/)
IMAG0268 (http://www.flickr.com/photos/62740914@N04/6066112677/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

[twinturbo]

Always cool when they are rolling, I am doing my exhaust once that's done I am driving it out of the garage ( with no brakes :rolleyes: )

TT

[leroybrown911]

Well done Mike! I hopefully wont be far behind you!

You aiming for IVA next year?

[MikeB]

yep hoping for IVA next year hopefully in time for the summer! Its cash dependant though!

[K4KEV]

That smile sez it all...nice one Mike:cool:

[wylliezx9r]

If i were you Mike i would fit all brake lines, fuel lines and wiring harness next, while there is a minimum amount of parts on your chassis. That will make your life a lot easier, I didnt do it in that order but i wish i had lol. Also if you havn't done so already i would fit your steering coupling and fuel tank as well.

All just my opinion though.

Cheers Dan.

[HandyAndy]

Nice one Mike , a great milestone of your build & as Kev says " that smile says it all":cool:

Its alot easier being able to roll it out onto the drive to work on it rather than on the build table etc .

I look forward to the first start up video :cool:

cheers
andy

[MarkB]

Plumb up the brakes do the loom then bodywork that way you won't damage your panels while doing the above..is that a tad further than you got before? if so "carry on and keep at it":)

[MikeB]

yep never got the old one rolling, I might tinker with a few small things like brake lines and other small jobs whilst I try and save up some cash for the bodywork

[MikeB]

I gave my build a bit of rest after the big push to get her rolling.

This month though I decided I start to get the engine running.
First up getting the starter circuit sorted.
First up was a battery, I managed to pick up a brand new oddessey PC545 fom a fellow builder for a really good price. Its a very small battery but seems to crank the engine just great

I only did a basic circuit for the starter, + to starter neg to engine, and a flying lead to the solenoid plus saw her cranking over.

I connected an old indicator to the oil pressure swith and to the positive on the battery but his didn't go out during cranking.
I have absolutely nothing else on the engine, theres a large breather at the back drivers side, I blocked that off but still no light out, any other tips as I'm confident it either the a faulty sender or its loosing its pressure somewhere rather than a dodgey oil pump pick up?

I've also ordered a fiesta coil pack with HT leads for a grand total of £4.99 this should connect up to the edis module stanalone to give a basic spark to get her running.

All thats needed now is some carb and an inlet (i might try her on the old sierra carb as as starter for ten)

[davedew]

Mike,

I had a simiilar problem with my 1.6 cvh. Oil pressure switch was working fine. I took the sump off injected oil straight into the pump.

No matter how long I cranked it for it would not turn the oil pressure light off. I looked on one of the ford forums and apparently it is a common thing on the 1.6 cvh.

In the end I just started it and it went out within a few seconds.

[brainbug007]

Mine wouldn't go out either with hand cranking or when the engine was spinning from the starter but not starting up. Once I got it running though the light went out after 5-10 seconds.

[MikeB]

I had a go a wiring up a simple ignition circuit for my CVH just using the EDIS module and coil pack
http://farm7.static.flickr.com/6095/6241340193_357ea50b49.jpg (http://www.flickr.com/photos/62740914@N04/6241340193/)
IMAG0307 (http://www.flickr.com/photos/62740914@N04/6241340193/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

http://farm7.static.flickr.com/6060/6242062526_090c60102d.jpg (http://www.flickr.com/photos/62740914@N04/6242062526/)
edis4 (http://www.flickr.com/photos/62740914@N04/6242062526/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

I did get a spark when cranking the engine over but it seemed a little weak.
So i wondered if I had it wired correctly.
The black wire is the positive feed to the coil pack and edis.
I didnt' have the 25uf suppression to ground fitted as I dont' have whatever a 25uf looks like :)
Also I wasn't 100% sure on the terminals 1 and 3 on the coil pack

The leads and plugs are fairly old also.
Any thoughts

[MikeB]

The ht leads dont fit the cvh head so I wandered what any ones anyone have used?

Also what spark plugs? as apparantly this can have an effect when swapping to EDIS

[wylliezx9r]

25 uf is a 25 micro farad capacitor. Available from rs maplins etc.

[mark]

The ht leads dont fit the cvh head so I wandered what any ones anyone have used?

Also what spark plugs? as apparantly this can have an effect when swapping to EDIS

I ran my cvh on megajolt and used standard cvh plugs with no probs

I think i used fiesta leads or ford ka, just went to local motor factors and looked at a few ford sets from around the coilpack era until i found some

[twinturbo]

The Radio Supressor should nto make any difference on starting, it's often even ommited from the ford diagrams.

TT

[MarkB]

Stop faffing about man and get it running:)

[MikeB]

Thats the plan, got it sparking properly now, so just need the carbs sorting, will try the sierras carb just for a giggle!

[twinturbo]

It's a good starting point!

I have ZX6 carbs for mine, but there's no way I would put them on before having the engine running in stock for first.

TT

[MikeB]

It's started, bolted the old knacked carb on found the mechanical fuel pump and regulator in a box of bits, bodged some spark plug leads from halfrauds, wouldn't go on first try, swapped the coil pack connections over and it rawed into life, sacred the crap out of me with no manifold on, only ran for 10 seconds, but it went!
The carb had none of its other connections hooked up just fuel.

[MikeB]

Thought I'd try and get a start up video to prove to the masses she lives.

Connected up the manifold so it wouldn't be so noisy in the garage.

Fired her up and tweeked the carb so she didn't stall.

Great I thought as she sat there idling, then it dawned on me, how the hell do I turn this off!
I'd hard wired the ignition.
What proceded was about a 30 seconds of blind unrational panic!
I pulled the fuel feed to fuel pump, no luck there must have been plenty in the lines and carb.

Mad panic to disconnect the battery with a spanner. this did the trick!

Man it made me sweat for a minute, in the cold light of day it would have been easy just to pull the lead from the coil pack or a rag over the carb but I was in panic mode!

Only damage I hope is a couple of melted cable sheafs where they were touching the manifold, it got pretty hot quicly and was glowing red. Should the manifold got that hot that quickly?, !

[Bonzo]

Can definitely relate to that scenario.

Strange how quick logic goes out of the window in a brief moment of panic.

I once changed the engine on my nephews Turbo charged XR2
He didn't tell me that he had fitted one of those fangled gadgets on that keeps the engine running for a while after the ignition has been turned off ( Supposedly to allow the turbo to spool down properly ?? :confused: )

After first start, I immediately noticed a major oil leak, quickly turned the ignition off.
Imagine my shock when nothing happened, blind panic when faced with the reality of a newly rebuilt engine likely to go pop ( I jumped in & stalled it on the clutch )

Turned out that I had not fully tightened the turbo's oil feed pipe :o :o ( Thankfully, no harm done )

All that aside, it is not uncommon for a manifold to glow a bit when very hot ( very noticeable in poor light conditions )

[shh120m]

i wonder how many of us have dropped a spanner over both battery terminals and paniked like mad getting it off. I tell myself not to do it over and over, but the flat top of the battery is such an apealing place to subconciously put tools!

[MikeB]

Picked up some Zx6r carbs from ebay for a good price.
They look ok I just hope I haven't been sold some lemons.
So it was time to make a manifold for the CVH. FastDan cut me an inlet flange for the CVH that blanks off the water take off. He also supplied me with a length of 45 OD pipe.

I sat down with my drawing board and worked out the cut angles for the pipes to give me a 20deg incline on the carbs, I'm sure I read its not necessary to get the float chamber line horizontal so 20 deg is halfway so should be good.

Using the trusty rage saw to cut the compound angles made things easier, it was still tricky getting everything the right length after compounds cuts.

heres the result

http://farm8.staticflickr.com/7006/6400776245_d73c1e3454.jpg (http://www.flickr.com/photos/62740914@N04/6400776245/)
IMAG0321 (http://www.flickr.com/photos/62740914@N04/6400776245/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

[MikeB]

I'm actually quite impressed with my skills!
The inlet looks good all painted, I've gone for a red highlight theme, so will be using red coolant hoses etc so should look nice and will go well with the white and black body work I have planned.

Just need a fuel pump and som 8mm hose to try out the bad boys!
No idea what hp whe will put out over the standard, hoping for about 115bhp.

http://farm8.staticflickr.com/7171/6458905273_181fbedbeb.jpg (http://www.flickr.com/photos/62740914@N04/6458905273/)
IMAG0331 (http://www.flickr.com/photos/62740914@N04/6458905273/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

http://farm8.staticflickr.com/7020/6458905943_606de7379d.jpg (http://www.flickr.com/photos/62740914@N04/6458905943/)
IMAG0330 (http://www.flickr.com/photos/62740914@N04/6458905943/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

[MikeB]

Well here it is finally.
The first start vid!

http://www.youtube.com/watch?v=LJ53Gd4fa14

Its actually its second start, but first start with the new manifold and bike carbs.

It needed a lot of choke on the carbs but seemed to run nicely, a lot better than the old carb and the exhaust manifold didn't glow bright red this time!

First mod to the carbs will be adjusting the idle mixture to get it running without lots of choke, then not sure what to do for IVA. Leave it or open up the jets to 1.5mm or 1.6mm.

I've also laid my loom in place and will be connecting up the ignition , so it will start off the key next time (super cool!)

[mark]

Well here it is finally.
The first start vid!

http://www.youtube.com/watch?v=LJ53Gd4fa14

Its actually its second start, but first start with the new manifold and bike carbs.

It needed a lot of choke on the carbs but seemed to run nicely, a lot better than the old carb and the exhaust manifold didn't glow bright red this time!

First mod to the carbs will be adjusting the idle mixture to get it running without lots of choke, then not sure what to do for IVA. Leave it or open up the jets to 1.5mm or 1.6mm.

I've also laid my loom in place and will be connecting up the ignition , so it will start off the key next time (super cool!)

Mine passed iva on the standard jets with flying colours, obviously you cant drive it hard up in the revs like that as it will be lean

After a good few runs on a rolling road I ended up with 180 jets, 170/175s were safe too mixture wise but 180s had a touch more power

Still would have passed emmisions tests if required with the bigger jets in

The cvh head doesnt flow very well so doesnt suck very well hence the quite large jets for a modest power output

[will_08]

Well done Mike, looks a tidy build so far you should be proud :cool:

[HandyAndy]

Congrats on the first ( 2nd in vid ) start up, sounds great :cool:
A major milestone of anyones build, :)

cheers
Andy

[MikeB]

Yeh the builds really starting to come together now.

Mark, did you do anything to the carbs to get the engine idling as mine needs lots of choke at the minute, i was planning on just adjusting the idle mixture on each carb.

Mike

[mark]

Yeh the builds really starting to come together now.

Mark, did you do anything to the carbs to get the engine idling as mine needs lots of choke at the minute, i was planning on just adjusting the idle mixture on each carb.

Mike

Mine ran pretty well as they came off the bike

If you havnt already make sure the idle screws under the carbs are all in the same position by screwing them all home then back out the same ammount (approx 3 turns should be somewhere near)

Running without a silencer/no airfilter and no coolant isnt going to give you a steady idle with no choke after 30seconds running

I suspect once you have coolant in and can let it run for a while with the throttle stop adjusted accordingly it will idle anyway

When you get around to fitting an air filter i would change two of your trumpets also so they are all the same length

Something else to consider with the zx6r carbs is the heating circuit underneath with the little coolant pipes

Every man and his dog will tell you, you dont need to use them but i would suggest you do! My carbs froze up in temps nowhere near freezing point (due to fuel atomisation having a refrigerant effect)

I know the same happened to Spuds car with these carbs too

I have them plumbed in and its never happened since

So unless you are using it only during summer months i would plumb them in, but you do get some nice dry sunny crisp winter days where you cant help but take it for a spin :)

[MikeB]

Small bit of progress.
I bought a susuki tl1000 LH silencer off ebay for £10. made up a link pipe.
Looks ok, its mainly to keep the neighbours happy, sound pretty good to.
May have to upgrade for IVA but fine for now. Will post a pic when I get her outside next.

So £10 for an exhaust not bad!

[MikeB]

Started to plumb in the cooling system.

Ordered the parts from ASH on ebay, good service.
1x 32mm 180 bend
1x 1m long pipe
1x 32mm joiner *may need one with a T-piece
1x 500mm length of 32mm hose, to be cut up and used as joiners.
1x 1m 16mm length of pipe

A polo radiator for less than £30!
and a push pull 12" fan from ebay, seems ok quality and powers up nicely

http://farm8.staticflickr.com/7100/6922274074_bc29916037.jpg (http://www.flickr.com/photos/62740914@N04/6922274074/)
IMAG0362 (http://www.flickr.com/photos/62740914@N04/6922274074/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

I'm reusing the sierra hose for the bottom rad pipe its not perfect but looks pretty good (not sure if this was the top or bottom hose on the sierra installation)
The pipe exiting the water pump was cut a re welded to make it shorter, I also welded it 180 deg so the small pipe exits downwards away from the manifold.

[MikeB]

I'll get some more pic ups tonight,
Progress, mounted the radiator, well at least the top mounts, I used rivnuts rather than welding the top mounts as I want to check the fit with a nose cone later one, once checked I'll weld on the bottom mounts.

Fixed my thermo housing by filing the ali away from around the snapped off steel pipe, got about 10mm clearance and using a cut off from an old coolant pipe with a flaired end I welded it on. Should work ok.

I've also started work on an alternator bracket. I've had to mount it the other side as the westfield exhaust manifold meant I needed to move the engine mount to where the orignal alternator bracket was.

I think I've got it to clear the carbs and the steering rack and I'm using the sierra alternator belt.

The good news is come post IVA zetec fitment everything is where it needs to be so it should be a easy swap.

[MikeB]

http://farm8.staticflickr.com/7267/6943918456_fe67d2f64f.jpg (http://www.flickr.com/photos/62740914@N04/6943918456/)
IMAG0368 (http://www.flickr.com/photos/62740914@N04/6943918456/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr
http://farm6.staticflickr.com/5448/7090154791_6ee2fc5eec.jpg (http://www.flickr.com/photos/62740914@N04/7090154791/)
IMAG0366 (http://www.flickr.com/photos/62740914@N04/7090154791/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

Just trying to wire up the alternator

Internet suggests this for the sierra alternator

B+ thick wire to battery
D+ to warning light
W is a 8 or 12v output for autochoke

[MikeB]

Tried it again last night with the middle post to the bulb,
Worked a treat, not sure why the wiring diagram in the haynes manual has it wrong! Bulb now goes out when the engine starts.
Ran out of cash for this month so it finishing jobs I have bits for. Mounting pedal box and front brake lines, fit rear ali panel, fit throttle cable. That should keep me going until the end of the month!

[MikeB]

http://farm8.staticflickr.com/7071/7208923886_1df68cc1c9.jpg (http://www.flickr.com/photos/62740914@N04/7208923886/)
IMAG0372 (http://www.flickr.com/photos/62740914@N04/7208923886/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

http://farm6.staticflickr.com/5332/7208935694_0834f59acb.jpg (http://www.flickr.com/photos/62740914@N04/7208935694/)
IMAG0371 (http://www.flickr.com/photos/62740914@N04/7208935694/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr
Renault kangoo/clio expansion tank, its nice and small and should bolt to the bulk head really easilly, bargain on ebay around £12!

[MikeB]

Got my cooling system plumbed in and run up with no leaks, so thats great. Need a temp sensor though.
Ran her up for 5 minutes, no problems and no leaks.

I've ordered a steering rack from rally designs, and even though I'm flat broke, I'm going to go all out and get a prop shaft made in July.

With a days work I should be able to drive it out of the garage. (no brakes mind!) Pushing it with no steering sucks big time.

So heres to hopefully driving it in July, with brakes in August :) :).

It will then be the big save for bodywork and megajolt. Unfortunately its not going to be on the road this year, but next spring. Time flies so I'm happy to take it steady, its frustating but heh hoa

[MikeB]

Planning so make some progress on the build.
I've ordered

Brake lines from Exact through Vouch, they look the dogs so can't wait for them to arrive.
Brake resevoir and couplings/fixings so I can finish my brake circuits. Will just need to rebuild the rear drum setup and brakes will be done

I'm going to service the engine with some new valve stem seals and cambelt.
Sort the throttle cable out.

And with a bit of luck order some bodywork!

Can't wait for bank holiday week!

[MikeB]

A quick shot with the bodywork plonked on top from AGM.
Very good quality its going to look awesome when finished

http://farm9.staticflickr.com/8172/7969842786_ebcafdef38.jpg (http://www.flickr.com/photos/62740914@N04/7969842786/)
IMAG0407 (http://www.flickr.com/photos/62740914@N04/7969842786/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr
http://farm9.staticflickr.com/8033/7969843386_e21bbe95b2.jpg (http://www.flickr.com/photos/62740914@N04/7969843386/)
IMAG0408 (http://www.flickr.com/photos/62740914@N04/7969843386/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr
http://farm9.staticflickr.com/8297/7969844040_258a7a81db.jpg (http://www.flickr.com/photos/62740914@N04/7969844040/)
IMAG0412 (http://www.flickr.com/photos/62740914@N04/7969844040/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr


I've got the nose fitted properly with a couple of rivnuts now, hopefully make the cuts to the scuttle tonight so it lines up properly.
The scuttle has the front face fille in so no need for a seperate firewall panel if that makes sense, I'll just need to put a base in for the battery to sit on etc

[MikeB]

Front brake lines in

http://farm9.staticflickr.com/8306/7969841424_5e2079b1ed.jpg (http://www.flickr.com/photos/62740914@N04/7969841424/)
IMAG0404 (http://www.flickr.com/photos/62740914@N04/7969841424/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

[MikeB]

I haven't done an update since spamgate.
So here we have it.
Seats are now in, they are nice westfield leather ones really comfy and don't restrick my thighs!

My side panels are nearlly fitted, need to solve my issue with the throttle linkage on my pedal box then I can finally fix them in place.

Next jobs: throttle linkage mod, engine bulk head panel, then start to sort out proper engine bay electrics. here's hoping for a drive in the summer!!

http://farm9.staticflickr.com/8367/8484436951_407f3fda20.jpg (http://www.flickr.com/photos/62740914@N04/8484436951/)
20130217_170950 (http://www.flickr.com/photos/62740914@N04/8484436951/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

http://farm9.staticflickr.com/8518/8484436765_81d0d9227c.jpg (http://www.flickr.com/photos/62740914@N04/8484436765/)
20130217_135619 (http://www.flickr.com/photos/62740914@N04/8484436765/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

[K4KEV]

Nice to see you have been tinkering forward with your build and really looks as if it is coming together.... roll on the summer eh:D

[MikeB]

Hoping for a bit of time on the old girl over easter (and the car ;)
Lots of little jobs, throttle cable/pedal box is the one I want to get sorted, then I can fit the engine bay bulkhead plate, think I might make it two peice to get access to the pedal box from above. Finish off brakes, this involves working out all the springs for the rear drums argg. then I might start tidying the wiring up in the engine bay and few bits of bodywork tweaking, not major just lots of little bits that need doing.

i'm hitting a lull with the build thinking theirs still lots to do and no time and money to do it. So hoping to push through that!

[Eddy]

I took a pic of the rear brake arrangement when I was stripping the donor - Might be of use:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/DSCF1926.jpg

[MikeB]

thanks eddy thats helpful, driver or passenger side?
Also which end does the handbrake come in, from the front or back. I never got a definative answer last time I asked.

[Eddy]

I believe that pic is of the passenger side - The handbrake cable comes in at the top of the pic and attaches to the shoe towards the bottom.

On the sierra, I believe the cable goes in from the front and attaches to the shoe towards the back - If you were sitting looking at the passenger side drum, it would go in from the left of the drum and attach to the shoe on the right.

You can see the cables in this pic:

http://i6.photobucket.com/albums/y204/eddycorsa/Donor%20Car/DSCF1911.jpg

This pdf will probably help you out a bit too: http://ford-sierra.misto.cz/pdf/10-Braking_systems.pdf

[MikeB]

Thanks Eddy,

Mananage to get my rear brakes sorted, still need to shorten the handbrake cable but other than that the rear brakes are sorted.
I had to put a notch in the uprights to fit the rear flexis.

I spend a good amount of time on my pedal box,its the OBP kit car one.
I couldn't work out a good way of connecting the throttle cable, OBP weren't very helpful. In the end I completely changed it by raising the pedal and coverting it to a bottom pull arangement with the cable coming in through the lower chassis member. It has just enough pull to fully open the carbs, action is now smooth with no funny angles of the cable, very happy I got that sorted, I'll post some pictures when I get a chance.

[Johno]

Hi Mike,:)
Any photos of your body kit fitted or are you keeping this under wraps?
I'm interested as I also have an AGM bodykit.

[MikeB]

The ones a page back from 18th Feb are as good as it gets at the minute.
I've had issues with side panels and rear tub join, but from recollection you only went for the 3 piece kit so might not have run into those.

It looks a bit knaff on its build wheels and no headlights so wanted to sort that before stunning you all with some nice shots! lol

[MikeB]

Well I got a day or two in the garage this month. With the weather improving and lighter nights I might get in there in the evening a bit more.

Main task was starting to tidy up the engine bay and make the bulk head panel. I've done this in two parts to give access to the pedal box.
I've installed the cooling system properly now and mounted the expansion bottle. I think the installation looks quite neet. The next step will be tidying the engine bay and scuttle wiring. Can't make my mind up where to have the fuses. Thinking of a drop down panel in the passenger footwell for the fuses and relays.

http://farm9.staticflickr.com/8260/8651990962_7d55fe7602.jpg (http://www.flickr.com/photos/62740914@N04/8651990962/)
Untitled (http://www.flickr.com/photos/62740914@N04/8651990962/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr
http://farm9.staticflickr.com/8539/8650893901_3d2eaa3e6f.jpg (http://www.flickr.com/photos/62740914@N04/8650893901/)
Untitled (http://www.flickr.com/photos/62740914@N04/8650893901/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

And heres the mod to the opd pedal box to convert to a bottom pull throttle cable.
http://farm9.staticflickr.com/8523/8651989624_816a4fddf1.jpg (http://www.flickr.com/photos/62740914@N04/8651989624/)
Untitled (http://www.flickr.com/photos/62740914@N04/8651989624/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

http://farm9.staticflickr.com/8265/8651990252_2968354393.jpg (http://www.flickr.com/photos/62740914@N04/8651990252/)
Untitled (http://www.flickr.com/photos/62740914@N04/8651990252/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

[twinturbo]

Your CVH looks good, who made the inlet manifold?

TT

[MikeB]

my own fair hands! its a laser cut steel back plate then I used my rage compound mitre to get the tube cuts close.

[MikeB]

No progress this weekend but I've got my NODIZ on order.
It seems to be a step up from megajolt as it has bluetooth for mapping and a funky android app, think there may be some data logging add on functionality coming to.

If you take out the cost of a EDIS 4 module it only a bit more pricey than a megajolt.

Next step sorting out some of the wiring and running her up with the NODIZ :)

[Eternal]

Looking great!

Wish i had that much space in the engine pay as having loads of trouble trying to work out water pipe routes.

Dont suppose you can remember where you got that nice chrome pipe stuff from?

:D

[MikeB]

Trying to keep the engine bay install nice and neat with minimal bits.
Think I got all the red hoses and pipe from ASH

http://www.autosiliconehoses.com/silicone-hose-shop/alloy-stainless-steel-pipes.html

I've got to run the wiring round the exhaust side yet, the inlet side has the fule hose and brake lines.

[MikeB]

Not much progress to report recently as I havne't really had much time.
I put a new start motor in which solved my cranking problems.
I have wired in to a basic level a NODIZ ECU, it was easy (haven't connected teh TPS yet on the carbs) the engine starts first time now, but currently wont rev at all. I suspect the fuel pump isn't a good match to the carbs so I'm waiting for a proper bike one in the post so hopefully that will solve that issue.

I've had this wheel a friend gave me for ages and I've finally found a boss kit for it that wasn't silly money. can't wait to put it on and pretend to drive!
Hope to make a bit more progress over teh next month tidying wiring and starting the dash etc. Still got wheels, lights, clocks gauges as the big expenses to go!

http://farm6.staticflickr.com/5479/9680279000_02a41e1e55.jpg (http://www.flickr.com/photos/62740914@N04/9680279000/)
Untitled (http://www.flickr.com/photos/62740914@N04/9680279000/) by mjb22001 (http://www.flickr.com/people/62740914@N04/), on Flickr

[MikeB]

Managed to get a couple of hours in the garage this weekend.

New steering wheel is on, looks really nice!

Plumbed in a new fuel pump, engine runs nice now!! Will rev up now quite smoothly. Bike pump for bike carbs! (even though the one I had was meant to be compatible)

Fixed my welder and added a few mounts for the rear panel so that can be poperly secured and rear arches fitted.

[Davidbolam]

Managed to get a couple of hours in the garage this weekend.

New steering wheel is on, looks really nice!

Plumbed in a new fuel pump, engine runs nice now!! Will rev up now quite smoothly. Bike pump for bike carbs! (even though the one I had was meant to be compatible)

Fixed my welder and added a few mounts for the rear panel so that can be poperly secured and rear arches fitted.

Can you post a picture of how you are mounting the rear panel?

Thanks

David

[MikeB]

Been a slow few months, haven't really made any progress with my car :(
Really need to wrestle with my wiring loom to get it in place.
However I did make a dashboard yesterday, I'll get some pictures up when its sanded.

I used some 9mm marine ply reinforced across the bottom, with some quadrant beading across the bottom edge, but typically I've just read the IVA manual again and I've got the radius wrong thinking it was around 19mm diameter not radius, think I'm 5mm short in the radius department, shame as I've glued it all together :(. I could cover it some compressible material rather than carbon effect I was going to do it in or just remake it again.

[Davidbolam]

Been a slow few months, haven't really made any progress with my car :(
Really need to wrestle with my wiring loom to get it in place.
However I did make a dashboard yesterday, I'll get some pictures up when its sanded.

I used some 9mm marine ply reinforced across the bottom, with some quadrant beading across the bottom edge, but typically I've just read the IVA manual again and I've got the radius wrong thinking it was around 19mm diameter not radius, think I'm 5mm short in the radius department, shame as I've glued it all together :(. I could cover it some compressible material rather than carbon effect I was going to do it in or just remake it again.

I did the same thing! I measured my broom handle and bent the ally around it only to realise it was too small. I then covered it in camping mat and leatherette as the radius can be smaller if its padded.

[MikeB]

Trying to get back on with my build. Thought I'd try and sort my wiring out. Went to retrieve the diagram and pin outs that came with my loom.. that really safe place I left it in.. doh can't find it anywhere! So I sat in the car last night and worked out most of the lighting circuit and column switches for the sierra, I'll have a few queries to resolve but hopefully not too many.

First one is the side lights from the stalk, think its slate grey colour, all other lights go to a relay but no relay for the side lights, does this wire go directly to the side lights?

Just ordered some dominators and front indicators so I can try a few things out. I used Furore, email russ on locostbuilders and if your nice they might give a discount. Will hopefully post my new headlights if they arrive this weekend all bright and shining! Along with my new (2nd hand wheels).

[davedew]

Mike,

You are correct. The grey wire from the light stalk feeds the side & tail lights directly.

I got my Dominators from Russ and they went through IVA no problems.

Dave

[MikeB]

Headlights didn't arrive in time for the weekend but I put my new wheels on and gave her a clean up and took the chance to sweep out my garage (amazing how much dust and crud was in there)

Here she is, next shot will have headlamps fitted....
I was going to buy a new set of wheel in black but couldn't find the funds, found these cheap but was worried I wouldn't get the look I wanted with silver. However seeing it now I really like them, if not more so than what I originally planned. Think she'll look great when finished

https://farm6.staticflickr.com/5555/14327017224_467b387903_b.jpg (https://flic.kr/p/nQ2H5m)20140601_172850 (https://flic.kr/p/nQ2H5m) by mjb22001 (https://www.flickr.com/people/62740914@N04/), on Flickrtps://flic.kr/p/nQ2H5m]20140601_172850[/url] by mjb22001 (https://www.flickr.com/people/62740914@N04/), on Flickr

https://farm3.staticflickr.com/2902/14141096870_5601debedc_b.jpg (https://flic.kr/p/nxAPr1)20140601_172548 (https://flic.kr/p/nxAPr1) by mjb22001 (https://www.flickr.com/people/62740914@N04/), on Flickr

[alga]

Looks great! I would make the exhaust hole in the side panel larger.

[MikeB]

Yep I thought that, I was admiring my accuracy with that hole but it does need to be bigger!

[K4KEV]

If you make a largish circle or oval in your case, out of sheet ally to go on the outside it will also act as a great heat sink to protect the fibreglass....that is certainly the case with mine as when I have checked it after a bit of a hoon then it is always touchable.

[Eddy]

That's looking really good

You could always paint those wheels if you really want black ones

[MikeB]

A bit more progress, I couldn't get my engine running, it did in the past but lately wouldn't start with the odd cough and back fire.
I replaced the coil pack and leads to no effect, I cleaned the jets out etc Still no good. As a last resort I send my NODIZ ecu to be checked. As it turns out they just send me a new one as they have changed the connector design. Long story short once I had swapped the connections for the new plug to the loom and hooked it up it fired first time so there must have been a fault there somewhere.
I've also started to tidy up my wiring loom and mounted the fuse boxes on the scuttle. Next job wire up the front lights. No she's running again I feel a spurred on to break the back of the wiring!

[MikeB]

Not strictly a first start but first in a long time

https://www.youtube.com/watch?v=667sDnVxgRE&feature=youtu.be


Really starting to make progress with my wiring now, fuse boxes now located on scuttle, routed main parts of the wiring loom and just connecting up my column switches. It it goes to plan tonight I might have a headlight light up! whoop whoop

[MikeB]

Made some good progress last night.
Bearing in mind I lost the wiring diagram and pin outs for my loom (doh)
I managed to get my headlights working (mostly) using sierra stalks.

It turns out there are two types of sierra stalks the late one are made for connection to switch negative relays. The old ones (pre 87 I think) were for switch positive (direct or via relay depending on light circuit).

Long story short I had later type stalks but my loom is set up for switch positive relays on each lighting circuit (It took a while to come to this epiphany!) Luckilly I also had some old column switches as well from my TVR (but only the wiring from the new ones) It took a bit of time with a multi meter but once I worked everything out it was quite straight forward.

For the front headlights I just need to put a perm positive to the full beam flash.
One question when you click full beam should it turn off the dipped beam on my tin top both stay on but they are separate lamp not like the H4 bulb which does both.

Still good progress!

[MikeB]

Seem to making progress on the build at the minute, beginning to think I'm not really to far away. Made two U channels to clamp side panel to chassis in the cockpit, would have been easy with a proper cutter and folder but made a reasonable job with an angle grinder and some wood. Fitted my other rear wheel arch and have fitted both side panels properly. Started on my bonnet catches, have one side done. Also made an exhaust hanger for the silencer to sit on. Overall the car doesn't look much different but its good to get all these little jobs out the way.
My To Do list is:

Rear Lights (mount and wire) £80
Indicators (mount and wire) Rear Arch repeaters £20
Fuel sender and plumb in fuel tank with filler £100
Dashboard (gauges and wiring) £250
Handbrake (shorten cable and mount lever)
Finish Roll bar (harnesses mounts, rear stays) £30 plus powder coat
Mount Interior Panels (cover in 3m etc)
Tranny Tunnel Finishing (gaiters and surrounds) £50
Bleed Brakes (New front discs and pads) £30
Front Grill £10
New exhaust link pipe (draw up and get made) £25
Front Wing Stays £35
Nuts and Bolt check (new bottom ball joint as gaters split) £20
Mirrors £50
IVA Trim

So about £600 to go :( unfortunately funds are a bit tight so I think about 4 months away (that's nothing after 4.5 years currently building) So final push to get it finished over xmas (maybe sooner if funds allow)

September - Rear Lights and Indicators, Bonnet Catches, Mount interior trim panels, cover and mount dash blank
October - Roll Bar and Dash Gauges Phase 1, Hand Brake
November - Dash Gauges Phase 2, Grill and Brakes
December - Harnesses, Fuel Sender and Filler and Finishing

That doesn't seem to bad!

[SeriesLandy]

rear indicators (http://www.ebay.co.uk/itm/390619547926)

Put the filler in the tub cover. I had mine on the rear panel but I've had to move it to the tub cover to actually get fuel into the tank. With it in the rear panel it just went all over the petrol station floor.

[MikeB]

Thanks for the indicators links. Do I need a resistor or something to run LED's like these, the other indicators will be normal bulbs?

Interesting on the fuel filler, not quite there with that just yet!

[SeriesLandy]

My LEDs are just tee-ed straight off the rear lights, no resistor and std ford relay. I did put a connector (superseal) in so I can disconnect the wing if I need to.

Also I had to remove the plug on my boltonbits rear lights and solder it straight to the bulb holder as the wheel rubbed on the light plug.

[MikeB]

Right I'm building up for the big push!
I have enough funds at the end of the month to get all my outstanding bits. I have a week off booked 24th November and another week left to take before xmas, surely I can get this thing finished!

If anyone wants to come down for coffee and bacon butties let me know, major jobs are wiring up my dash, rear lights, interior trim, roll bar!

Is the end is sight???

[flyerncle]

Are the led's ok to mount on the scuttle panel ie view angle etc ?

[MikeB]

I didn't think they were hence the rear wing position.

[MikeB]

Took a couple of days on and off but the dash is finished!



https://farm8.staticflickr.com/7555/15704673827_bab35a09a9.jpg (https://www.flickr.com/photos/62740914@N04/15704673827/)
image (https://www.flickr.com/photos/62740914@N04/15704673827/) by mjb22001 (https://www.flickr.com/people/62740914@N04/), on Flickr

https://farm8.staticflickr.com/7557/15702941368_43f5380cdf.jpg (https://www.flickr.com/photos/62740914@N04/15702941368/)
image (https://www.flickr.com/photos/62740914@N04/15702941368/) by mjb22001 (https://www.flickr.com/people/62740914@N04/), on Flickr

[thailoz]

nice job looks neat and tidy

[twinturbo]

lookin good. just the pain of wiring it to the loom now ....

[MikeB]

This wiring takes longer than I thought, have most of the dash wired in, its on multi blocks for easy removal.

Rear lights to install and indicators should see the back of most of it.

Can't get my temp gauge working though, thought it would be easy!

[MikeB]

I have been tinkering away making small bits of progress.
I got bored of sorting out the wiring (still have indicators, speedo, brake and reverse lights to sort out).

But I have made some progress with the interior, I've carpeted the back panel and under the seats, made and trimmed my tranny pannels. And cut and tack welded the back stays for my roll bar.

https://farm8.staticflickr.com/7697/17003937627_a64956110a_c.jpg (https://flic.kr/p/rUzCfp)image (https://flic.kr/p/rUzCfp) by mjb22001 (https://www.flickr.com/people/62740914@N04/), on Flickr

https://farm6.staticflickr.com/5442/17023834880_a9f5c0432e_c.jpg (https://flic.kr/p/rWkB1u)image (https://flic.kr/p/rWkB1u) by mjb22001 (https://www.flickr.com/people/62740914@N04/), on Flickr

Its just a case of sorting the rest of the wiring and small tidying up/trims jobs that seem to tage ages! But really not far away, will get some more time next month.

[tkpm]

Mike where did you get handbrake and gear surrounds from?

Terry

[MikeB]

Car builder solutions, not sure if they will IVA, is there a radius limit for the centre console?

[voucht]

It was a long winter break Mike :) !
Your interior looks very nice, and I love the seats.
Keep up the good work!

[CTWV50]

Car builder solutions, not sure if they will IVA, is there a radius limit for the centre console?

100mm ball test same as the exterior due to a lack of windscreen or roof etc.

I like that dash btw. :cool:

[MikeB]

Might have to trim around then for iva maybe some L shaped trim to give a soft edge.

Not sure where the last 4 months have gone. I did wire and mount rear lights, sorted my temp gauge and get my fuel sender wired in so not a complete break.

Just seems like endless small jobs at the min, think there is light though,maybe a summer drive!

[MikeB]

First time this summer I got a day in the garage.
Finished my roll over bar and harness mounting points.
Hoping to get a couple more days on it so hopefully finish my indicator and reverse, brake light wiring then get on with the small finishing jobs.

https://farm1.staticflickr.com/380/20234186296_a1da02bed6_z.jpg (https://flic.kr/p/wQ2uCY)11822827_10155916342065608_3775867155342225 375_n (https://flic.kr/p/wQ2uCY) by mjb22001 (https://www.flickr.com/photos/62740914@N04/), on Flickr

[MikeB]

Another small step forward.
Managed to get my indicators flashing, doesn't sound like a great achievement but it took a lot of time with different wiring diagrams and flasher relay pin outs and blown fuses before i got it right. I need to properly wire in the side and front indicators now.

They do flash fast though, so I'll need to sort that, any suggestions, wondered if it was bulb resistance compared to the flasher unit spec. Flashes at the right speed on hazards. Haven't got the dash tell tale wired in yet either.

[voucht]

Hi Mike,
Try to connect front and rear at the same time, and the flashing speed will be divided by 2. It is actually proportional to the current. 1 light bulb flashed 2 times quicker than 2 light bulbs.
Hope this is where your problem comes from, and it can help :)

[rpjg1975]

I did have that problem when I first fitted my front bike indicators....needed different bulbs in mine!!

[MikeB]

Had all three temp wired in so full load except the tell tale, they are bike indicator on the front so maybe that's the issue, I've got another really to try then bulbs, cheers for the tips!

[MikeB]

Slowly making process.
New front disks and pads in, connected braking system, bled it all and stopped any leaks, adjusted pedal box to get a better clutch position and played with bias bar. Brakes seem to work, will need a bit of tweaking but happy with that.
Brake lights working :)
Hopefully won't have to take pedal box out again any time soon
Still have a few bits of wiring to get working before tidying it all up:
- brake warning light
- speedo
- reverse light
- rear wing side repeaters

Fitted a new set of QH maxi ball joints to replace the tat that split gaiters with 0 mileage

Thought I'd try the brakes, but typically engine wouldn't run properly, think its the carbs again, it ran on idle for 2 mins but wouldn't rev, then it died and wouldn't really run again so might have to clear carb jets again.

Still to do:
- mount front indicators
- front mesh grill
- chassis number
- mount and wire horns
- rear covers and fuel filler
- rear sus nylocs and torque up rear end
- shorten handbrake cable
- rear view and wing mirrors
- tidy scuttle wiring
- under scuttle panelling
- IVA trimming

doesn't sound much but it all seem to take ages!
Wish the magic fairies would come in and finish it off!

[rpjg1975]

Don't shoot the messenger but I think I remember something about bias bars not being allowed for iva?

I may be wrong though so hopefully someone else will comment.....

Russ

[K4KEV]

Its not the bias bar...its the brake proportioning valve that is not allowed in the system....you would have to have one or the other (although my car had niether) to be able to dial in the "split" effort between front and rear to make sure the rear locks up before the front

[Stot]

I had a proportioning valve from a Fiat Uno. They asked me what it was and I explained. It isn't adjustable (in stock form) so it passed.

I do seem to recall that bias bars must be locked and non adjustable too, nuts welded after adjustment for example but I didn't have one.

Cheers
Stot

[rpjg1975]

Ah, that's that confirmed then :)

[MikeB]

I've drilled it so can lock wire it into place :)

[MikeB]

Well I haven't written here in ages.

Mine is nearly done and I've just applied for IVA before the new emission regulations come in.

So hopefully be heading down to leighton buzzard VOSA sometime in March.

[Numplumb]

Good luck I hope you get a pass.
I am trying to sought mine so I can book my IVA test before the new rules, they are coming in May I think for sure.

[MikeB]

It went for Iva last week.
Minor fail main ones were fog light coming on with side light and not f marked, they want some strengthening of top seat belt mounts that were made to book spec.

Not bad retest booked for first week in may,

[twinturbo]

Nice easy fixes then, ready for the summer...


Oh wait,,, the 1st week in may is the summer. :rolleyes:

[MikeB]

Assuming it passes I'll then have to wait for registration documents I'm guessing 3 weeks min?

[twinturbo]

I thought "Technically" you can drive it without the Registration Document. How you do this with no plates I have no idea. Or it may be an out of date thing now.

[Ianr]

You will not be able to drive without tax registration and insurance after an IVA pass so that would not be a goer. Insurance companies will cover you on a chassis number but only to and from IVA as well.
My car took 11 days from IVA to being registered and would have been quicker if I had had everything ready to go as soon as the pass certificate was in my hand. It was on the 11th day that I rang DVLA and spoke to Danielle Dymond who said, 'No problem , I'll find your file out and sort it out myself'. She did and emailed me the form at 4pm which allowed me to get number plates made up and on the road that day. Unlike some others I have always found DVLA very helpful if they can be.
Good luck with yours

[MikeB]

Happy to get my IVA pass today at Leighton buzzard, great test centre.
Enjoyed the 30 miles home, the drive there was nerve racking, I thought will it break down, overheat, wobble. On the way back gave it the beans. Goes ok for a CVH, need to swap my jets for 1.6mm from the 1.4mm standard one, that should see a few more horses out of here until zetec over the winter.

https://farm1.staticflickr.com/872/27004816537_27320de32e_z.jpg (https://flic.kr/p/H9jK88)IMG_0678 (https://flic.kr/p/H9jK88) by mjb22001 (https://www.flickr.com/photos/62740914@N04/), on Flickr

[dean211277]

Congratulations! Car looks stunning.

[voucht]

Well done Mike! Great Job!
And good timing with spring/summer too :)

[MikeB]

thanks all, it was a long hard slog to this far. Still loads to do:

setup
windscreen
zetec conversion
willwood brakes
bigger fuel tank
better trimming on the tunnel

etc etc etc :) Think I'll get a screen on and it setup and enjoy it for this year!

[RandyBMC]

Just spent time reading through your entire build. Very nice! I'm loving those rear lights - where did you get those? I also have the OBP pedal box, but I'm using a Miata (MX5) donor. Still sorting out what I'm going to do with the throttle.

I say get a helmet, set up the car, and drive it all summer long!

[MikeB]

Yeh I think I replied on locostbuilders. There's probably a better way to get the throttle sorted, a nice bell crank would make it all a lot more adjustable and no welding the peddle box. Don't think OBP are that helpful with that pedal box and the throttle it could do with a return spring and some adjustment as standard for a few extra £.

Think the lights are from boltonbits on ebay, not forgetting the fog light isn't a fog light and will fail IVA as id doesn't have a F mark on it.

I got a helmet to drive it to IVA, so it will be on the road as soon as the paperwork comes through

[twinturbo]

Very well done, I bet the relife is huge and you probably have a bunch of new friends looking for a lift ;)

TT

[MikeB]

I've done 250 miles now.
dropping the tyres pressures and dialing back the shocks has made it driveable on the bumpy b roads I'm surrounded by.

It could do with a bit more shove, I have one jet size to go up but then i think its Zetec time. I'm not sure if I can wait until winter!