notroubleclubber

Hi. I bought this S2 ERST about 3 weeks ago off my nan. She had owned it from new and as it has been sat in the garage for about 2 years she decided to sell it as it needs quite a bit of work. I have always loved this car so when it came up I sold my rover coupe turbo for £1250 and bought this for £850.Now i wonder what i let myself in for!!!!
As my nan is the only owner, it is completely original with the only change being the stereo (which i fitted for her about 3 years ago!).
When she bought it she opted not to have the recaros (as she is getting on!!!).
I paid her the money and went to drive it away. being my nan, i didnt even think to test drive it and as soon as I started it i wondered what i let myself in for!!! I couldnt get it to start!!!! My nan said you need to crank it for a bit with your foot to the floor. So after that i managed to get it going!!! However drove it the 5 miles home and it was spluttering,hesitating,burning & fuel smelling,no power and clutch slipping and basically drove like a piece of shit!!!! What had i done!!!!

The outside looks very good condition. I believe it had a respray a few years ago and they even put the original grafix back on (though a bit wonky!!!). However, i didnt look underneath.......

I went through all the old mots (got all of them) and found that on the majority of them it had some welding work done. Chassis legs, crossmembers,floorpans,boot floors,arches, you name it it had been welded.And not parts replaced, just patches. And finally looking under the car I saw that the welding was crap!!!! Messy and horrible looking!!!

So I had bought a rot box,crap running but looked good on the outside!!!

The next day I booked it in to have an immobiliser fitted (bearing in mind that my nan had previously had a shitty alarm fitted that didnt even work and lost the fob to anyway!). £130 later and a cobra cat2 was fitted. the fitter said he had never seen an RS so original with no bodgy wiring. At least that was a good thing!!

I went on various websites and asked a few questions on getting the car running better.After a bit of digging around i had managed to sort the bad starting by unplugging the cold start valve. As its rarely needed I have not replaced it as it starts 1st time without any throttle.
I also managed to get hold of another fuel pump relay that I knew needed sorting for £15 off a forum member so that sorted that too.

Next, as i had a spare tenner i got a set of new plugs and put them in. The old ones looked ok but thought id replace them anyway. Didnt really help the running but now i know they are done.

I also managed to get hold of a set of recaros (in 88 spec) to go with the rear seats and trim from a forum member for £40 so cleaned them up and fitted them too. They are not concours condition but look very good and feel alot better - like a proper rs!!!!

Today Ive fitted a boost gauge and tried to sort out the no boost problem. I took off all the turbo hoses and checked them over then retightened them all up. no splits or leaks there. I then checked the amal valve. No clicking when unplugging and plugging it in so thought it could be dodgy. Checked the voltage and found only 5v getting to the valve. Furthur fault finding and i found that the earth was bad to the valve. So i ran a temporary new earth to the amal valve and now its boosting as it should to about 8-10psi.
Just got to sort the hesitant acceleration and it should be running fine then!!!
Ive found that the clutch seems to be alot better than what it was so wondering if there is a small oil leak into the clutch (for instance, when i 1st drove it it hadnt been drove for years so oil could have built up - now ive been driving it more, it doesnt slip as bad at all).

Next up is to get it motd to see what it fails on (due end of nov but tax runs out end of month so will get it done there). There is a local mot place that do an mot and if it fails its free.
Ive taken the car around a few garages and alot of them refused to srt the welding as too far gone, but i have found a guy who said he would sort what he could see for £150 + painting costs. He advised to wait until the mot to see what else needs doing.

Plans for it is:

Remove Grafix (needs to come off anyway for welding and panel work)
Sort out hesitant running issue
Replace clutch (got a new one to fit anyway)
Sort out loose gear linkage
Get welding sorted, strip it completely (except engine and running gear) and stone chip or smooth hammerite everything to stop any more rust.Also get delocked for below.
While stripped fit new stereo system,alarm & central locking system

When running great with standard kit then time to up the power:
Uprated ECU/Chip
Uprated Actuator (-31 should be fine) - apparently can run about 15psi safely.
Rebuild head (may stick a better cam in and get it ported a bit)
Uprate front brakes to cosworth
May Uprate rear brakes to discs too with goodridge all round
Uprate exhaust to a nice sounding stainless

As long as it looks good and has about 180bhp then i will be happy!!!


Heres a pic at the mo: (will update as more things are done with more detail)

WRCjames

Cant believe your Nan had an RST! ive seen a few d-plates without Recaro's, does look a bit odd without them but keeping the car original is a good thing.
Those graphics have gotta go though mate!

Ive got a load of RST bits if ya need anything??

Twins

iTrader: (18)

Blimey look at the graphics get some more pics up ,your starting prob may be to do with the cold start valve ,we normally disconnet them

notroubleclubber

cheers guys. twins - thats what ive done, left it discon. Im hoping the hesitant accleration is due to the tps. My nan drove the car and of course never gave it any welly so i think its just worn with how she drove it!!!

Barry R

iTrader: (3)

i know a old lady in bristol with a mint 90 spec s2 on 23k immaculate she wont sell it for love nor money she says she is gonna run it in the ground cos she bought it new

notroubleclubber

UPDATE - Had an mot done on it to see what needs doing and it failed.

Basically the tester said he would recommend a whole new floor. What welding had been done is to a crap standard so he said if its gonna be done then do it properly.
Needs inner and outer sills both sides, inner wheel arches rear both sides, n/s inner wing front, both floor pans, boot floor,chassis legs.
He said its worth doing as the car is a 1 owner example (well, now 2 inc. me).
Thing is how much is that gonna cost me???? Im gonna fone around and take the car around to various places today. He gave me a number who specialises in this kind of work as the mot place quoted me a high number just dyue to the fact that they charge quite a lot of labour.(£45 an hour and about day and a half work). It also failed on a steering lock something missing on front arm(?) and a couple fo bulbs blown in the lights.

Zetec_mk4_XR3i

i wish my nan had an S2 in her garage!!!

hope your saving her matey although it does sound a fair bit of work - there is prob a fair bit of sentimental value in it!

My S2 is also a bit of a pain to start when cold, turns over for ages and needs throttle to fire - did you just unplugs the cold start valve? Is it the one underneath the inlet manifold?

notroubleclubber

thats the one.

notroubleclubber

Took the car round a few garages and managed to get a cheap quote to fix all of the mot welding stuff, sort out and tidy up the crap welding too and sort out and tidy up my rear inner arches (as didnt fail on that!) for £250 - £300. Got it booked in for next tuesday. I might also get him to plate up the locks to delock it but then id need to get my alarm and central locking fitted. Once the welding is done then its time to get cracking on it. Plan is to get it welded, mot it, then underseal it (not b4 so the tester can see its all been done properly),stone chip it,smooth hammerite it white, rust proof all the arches and all the areas outside the car that cant be seen (under bodykit,bumpers etc), run all the wiring for alarm,c locking,stereo etc.Then refit all interior and bodykit properly(once sprayed nicely again as scuffs etc), might take grafix off,then get clutch done then rolling road it and get hopefully 180bhp out of it then THATS IT!!!!!

cozzymatt

for that price, all that welding is not going to be done properly!! Do it properly now else you are going to be spending this amount on welding every year.. just my opinion..

notroubleclubber

He explained what hes going to do and it sounds ok to me. That price didnt include respraying panels etc or stripping it all down to a shell. I need to get all that done too.

notroubleclubber

Started stripping out the car today. Took me a few hours but got out seats, carpet,insulation,all the trim,basically everything from back to front except dash. Need to drive it to the workshop to be welded. Also got the back bumper off and drivers side bodykit sill. Will take some pics when i get my camera back off the inlaws.

Basically all 4 corners of the car has holes in so will get them all welded up.Floorpans look good.Also found that even though the carpet at the front was dry, the insulation underneath was absolutely soaked and come off in bits. It also stinks!!! I expect the water came in through the bottom as the carpet was dry. Cant figure out how to get the insulation off under the dash without taking all the dash,pedals,steering column out etc so pulled it up enough to look under and enough room to weld if necessary.

Pics to come...

notroubleclubber

Ok, got new pics - soz its been quite a boring thread with no pics but now ive found my camera again i should be able to get some pics up:

THE WORK AHEAD....

notroubleclubber

Even more work im afraid - got the bodykit off today after drilling out the rivets and it gets worse. Both back arches are gone so looks like they have to be replaced too. At least I can get these done and the inner arches together. Instead of getting the welding done over 1 month (get paid monthly) im gonna have to get it stretched over 2 months so i can afford to pay to have it all done properly. Ive started getting the stickers off too though my nan decieded to paint one bit with paint (sticker must of peeled off!) though this isnt a prob as its gonna have a full respray anyway.Ive managed to talk my bro in law into giving me a hand, my dad is lending us his garage so hopefully with the right tools we can get this done properly!!!! As the stickers are going and dont fancy paying too much to get them recreated, im thinking of getting s1 grafix or st grafix put on instead as i think it looks too plain with no grafix on. Hopefully gonna get the welder to blank the locks off too.
Looking at it (and im no expert) the front wings are good as these were already replaced so im hoping they can be taken off and either new inner wings or a good patch can be welded on before putting the wings back on again. The sills should be able to be tidyed up and plated at the corners under the wings and in the inside. Both outer arches will need replacing and if these are being cut out then should get new inner arches welded on too.
Here u go:






As you can see from the last pic the off side rear wing is the worst part. Looked on beevers panels and can get new arch but only the van bottom section bit so might have to fabricate something up.
The welder knows his stuff so will leave it to him.
Its going in friday.
Might just get the front bumper off (prob need to ,to get wings off), as soon as i can find where its bolted too as it seems hard to reach.

Twins

iTrader: (18)

Good luck on the build ,4 bolts on the front bumper feel up in the arch at the front of the chassis leg for one each side and the same inside the bay for the other two and then a screw on each side near the wheel

MrCapriScort

Check out them graphics !! I can remember loads of cars had them at one time. Looks like you have your work cut out. Keep up with the updates mate

craigos

be worth the hard work tomake a nice car just do all the work right be worth a bit then when done

notroubleclubber

Im aiming to take my time.Luckily got about £400 spare this month for it. But normally would have about £150 per month to spend on the car. Plan is to get the rear wheels arches done 1st (inner and outer), ns inner wing repaired (maybe replaced if needed),hopefully be able to use same front wings as they are good.Also need to get the front of the floor where it meets the chassis and front inner wings sorted and tidy and sort the sills.
Costs for panels from beevers is £146.18 inc del for both sides under sills,complete inner lh wing,both rear wheels arches inner & outer. If the welder can repair the sills and inner wing himself then costs reduce to £84.11.Hes quoted me £250-£300 himself. Car nearly stripped, just need to get under dash insulation off (dont wanna take dash out so gonna have to cut it - wet anyway) and front bumper off. this needs to be done by tuesday and i need to get everything out the car and give it a hoover out b4 it goes too and stick a spare xr3i seat i got in to drive it to the welders.Gonna also get the rest of the stickers off too.
Plan is when it comes back from welders (may need to take 2 months - see how money goes) to completely underseal,stonechip,smooth hammerite it,fit arch protectors and mudflaps to stop furthur probs then get it resprayed.This is probably gonna take another 3 months (so i can afford it) then start to build it back up again hopefully with a few new goodies!!!

notroubleclubber

Dropped the car off last nite. He took a good look and said he will do both rear arches,sills,inner wing and anything else for mot and said it would be £300 plus price of arches so not expecting anymore than about £350. There was more rust when i took the kit off that he didnt see b4 so getting the whole lot done (not sprayed tho - more money!).Just told him i want it solid.Hopefully get it back next week though im in no rush. Then if its £350 i got enuf funds to start the rustproofing and hammeriting. Then will get the car back to him (or his bro) and get them to spray it all up nice(car has been resprayed b4 so not sure just to get it blended as paint quite new or get a blow over - will see what it costs), sorting any little dinks,prob delock it (should have central locking and alarm in by then) and just touch up any scuffs on bodykit and bumpers. Then its a case of getting it back to the house and building it back up again, mot it,tax it then going down to interpro for a proper tune up and aim for about 180bhp. Will get the clutch sorted b4 that tho too!!

notroubleclubber

UPDATE - Popped to the welders today and the car was on the ramps.Hes taken off the ns front wing and basically remade the inner wing.He said whoever done the welding and put the wings on b4 done a crap job so hes doing it all proper. hes sorted the sills out already and made them nice and tidy and hes grinded back the rear wheel arches ready to put on. The car looks a mess at the mo but it will come together.From what ive seen hes done a good job so far and he rekons it be done by sat.Hes also gonna but the missing bolt back in the suspension so once the wleding is done, i just got to put the interior back in and replace a tyre and it should go through the mot ok!
Should get him to do the clutch too while its on the ramps but i havent got the moohlah!Got the part tho.
Will get pics when its back home b4 the clean up.

thebigman48

bloody hell mate what a lot of work would you not have been cheaper re shelling it

notroubleclubber

If i reshelled it then it wont be a 1 owner example (well 2 owners but still in the same family!)

Brian

iTrader: (2)

Good luck with it mate


Brian

cossiegreg1

pics

notroubleclubber

Will put pics up when i get the car back!

RSmark84

cor, that is some work. enjoy doing it, mine was sitting in a barn for a few years, but didn't look as bad. just take your time, its not a race, i took 6 months to do mine, then it flooded(people remember the white RS in honda car park?) its still alive today, although ive taken it apart again(new toys)

anyway. good luck with it.

costina

iTrader: (1)

Yes i do i was on earlys that day glad to see yours is sorted now

Paul

notroubleclubber

if i get time i will pop down the welders again as he said it was gonna be ready today (but then he has been saying that the last 4 wks!!!).

RSmark84

just noticed under you avatar pic, you have a cortina cossie, im sure ive seen it in honda car park years ago? also used to see a nice mate black capri in there too.

dazoriginal

worth the saving
good luck mate

costina

iTrader: (1)

Yes Mark thats me also have the flint saff A guy called Stu owns the black capri

Paul

Rs Adz

cars going 2 look brill mate just keep up the good work just make sure u get the welding done properly

COLEYST200

iTrader: (3)

Good look with it mate iv not read all the tex as reading is not my fing photos are it looks like you have got a lot of work ahead of you but stick at it mate if i can do it any one can all the best

notroubleclubber

Quick update - popped to welders to see how they are getting on and car nearly done. All floor,inner wings,sills and ns wheel arch outer and inner done.Just got to do os rear wheel arch as wrong part was sent down which he said he will prob do tonite. He did say it be ready 2moz about 7pm but im busy and hes away at the weekend i said i will pick up monday.
Id like to say the car looks good but it dont, needs the rest of the stickers taken off,arches smoothed off, bodykit back on and the whole bottom of the car sprayed again!!!!
Soz there is no pics but as i pop in there on the way home from work i never have my camera with me. Hopefully get some pics up monday/tuesday.

fezzajsy

iTrader: (9)

notroubleclubber

BIG UPDATE-

Got car back today. Was charged £350 all in. What do u think. Got both rear arches done,front inner wing done (had to take off old outer wing but as nearly new put back on) and basically all stuff needed for mot inc. a bolt missin on suspension.

Rear arches got a lip on them - is this how its supposed to be? Needs to be grinded down and filled and smoothed.
Bit cheesed off as he didnt do the bit under the bumper but as this is covered by the bumper itself i might just cut this off and rust treat it. Inner wheel arches all done too.
Now just need to get the inside tidyed up and smoothed hammerite everything!!!
Then put interior back in after a good clean - mot it then get the painting sorted on the outside.
The bodyshop nxt door quoted £600 for smoothing all the arches and blending them in. He reckons as the car has had a respray before he will be able to get a good blend and wont need a full respray.

Pics:





Bonnet wont catch - had probs before - is there something missing from the pic above?








Cant really tell from the last 2 pics whats been done as he sealed everything.

carlo

iTrader: (4)

That sealer looks terrible least your making progress tho

notroubleclubber

Started clearing inside up and got a bit of hammerite on. Checkd the welding and it looks solid but obviously a bit patchy inside so im gonna rust treat it then fill it so its smooth again then spray it with smooth hammerite. Found a small hole in the rear sill very small but under the bodykit so gonna cut it out and fill it. Keep finding little bits here and there so just gonna get the car tidy.Lots of work to do.

RSmark84

remember that saff aswell (blue calipers?), you used to flash me on the way to work.

RSmark84

should off removed all that rust before he acked all that waxoyl over the floorpan, remove it and do it yourself.

on the drivers side, rear has he welded onto rusted metal?
( rear part of the arch?)