Looks like it may be complete soon
13-04-2010, 07:27 AM
#1
Happily retired
Thread Starter
Looks like it may be complete soon
I closed down my previous thread because we had basically ground to a halt. When i went on my Hols it looked certain that Central Day would be on the cards, when i returned that was not going to happen. I had promised Pete at Spec-r that it would be available on his stand & i felt i had let him down.
The problem was the beam, all normal brute force methods had failed to get it apart, it was seized big time. Being a Zoo Jag Diff conversion it was not a case of just getting new bits for it.
We came to the conclusion it had to be sorted so Deano/Myself were told to ' Get it apart' so Brute Force was the order of the day. The Beam was then given shock tactics, that consisted of hitting with a sledge then heating it up whilst hitting, then cooling with Rostoff Ice, nothing happened
.
Deano is a persistant bugg*r though after 40 min it finally moved a few thou & finally the adjuster came free. Deano by this time had a Headache & dead arms so the reserves were called in namely Mark & Red Bull Paul & boy to do the other side boy did they have probs, They took longer despite using bigger bashing impliments but finally the beam was apart. I had already sourced new Rod ends & bolts but the adjusters, pins & spacers etc were all destroyed. The beam itself was fine & i cleaned & painted it.
The machine shop next door was asked to make the new parts & yesterday they were completed, After cleaning everything the new adjusters can be wound in by hand
. I will be trying to source the final parts this morning hopefully getting them to Mark sometime today.
We wont make Central Day because there are many jobs still to do but it will be at Dunsfold in May
.
Maybe we are within a week or so of starting the car but i expect there will be other hidden problems, dont leave your car standing for 4 years
its aggro to get it back to perfect condition as im finding out.
The problem was the beam, all normal brute force methods had failed to get it apart, it was seized big time. Being a Zoo Jag Diff conversion it was not a case of just getting new bits for it.
We came to the conclusion it had to be sorted so Deano/Myself were told to ' Get it apart' so Brute Force was the order of the day. The Beam was then given shock tactics, that consisted of hitting with a sledge then heating it up whilst hitting, then cooling with Rostoff Ice, nothing happened
.Deano is a persistant bugg*r though after 40 min it finally moved a few thou & finally the adjuster came free. Deano by this time had a Headache & dead arms so the reserves were called in namely Mark & Red Bull Paul & boy to do the other side boy did they have probs, They took longer despite using bigger bashing impliments but finally the beam was apart. I had already sourced new Rod ends & bolts but the adjusters, pins & spacers etc were all destroyed. The beam itself was fine & i cleaned & painted it.
The machine shop next door was asked to make the new parts & yesterday they were completed, After cleaning everything the new adjusters can be wound in by hand
. I will be trying to source the final parts this morning hopefully getting them to Mark sometime today. We wont make Central Day because there are many jobs still to do but it will be at Dunsfold in May
.Maybe we are within a week or so of starting the car but i expect there will be other hidden problems, dont leave your car standing for 4 years
its aggro to get it back to perfect condition as im finding out.
13-04-2010, 07:52 AM
#2
well, yay! for gettin ghte beam apart, yay! for telling us you've had to let soeone down because of problems, yay! for the car getting sorted 
and yay for continuing (and hopefully another yay! for getting some record breaking times down for when it's out again
)
and yay for continuing (and hopefully another yay! for getting some record breaking times down for when it's out again
)
13-04-2010, 05:32 PM
#6
Happily retired
Thread Starter
Today was the 1st Good day since my car returned from Petes. More went right than went wrong 
.
Had a 50 mile round trip to get some parts before going to Marks.
The beam was built up then helped Mark/Deano bolt it into place. Then fitted the new tank & strap & fitted all the pipes. So beam is 95% & Tank 100% what can i say kept waiting for something not to fit or break & it didnt
.
Common sense & the Missus says i should take it easy tomorrow & just potter around the garden for a day but im going to try & fit the Brakes & rear shocks tomorrow so that maybe just maybe Mark can bleed the brakes.
Also a new handbrake cable was fitted.
.Had a 50 mile round trip to get some parts before going to Marks.
The beam was built up then helped Mark/Deano bolt it into place. Then fitted the new tank & strap & fitted all the pipes. So beam is 95% & Tank 100% what can i say kept waiting for something not to fit or break & it didnt
.Common sense & the Missus says i should take it easy tomorrow & just potter around the garden for a day but im going to try & fit the Brakes & rear shocks tomorrow so that maybe just maybe Mark can bleed the brakes.
Also a new handbrake cable was fitted.
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14-04-2010, 04:27 PM
#9
Happily retired
Thread Starter
Some progress today, set out to complete brakes & fit new Springs & rear coilovers.
Decided to start on the coilovers so removed Leda Spring so that the twin Eiabach Springs could be fitted but found they would not fit over the Spring retainers. Knowing they should fit looked closer & realised the retainers were cracked, this could not be seen with the old Spring in place, both rear spring retainers were cracked
. Have ordered new ones from BAD but they wont arrive untill Friday so fitting will now be next week.
Decided to re-fit rear Disc/Calipers, pipes, Handbrake, Wheelspeed sensors this went well but two pipes were declared as needing replacement so Marks going to make them up & they will be fitted also on Monday when the Brakes can be finally finished.
Tomorrow i will re-fit the Intercooler/Radiator & then list what pipes i still require to finish off. They had been removed to gain access to the Power steering pipes that were changed.
The only problem i see is the external wastgate pipe which appears not to fit even though it was on the car at one stage it seems miles out which is very strange but will fiddle with it & get it changed if need be on Monday.
All things being well we may start it mid next week, lets hope so 4years 2 months & 7 days is a long re-build.
Decided to start on the coilovers so removed Leda Spring so that the twin Eiabach Springs could be fitted but found they would not fit over the Spring retainers. Knowing they should fit looked closer & realised the retainers were cracked, this could not be seen with the old Spring in place, both rear spring retainers were cracked
. Have ordered new ones from BAD but they wont arrive untill Friday so fitting will now be next week.Decided to re-fit rear Disc/Calipers, pipes, Handbrake, Wheelspeed sensors this went well but two pipes were declared as needing replacement so Marks going to make them up & they will be fitted also on Monday when the Brakes can be finally finished.
Tomorrow i will re-fit the Intercooler/Radiator & then list what pipes i still require to finish off. They had been removed to gain access to the Power steering pipes that were changed.
The only problem i see is the external wastgate pipe which appears not to fit even though it was on the car at one stage it seems miles out which is very strange but will fiddle with it & get it changed if need be on Monday.
All things being well we may start it mid next week, lets hope so 4years 2 months & 7 days is a long re-build
.
15-04-2010, 04:13 PM
#11
Happily retired
Thread Starter
Enjoyed today putting everything back under the bonnet.
Found 3 pipes that didnt fit when routed as i wanted so these have been ordered.
Having a day off tomorrow as i want 3 days in the garden. If all the parts have arrived it should all be back together on Monday.
The brakes, Clutch & Power Steering all need bleeding & thenit may be starties time.
Found 3 pipes that didnt fit when routed as i wanted so these have been ordered.
Having a day off tomorrow as i want 3 days in the garden. If all the parts have arrived it should all be back together on Monday.
The brakes, Clutch & Power Steering all need bleeding & then
it may be starties time.
15-04-2010, 06:07 PM
#13
cossie fan (unluckerly)
sounds good rod glad things are going your way at last will be good to see the old girl back on the road if not just to shut some of them haters up a lol
17-04-2010, 06:44 PM
#20
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Thread Starter
I wish aint breaking my back on a 20 year old Taxi
, I get to Marks at 11 & leave at 3 with a dinnerbreak. Dont work at weekends & my garden is a higher priority at the mo. It will get finished but cant give a date at the mo. Dont do anything fast at my age..
17-04-2010, 06:53 PM
#21
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Thread Starter
The engine has been in the car since December 2008, basically everything else around it has been changed. The engine made 838bhp/666ft-lb on the Dyno & has a 200bhp Nitrous Capability. We have yet to decide how much of the potential Power we are going to run, anything over 940bhp will get us near the dream of 215mph but my sights are a tad lower than that, i see 213 as being a realistic maximum for this car & if we get over 212 then its game over for my attempts.
19-04-2010, 03:28 PM
#22
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Thread Starter
Another days graft, well 11 to 3 .
The suspension is now completed & the Brakes almost complete, Mark ran out of unions so the last pipe could not be made it was decided to replace all the pipes so took a bit longer to complete than expected. The new pipe will be fitted first thing tomorrow so Brakes, Clutch & Power steering can all be bled.
Mark suggested i charge up the battery so i went to the boot, guess what no battery in the box not sure when it went awol but ive not checked for 4 years . Just purchased a new one on my way home.
Still waiting for parts to get engine started & they are due next Monday. we may well make do with parts we have to at least get it started before weekend.
Suspension & Beam need to be set-up & then Mark can drive it to get an MOT. I wont tax it till 1st of May now.
.The suspension is now completed & the Brakes almost complete, Mark ran out of unions so the last pipe could not be made it was decided to replace all the pipes so took a bit longer to complete than expected. The new pipe will be fitted first thing tomorrow so Brakes, Clutch & Power steering can all be bled.
Mark suggested i charge up the battery so i went to the boot, guess what no battery in the box
not sure when it went awol but ive not checked for 4 years . Just purchased a new one on my way home. Still waiting for parts to get engine started & they are due next Monday. we may well make do with parts we have to at least get it started before weekend.
Suspension & Beam need to be set-up & then Mark can drive it to get an MOT. I wont tax it till 1st of May now.
21-04-2010, 07:31 AM
#24
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Thread Starter
Mixed day today ( Tuesday).
Started well the Brakes are bled & fine. Within a few seconds of trying to bleed the the Clutch it was realised the Master Cylinder was seized in the pedal down position.
Sounds easy but all the heat Shields had to be removed to remove it & that aint easy. The cylinder is mullered & ive ordered a new one to be delivered on Thursday.
Also found an electrical gremlin, the car last ran with SM2 & the changeover to SM4 has not been tried in car. I thought
that because it worked on the Dyno that the loom was proved correct, but we didnt drive the Fuel Pump on the Dyno & their is a problem. A quick look at the circuit diagram showed that a second relay is required on my set-up as the Pump is driven off 15v not 12v & needs to be ECU triggered not ignition triggered as it was before TWAT.
More fun on Wednesday.
Started well the Brakes are bled & fine. Within a few seconds of trying to bleed the the Clutch it was realised the Master Cylinder was seized in the pedal down position.
Sounds easy but all the heat Shields had to be removed to remove it & that aint easy
. The cylinder is mullered & ive ordered a new one to be delivered on Thursday.Also found an electrical gremlin, the car last ran with SM2 & the changeover to SM4 has not been tried in car. I thought
that because it worked on the Dyno that the loom was proved correct, but we didnt drive the Fuel Pump on the Dyno & their is a problem. A quick look at the circuit diagram showed that a second relay is required on my set-up as the Pump is driven off 15v not 12v & needs to be ECU triggered not ignition triggered as it was before TWAT.More fun on Wednesday.
21-04-2010, 05:51 PM
#26
Happily retired
Thread Starter
Sorted the wiring gremlin out quickly & Mark suggested, fitting Exhaust, Filling with new Oil & then TRY & START IT . It fired up straight away & ran for a few seconds before Oil was spotted underneath. This gremlin was a mechanical one so not mine . Pete had fitted the Turbo when sorting my IC etc & although all looked OK the Oil return to sump pipe was not bolted to the Turbo it just looked like it was. Will probably have to remove Turbo to fit not sure yet.
Quick Test of all gauges & lights & switches showed all the new wiring was correct. Something we had not touched wasnt working though the Alternator warning light did not work when ignition was switched on. The circuit wont work with a duff or missing bulb so will check that on Friday it may have fallen out or more likely nicked when a bulb was needed 
.
Having a day off tomorrow but Friday should see the new Clutch cylinder fitted & the new pipes will be in on Monday & then its just replace a few parts & its ready to go next door to sort out Beam adjustments & Suspension Heights, MOT & its FINISHED.
Cant believe it
.
Its always been insured but i wont tax it till 1st May.
I now need to think about clearing my Garage out its part storage & the Cossie half now has a running Machine & is my Gym.
. It fired up straight away & ran for a few seconds before Oil was spotted underneath. This gremlin was a mechanical one so not mine . Pete had fitted the Turbo when sorting my IC etc & although all looked OK the Oil return to sump pipe was not bolted to the Turbo it just looked like it was. Will probably have to remove Turbo to fit not sure yet. Quick Test of all gauges & lights & switches showed all the new wiring was correct
. Something we had not touched wasnt working though the Alternator warning light did not work when ignition was switched on. The circuit wont work with a duff or missing bulb so will check that on Friday it may have fallen out or more likely nicked when a bulb was needed .Having a day off tomorrow but Friday should see the new Clutch cylinder fitted & the new pipes will be in on Monday & then its just replace a few parts & its ready to go next door to sort out Beam adjustments & Suspension Heights, MOT & its FINISHED.
Cant believe it
.Its always been insured but i wont tax it till 1st May.
I now need to think about clearing my Garage out its part storage & the Cossie half now has a running Machine & is my Gym.
21-04-2010, 06:05 PM
#27
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24-04-2010, 07:05 AM
#37
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Thread Starter
On Friday the new clutch cylinder was fitted & then Bled. The altenator circuit was checked & found OK so the problem is a dead Alternator. Mark had to remove the Turbo front end to get at the oil return so i only had to remove the fans to easily get the Alternator off. A new one was purchased & modified to take the heat Shield cover from a Audi & it can now be refitted.
Not sure of next week as Mark wants me to work on a RS200 Replica he has in & also make a loom for another Cossie.
Only parts we are waiting on are 3 pipes & then it can all be buttoned up.
Not sure of next week as Mark wants me to work on a RS200 Replica he has in & also make a loom for another Cossie.
Only parts we are waiting on are 3 pipes & then it can all be buttoned up
.
sounds promissing. onne question fella are you runing a standard Alternatoror or have you gone uprated