[Body_Work] Rust Rust And More Rust!

[Telf 222 2 Cars]

there the original ones

[jackherer 543]

It should be the same ride height then really, maybe a few mm more if your old top mounts were a bit soggy.

[Gaz205 50]

Bet you never saw the day when it was nearly finished ..... it looks like it was defo worth the wait!

 

[Telf 222 2 Cars]

Gaz it's been a long time coming. Now just hoping the engine survives the rolling road session!

[Telf 222 2 Cars]

So as already posted the car survived the rolling road. Made a respectable 129bhp and 101 at the wheels

[Telf 222 2 Cars]

In other news the grill and valances are finally painted

[jackherer 543]

Very nice.

 

Have they done the fuel cap?

[Telf 222 2 Cars]

They are doing it mate yes

[Telf 222 2 Cars]

So here it is nearly finished apart from the bonnet and some interior trim that is being painted ..

[Telf 222 2 Cars]

edited wiring diagram post the issues we discovered on start

[Telf 222 2 Cars]

So the MOT is on Thursday and the bastard is fighting me all the way! Nearly built and today I managed to have a weird moment when the headlights came on with no switch operated. Some fizzing and smoke followed by a rapid battery disconnect!

 

Headlights and grille removed and found the earth block near the driver's headlight toasted. No fuses popped,very odd.

 

Investigated further and found the issue. Somehow the earth block has been connected to the shunt box putting a 12v directly onto the earth block- via a 25 amp fuse!

 

I'd been fixing the wash wipe and as I topped up the bottle some wash fluid ended up on the earth block. This gave the right condition for the earth and 12v sitting there to short in spectacular fashion.

 

Luckily damage is minimal, melted plastic and and knackered plug that's now been binned. Cable repaired so no harm done.

 

This has occured as one of the cables from the shunt box has been connected to the earth as it has a green/yellow insulation coat. Looks like an earth maybe?!?? And got plugged in at some point- probably during the modification of the fan control. 

 

So there we have it , never assume a cable belongs somewhere without checking first! 

 

Good job it happened today rather than driving down the road in the rain. Randomly everything was working fine even though that earth block as been wired incorrectly for weeks.

[Telf 222 2 Cars]

MOT day..

 

Passed.

[Anthony 1,000]

Good stuff - now, go and enjoy the fruits of your labour!

[Telf 222 2 Cars]

Well I am waiting to tax it at the start of next month, I managed to have a fairly rapid drive to the MOT center. It drives well but Jesus it's unrefined compared even to my 207 GTI! It's been so long since I drove it I have forgotten what it was like. 

 

There's still quite a few bits to tidy up, interior trim mainly and a quite vexing issue with the fuse box, it seems to have a place to hinge it inboard near the center console but nothing to attach it to the dash outboard. I'm not sure if I'm missing something or other 

 

 

[jackherer 543]

[Telf 222 2 Cars]

Cheers Kieran. I think I've seen that bracket lying around somewhere!

[Philpooma 30]

Fantastic project and thread, I hope you enjoy the car once you get used to the rawness of the driving experience

[Telf 222 2 Cars]

So here it is sat in the sun pretty much rebuilt

[barneys66 120 1 Cars]

Looks great, Paul - you should be very proud.

 

Can't wait to see it (being driven in anger) in person 

[Telf 222 2 Cars]

Cheers Barney. It should be at the next ECR meet and is due to run the Ipswich/Felixstowe historic car run on the 5th May

[Richie-Van-GTi 70 2 Cars]

Looks mint, get the engine bay sticker pack off eBay, will finish it off under the bonnet

[Telf 222 2 Cars]

Well it's now completed one car show and about 250 miles.

 

Overall not to bad . I've had a couple of oil leaks and had to tighten afew bolts up bit nothing major. First leak was a lack of o ring on the plate blanking the dizzy end of the cam, the second I've still not found but I think it's the oil cooler o ring.. I may not have fitted a new one ! 

 

I'm marginally concerned about the gearbox. It seems quite noisy but I can't remember if they are noisy or quiet - I guess I'll keep an eye on it and see.

[jackherer 543]

What gear oil did you end up using?

[Telf 222 2 Cars]

3 hours ago, jackherer said:

What gear oil did you end up using?

As discussed the stuff we got from the barrel 

[jackherer 543]

The gearbox sounded fine to me earlier, and it seemed to drive well too.