Repair and Rebuild Begins

[mk1fan]

Thanks Kie.

Yeah, been a sequence of unfortunate events really. No weddings but one funeral. Terrible news and I feel for the guy, I certainly wouldn't want to have that sort of news to deal with.

Work to live everyone.

[glenrobbo]

Just live.

Live each day as if it is your last, coz one day it will be.
This is not a practise run.

[mk1fan]

Repair Approved.

Had to threaten them with court action and then all of a sudden, 'it was approved yesterday'. Ridiculous behaviour in a day and age when communication is 'instant'. I await the customary 'feedback form' on which to vent.

Right so now I'm out of limbo I can concentrate on repairs. Need to get Tamy back together first as she's blocking the drive -

http://www.pistonheads.com/gassing/topic.asp?h=0&a...

http://www.pistonheads.com/gassing/topic.asp?h=0&a...

&

http://www.pistonheads.com/gassing/topic.asp?h=0&a...

Then on to Samy.

Other than the crash repairs there is;
Major service inc dropping the sump for a clean out.
Fitting the coated manifolds and decat pipes - full exhaust may follow but it needs to be under 102dB for trackdays.
Renewal of the dif mounts.
Fitting 273mm vented rear discs.
Fitting the KA servo and master cylinder.
Spraying the dash, panels and door strips.
Flushing the fuel tank and system.
Sorting out the interior.
Do you think I should check the chassis??

After that, the MOT and VED before heading off to Matt Smith for a set up and possible suspension swap.

Edited by mk1fan on Wednesday 4th March 13:12

[glenrobbo]

Excellent news Stewart!
Sometimes that little extra push is all that's needed to overcome the inertia.

Yes, it might be a good idea to check the chassis.

Oh, and did anyone mention about checking the chassis?


Good luck with the repair & rebuild.
I'm looking forward to seeing which bonnet solution you choose.

Edited by glenrobbo on Wednesday 4th March 16:33

[mk1fan]

Spoken to Performance1 Coatings and looks like I'll be dropping some stuff off next week or the week after. Added a few more parts to the pile. The owner comes across as a really approachable guy. I'm up their way collecting a new bonnet for Tamy so two birds et all.

[mk1fan]

First delivery of goodies turned up this morning. Unfortunatley, probably the last item to be fitted but it was 40% off so took the plunge.

[White S3]

I notice that you have gone for a Ka brake servo. Is it a direct replacement for the Fiesta version that is becoming increasingly difficult to find (at the right price)? If it is, what era of Ka did you go for, I'm sure that there will be much interest from the forum and Grif/Chim to boot? Not up for a replacement yet but always good to have something on the shelf before its needed.
MRV

[mk1fan]

I have the mk1 KA servo and master cylinder. I have bought both the ABS and non-ABS items. Mounting holes need to be modified but I understand they are a 22mm bore to the master cylinder. I'll refurbish both then look at which one will fit best.

I'm not the first to use the KA set up.

[White S3]

Thanks for that - what is the difference between the non-ABS and ABS version?

[magpies]

the bore is the difference

the ABS version is correct at 22.2mm

I believe there is only the choice of abs/non abs (one of each) for the whole range of KA

[White S3]

Thanks

[mentall]

Here's my (limited) experience:

22.2mm bore is the Ka ABS Master cylinder; it only has 2 ports, so needs an external tee to the front brakes.

BUT the ABS servo that goes with it is 9 inch diameter: too big for the system, and just as important wouldn't fit between the body and the clutch cylinder (mostly the latter).

So a non-ABS servo (early Ka) which is 8 inch diameter is needed. The two fit together without problem, but the whole assembly sits (on my car!) about 10mm too high for the bonnet to close.

So, as well as redrilling the bulkhead for the new servo stud positions, we need to lower the holes sufficiently for the bonnet to close. And fit a drilled plate on the inside, to clamp the servo on to the (now mangled) bulkhead.

So far, this all fits together mechanically, but is untested as all the slave cylinders are seized.

As always, PLEASE don't try this at home!

[mk1fan]

Good job I bought both!

Thanks.

[DamianS3]

Give. The battering it takes what you folks planning to protect the new one with.. Put a new ford on mine in 2009 the underside is looking pretty nasty now. And it has most of last year off the road.

I would think some epoxy coat would be a good idea while its apart?

Thanks

Damian S3

[mk1fan]

I am going to sort the install then use some resilient finish. I'm also thinking of a short extension to the inner arch. I've also removed the remote header and brake resevoirs.

[mk1fan]

Had a spare 30-mins so did some work on Samy.





The alloy rad is readily available at £125ish but I'll need to sort out how to fit. If I can make it work I'll do a guide.

Found one of the brake lines has been rubbing the spring. Will sort once the brakes are drained.



Weather permitting will get the front prepped for repair next Saturday.

Got some parcels waiting for me at my weekday abode. Presents are so much fun.

[Ceejay73]

Is the rad an Impreza one? I looked at one a couple of years ago that looked kinda close to correct barring mountings.

edit for beer induced speeeeling.

Yes I know you have seen it all before from me.
But not usually on a Sunday.

Edited by Ceejay73 on Sunday 8th March 21:27

[Griffinr]

mk1fan said:

I am going to sort the install then use some resilient finish. I'm also thinking of a short extension to the inner arch. I've also removed the remote header and brake resevoirs.

Something like this works well, the servo gets no road dirt or water at all now.
Rob.

[mentall]

My car came without wheel arch liners (except the one supposed to protect the servo etc, which had been so hacked about that it protected nothing) so I have developed a CUNNING PLAN to replace all four, using these:



I will say no more until I have tried it out; same with the servo & m/cyl replacement.

[glenrobbo]

mentall said:

My car came without wheel arch liners (except the one supposed to protect the servo etc, which had been so hacked about that it protected nothing) so I have developed a CUNNING PLAN to replace all four, using these:



I will say no more until I have tried it out; same with the servo & m/cyl replacement.

I don't see how you intend to use 27 of them. You must be mentall

I don't know what they are, but they match my balaclava....