Body off refurb begins - parts list help appreciated
Discussion
Hi all, good news! A fortunate development offered up the opportunity to do the full body off refurb, and given that, I've decided it's best to replace many of the wearing items. The small challenge of course is identifying the correct parts so any comments you good folks can add to my list and findings would be very much appreciated.
But before that here it is ready for blasting :-)
So in the rebuild the following is planned to be replaced on my 89 S2 with 2.9 motor. I've used the Alternative Parts list as much as possible...
1. Exhaust manifolds.
I see ACT and Racetech offer stainless steel replacements at around £540 for the pair - any other options/sources?
2. Clutch kit.
Think I'm fine with this one. Given the type 9 box I'm going with a Borg & Beck 3 in 1 kit, HK9579. £130 ish.
3. Diff mount.
Ouch! Billet item item with poly bushes appears the only replacement, available from GGR, Compbrake, eBay etc at around £125 to £155 - any other options/sources?
4. Rear gearbox mount.
Sourced this from Bearingkits.co.uk for type 9 box @ £30
5. Front upper and lower ball joints.
Identified these as a combination of Saab/Fiat units, Delphi part numbers TC125 & TC76 at £25 a pair.
6. Handbrake cable.
Is this a standard Ford Sierra item for rear drums?
7. ARB bushes.
Will go with some Superflex poly bushes. I've read on here they are usually 26mm, in which case it's SF382-1004K @ £19
8. Rotor arm.
Sourced an Intermotor item, part number 47741 at £6.50
9. Fuel filter.
Sourced a Mann WK853 from ECP at £8.59
10. Rear AVO dampers.
Already have AVOs fitted but dampers tired so a pair of PG719s going on with existing springs, just need to check spring Id to see if it's 2.25" or 2.5".
11. Braided brake lines.
Fell in the Goodridge trap of ordering STV0910-5 which is a 5 piece kit for the S series!? Of course it needs a 6 piece kit which is STV0920-6 and has now been changed to that.
12. Heat protective matting.
Looking for something to reline the body either side of the manifolds - any suggestions?
On top of all this, new fuel line, front bushes, bottom hose, bolts, pads, engine mounts, etc. Gearbox and diff oil (engine oil and filter done 100 miles ago). Completely rebuild or rear brakes with new shoes, cylinders, springs and will also throw new mintex pads and EBC discs on it. Chassis will be 2-pack poly painted in silver/grey and will contrast the uprights, ARB, fuel tank in black :-)
I would be lying if I said I wasn't just a little bit excited by the prospect of the finished work, I imagine it will drive like it was new.
But before that here it is ready for blasting :-)
So in the rebuild the following is planned to be replaced on my 89 S2 with 2.9 motor. I've used the Alternative Parts list as much as possible...
1. Exhaust manifolds.
I see ACT and Racetech offer stainless steel replacements at around £540 for the pair - any other options/sources?
2. Clutch kit.
Think I'm fine with this one. Given the type 9 box I'm going with a Borg & Beck 3 in 1 kit, HK9579. £130 ish.
3. Diff mount.
Ouch! Billet item item with poly bushes appears the only replacement, available from GGR, Compbrake, eBay etc at around £125 to £155 - any other options/sources?
4. Rear gearbox mount.
Sourced this from Bearingkits.co.uk for type 9 box @ £30
5. Front upper and lower ball joints.
Identified these as a combination of Saab/Fiat units, Delphi part numbers TC125 & TC76 at £25 a pair.
6. Handbrake cable.
Is this a standard Ford Sierra item for rear drums?
7. ARB bushes.
Will go with some Superflex poly bushes. I've read on here they are usually 26mm, in which case it's SF382-1004K @ £19
8. Rotor arm.
Sourced an Intermotor item, part number 47741 at £6.50
9. Fuel filter.
Sourced a Mann WK853 from ECP at £8.59
10. Rear AVO dampers.
Already have AVOs fitted but dampers tired so a pair of PG719s going on with existing springs, just need to check spring Id to see if it's 2.25" or 2.5".
11. Braided brake lines.
Fell in the Goodridge trap of ordering STV0910-5 which is a 5 piece kit for the S series!? Of course it needs a 6 piece kit which is STV0920-6 and has now been changed to that.
12. Heat protective matting.
Looking for something to reline the body either side of the manifolds - any suggestions?
On top of all this, new fuel line, front bushes, bottom hose, bolts, pads, engine mounts, etc. Gearbox and diff oil (engine oil and filter done 100 miles ago). Completely rebuild or rear brakes with new shoes, cylinders, springs and will also throw new mintex pads and EBC discs on it. Chassis will be 2-pack poly painted in silver/grey and will contrast the uprights, ARB, fuel tank in black :-)
I would be lying if I said I wasn't just a little bit excited by the prospect of the finished work, I imagine it will drive like it was new.
AJC77 said:
6. Handbrake cable.
Is this a standard Ford Sierra item for rear drums?
No, it has been shortenned ("search" handbrake cable)Is this a standard Ford Sierra item for rear drums?
AJC77 said:
12. Heat protective matting.
Looking for something to reline the body either side of the manifolds - any suggestions?
Might be worth a phone call to this guy Looking for something to reline the body either side of the manifolds - any suggestions?
I'm sure it will drive a lot better after all that work but "like new" is maybe being a little optimistic, have fun
Hi There,
I have just done a similar exercise. The rear trailing arm bolts proved to be difficult but they are Landrover shackle bolts. They cost me £4.08 inc vat for the four!The bolt list wiki was a great help as well.
Give me a shout if you are stuck with anything while it is still reasonably fresh!
Bill
I have just done a similar exercise. The rear trailing arm bolts proved to be difficult but they are Landrover shackle bolts. They cost me £4.08 inc vat for the four!The bolt list wiki was a great help as well.
Give me a shout if you are stuck with anything while it is still reasonably fresh!
Bill
I've just come out the other side of this. I would add:
- Suspension bushes all round (I went for Powerflex)
- Brake and fuel lines all round (I went for Kunifer)
- Coolant and vacuum hoses (I went silicone)
- Body mounting rubber (comes in sheets)
- Radiator mounts
- Fuel tanks are sometimes past it
- Fuel cradles are sometimes past it!
- Seat belts? They're often grotty and rusted around the bases
- Brake discs/pads
Thanks for tips chaps. The bolt wiki looks very useful and I'll try the chap listing the heat insulating kits.
Think the handbrake cable looks like the trickiest.... Will give the usual places a call to see if they have anything. Might have to shorten a Sierra version assuming that's possible?
Think the handbrake cable looks like the trickiest.... Will give the usual places a call to see if they have anything. Might have to shorten a Sierra version assuming that's possible?
Cut out the chassis strut that sits under the sump pan and convert it to be bolted in. Enables the sump to be removed without taking the engine out.
Rear disc conversion.
Stainless steel frame for the fuel tank.
Stainless steel or alloy swirlpot and expansion tank.
Move the battery to the boot.
Remote oil filter. Add a cooler or heat exchanger.
Modify the gear box to move the selector rods forward to under the gear stick. This removes the 'homemade' linkage that TVR 'engineered'.
Rear disc conversion.
Stainless steel frame for the fuel tank.
Stainless steel or alloy swirlpot and expansion tank.
Move the battery to the boot.
Remote oil filter. Add a cooler or heat exchanger.
Modify the gear box to move the selector rods forward to under the gear stick. This removes the 'homemade' linkage that TVR 'engineered'.
AJC77 said:
Think the handbrake cable looks like the trickiest.... Will give the usual places a call to see if they have anything.
Think places like DG can supply but, Sierra cable + about a tenner on Ebay, "Genuine" TVR cable = about £50+++ It's crude but I believe some people have just cut and re-joined using these......... clicky
AJC77 said:
Hi all, good news! A fortunate development offered up the opportunity to do the full body off refurb, and given that, I've decided it's best to replace many of the wearing items. The small challenge of course is identifying the correct parts so any comments you good folks can add to my list and findings would be very much appreciated.
But before that here it is ready for blasting :-)
So in the rebuild the following is planned to be replaced on my 89 S2 with 2.9 motor. I've used the Alternative Parts list as much as possible...
1. Exhaust manifolds.
I see ACT and Racetech offer stainless steel replacements at around £540 for the pair - any other options/sources?
2. Clutch kit.
Think I'm fine with this one. Given the type 9 box I'm going with a Borg & Beck 3 in 1 kit, HK9579. £130 ish.
3. Diff mount.
Ouch! Billet item item with poly bushes appears the only replacement, available from GGR, Compbrake, eBay etc at around £125 to £155 - any other options/sources?
4. Rear gearbox mount.
Sourced this from Bearingkits.co.uk for type 9 box @ £30
5. Front upper and lower ball joints.
Identified these as a combination of Saab/Fiat units, Delphi part numbers TC125 & TC76 at £25 a pair.
6. Handbrake cable.
Is this a standard Ford Sierra item for rear drums?
7. ARB bushes.
Will go with some Superflex poly bushes. I've read on here they are usually 26mm, in which case it's SF382-1004K @ £19
8. Rotor arm.
Sourced an Intermotor item, part number 47741 at £6.50
9. Fuel filter.
Sourced a Mann WK853 from ECP at £8.59
10. Rear AVO dampers.
Already have AVOs fitted but dampers tired so a pair of PG719s going on with existing springs, just need to check spring Id to see if it's 2.25" or 2.5".
11. Braided brake lines.
Fell in the Goodridge trap of ordering STV0910-5 which is a 5 piece kit for the S series!? Of course it needs a 6 piece kit which is STV0920-6 and has now been changed to that.
12. Heat protective matting.
Looking for something to reline the body either side of the manifolds - any suggestions?
On top of all this, new fuel line, front bushes, bottom hose, bolts, pads, engine mounts, etc. Gearbox and diff oil (engine oil and filter done 100 miles ago). Completely rebuild or rear brakes with new shoes, cylinders, springs and will also throw new mintex pads and EBC discs on it. Chassis will be 2-pack poly painted in silver/grey and will contrast the uprights, ARB, fuel tank in black :-)
I would be lying if I said I wasn't just a little bit excited by the prospect of the finished work, I imagine it will drive like it was new.
Good luck with the project should be great fun!But before that here it is ready for blasting :-)
So in the rebuild the following is planned to be replaced on my 89 S2 with 2.9 motor. I've used the Alternative Parts list as much as possible...
1. Exhaust manifolds.
I see ACT and Racetech offer stainless steel replacements at around £540 for the pair - any other options/sources?
2. Clutch kit.
Think I'm fine with this one. Given the type 9 box I'm going with a Borg & Beck 3 in 1 kit, HK9579. £130 ish.
3. Diff mount.
Ouch! Billet item item with poly bushes appears the only replacement, available from GGR, Compbrake, eBay etc at around £125 to £155 - any other options/sources?
4. Rear gearbox mount.
Sourced this from Bearingkits.co.uk for type 9 box @ £30
5. Front upper and lower ball joints.
Identified these as a combination of Saab/Fiat units, Delphi part numbers TC125 & TC76 at £25 a pair.
6. Handbrake cable.
Is this a standard Ford Sierra item for rear drums?
7. ARB bushes.
Will go with some Superflex poly bushes. I've read on here they are usually 26mm, in which case it's SF382-1004K @ £19
8. Rotor arm.
Sourced an Intermotor item, part number 47741 at £6.50
9. Fuel filter.
Sourced a Mann WK853 from ECP at £8.59
10. Rear AVO dampers.
Already have AVOs fitted but dampers tired so a pair of PG719s going on with existing springs, just need to check spring Id to see if it's 2.25" or 2.5".
11. Braided brake lines.
Fell in the Goodridge trap of ordering STV0910-5 which is a 5 piece kit for the S series!? Of course it needs a 6 piece kit which is STV0920-6 and has now been changed to that.
12. Heat protective matting.
Looking for something to reline the body either side of the manifolds - any suggestions?
On top of all this, new fuel line, front bushes, bottom hose, bolts, pads, engine mounts, etc. Gearbox and diff oil (engine oil and filter done 100 miles ago). Completely rebuild or rear brakes with new shoes, cylinders, springs and will also throw new mintex pads and EBC discs on it. Chassis will be 2-pack poly painted in silver/grey and will contrast the uprights, ARB, fuel tank in black :-)
I would be lying if I said I wasn't just a little bit excited by the prospect of the finished work, I imagine it will drive like it was new.
Racetech do the ball joints the lower one not OE but better aftermarket.
White S3 said:
Give the man a hand, he managed to get, not one, but Two blue gloves in shot!! Those gloves come in handy but have yet to see them used for what they were intended - Tee Hee.
Looking good for the next 20yrs.
MRV
Ah yes, that's because the fuel tank hasn't been tackled yet, but we may well need a whole box of latex gloves just to hold that together lol.Looking good for the next 20yrs.
MRV
I'm surprised nobody has mentioned checking the condition of the brake servo casing. This is prone to corrosion underneath.Many threads on here on the subject.
And how old are the existing tyres?
Irrespective of their condition, if they are older than about 7 years, I would strongly recommend replacing them before driving your newly rebuilt P & J on the road.
Would hate to lose you or the car after all that hard work OP!
Safety!
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