My Indigo Blue Throttle Bodied 106 Rallye
Discussion
dom9 said:
MrMoonyMan said:
Worst comes to worst I've got a garage (st.albans) I could move my long term project car out of to make sure you don't sell this!
This is what PH is all about - what a fantastic offer!You'll be pleased to know I got my finger out and did a bit more on this tonight. Jacked it up and took the suspension off (again) *sigh* as need to drill out the struts to accept the 14mm Track rod end bolts.
I also need to drill the hole for the speed sensor which I envisage being an arse of a job. I can't remember how it was on my old struts when bob @ wire wizard did it, as I never took a photo arrrgh! But, I'm pretty sure it was drilled through the strut to take the reading off the hub. The area is super thick steel though so gonna be a test for my little festool drill. We shall see. It's small and mighty and German so should be able to get through it! I have been surprised by it's power before!
I need a 14mm step drill for the strut holes too, for the new track arms, but want to buy a good quality step drill bit as I loathe cheap nasty tools that don't work well. I bought a smaller expensive one a few years back from the motor factors in Silverstone (made in England of course), and it would cut through kryptonite it's excellent! Unfortuntely the only ones I can see online are cheap-ass 'Silverline' and the like. I could do with it fitting the 8mm chuck of my festool but don't think you can get them that small.
Few more updates from the week/weekend.
Got on with fitting my new 'TR' Rose Jointed Track Rod ends (Tommy Rallye ones). Had a tough time getting the old steering arms off, but when I reliased which way to undo the nuts that helped, then I was unable to undo them with relative ease!
Few pics:
Suspension off again *sigh*
When the rest of the troops in the toolbox aren't man enough for the job, you gotta dig out 'the Daddy' - 12 inches of pure steel!
Coming off:
Can see the size of the spanner against the steering arm!
New steering arm. Put some copper slip on the bolts to ensure they will be easy to remove next time if further adjustment/faffing is required:
Fitted:
Next onto drilling the strut to fit the speed sensor. My old struts had a similar set up, but I forgot to take a photo at the time. However, pretty sure this is how it was fitted:
Hole drilled:
Old speed sensor (broke it removing the damn thing so will need a replacement - another bloody one hundred pounds!):
This is how it will mount on the strut:
And how the car curently sits:
Next job is to drill out the holes where track rods ends bolt through. Standard ones taper from about 12mm to 8mm, the new bolts are 14mm. However, the chuck on my drill is only 8mm (doh), so my good pal Stu who works at a machine shop is sending me a 14mm drill bit next week that he has machined down to 8mm at the shank end for me (top man thank you!!) so will finish these next week and get them back on.
One tool I have realised that I am missing while doing this job is a big F-off pry bar. Getting the lower arms in and out is an arse of a job, not made much easier by not having a pry bar. I used a big screw drvier instead but will be investing in a pry bar I think!!
Got on with fitting my new 'TR' Rose Jointed Track Rod ends (Tommy Rallye ones). Had a tough time getting the old steering arms off, but when I reliased which way to undo the nuts that helped, then I was unable to undo them with relative ease!
Few pics:
Suspension off again *sigh*
When the rest of the troops in the toolbox aren't man enough for the job, you gotta dig out 'the Daddy' - 12 inches of pure steel!
Coming off:
Can see the size of the spanner against the steering arm!
New steering arm. Put some copper slip on the bolts to ensure they will be easy to remove next time if further adjustment/faffing is required:
Fitted:
Next onto drilling the strut to fit the speed sensor. My old struts had a similar set up, but I forgot to take a photo at the time. However, pretty sure this is how it was fitted:
Hole drilled:
Old speed sensor (broke it removing the damn thing so will need a replacement - another bloody one hundred pounds!):
This is how it will mount on the strut:
And how the car curently sits:
Next job is to drill out the holes where track rods ends bolt through. Standard ones taper from about 12mm to 8mm, the new bolts are 14mm. However, the chuck on my drill is only 8mm (doh), so my good pal Stu who works at a machine shop is sending me a 14mm drill bit next week that he has machined down to 8mm at the shank end for me (top man thank you!!) so will finish these next week and get them back on.
One tool I have realised that I am missing while doing this job is a big F-off pry bar. Getting the lower arms in and out is an arse of a job, not made much easier by not having a pry bar. I used a big screw drvier instead but will be investing in a pry bar I think!!
philmh said:
The world will end before he finishes it lol.
Oi! I will get it done...eventually!A few more updates tonight. Stew in his eternal kindness custom made me a drill bit that I could use to drill out my struts to 14mm (well he supplied and machined down the shank to 8mm, and also gave me some cutting oil so I have to say a massive thanks to him AGAIN for helping me out - top lad)
So tonight I got both struts drilled out, cleaned up, and fitted one complete back onto the car. Also fitted the track rod end but would you believe in my arsenal of tools I don't have an allen key that fits the bolt - doh! So will need to buy one before I nip them up tight.
Anyways pics as follows:
Drill and cutting oil:
8mm Shank:
Fits in - result!
Strut in vice ready for drilling:
In progress:
Drilled out:
Cleaned up - quite a clean hole actually, the oil works a treat:
Track rod end bolt through:
And finally a completely unrelated snap of a file my Dad gave me - it's ancient but such a good tool, super useful. Can't beat old english tools!
Will get on with the other side of the suspension tomorrow, then set up the camber and toe in roughly. Then got to start re-fitting the wiring. Arrrrgh why did I take it out!
Lewis
Beedub said:
absolutely stunning.... you would NEVER... forgive yourself if you sold this..... whatever you own afterwards you would regret it, this things is a keeper, do what you have to and enjoy it.....
Thank you It does test my resolve at times I must say, but hopefully it's rewarding to drive once I get it running properly! Trying to make a push on it now.
neilbauer said:
Just found this thread, lovely work
cheersCopied and pasted boys:
Ok, so in an attempt to try and fit my steering arms upside down and reduce the steep steering arm angle, I have hammered the chassis down a bit tonight, pretty much as far as it can be done without buggering it completely. The seam seal has split a little, so will cut it off and go over it with some more, or gasket seal or something just to fill the gap and prevent water ingress.
I reckon if I machine down one of the spacers (the gold ones that fit between the rose joint and the strut arm) it would just about fit and perhaps touch slightly when jacked up, but not so much that it would damage or bend/put excessive stress on the arms.
Pics as follows:
So hammered down they fit without the spacer like so:
Same as above but chassis in focus:
Rosejoint:
Cracked sealer:
Hammered down some more. I will tidy those corners up tomorrow. I was in a rush to get back upstairs the wife had cooked me a steak, it was going cold and I was starving!
If I could get the conical spacer machined to this size it would just fit and allow a few mm clearance against the chassis - tight like a tiger!
Also I figured that the camber is what screws up the toe in. I have lessened the camber and now the wheels are just about matching. Would need shorter arms if I set the camber more aggressively.
Track_Cit said:
The seam seal has split a little, so will cut it off and go over it with some more, or gasket seal or something just to fill the gap and prevent water ingress.
Gasket sealer won't do the job very well. Use something like Sikaflex 221:http://www.uksealants.co.uk/sikaflex-221-adhesive-...
fiatpower said:
Gasket sealer won't do the job very well. Use something like Sikaflex 221:
http://www.uksealants.co.uk/sikaflex-221-adhesive-...
Ok thanks dude. I may just buy some seal sealer and do it properly to be honest now! http://www.uksealants.co.uk/sikaflex-221-adhesive-...
Ok, so I spent the weekend hammering my chassis (sounds wrong that!) and trying to get the steering arms to fit on without knocking at full droop (more innuendos!)
Initially I was going to get some smaller mis-alignment spacers made up, but I ended up doing it the old fashioned way and cutting them down with a hacksaw. Unfortunately my blades weren't the sharpest as I used them sorting the Civic exhaust, so it was hard work. However, got there in the end, and success, they fit!
Next problem is addressing the toe in. The steering arms are still too long so the wheels point outwards despite the fact the are wound all the way in. I have been speaking to Tommy and I think we are going to cut them down slightly then he will weld them up and repaint them for me, top man. Think it's just the AST's putting a spanner in the works, as no one else has this exact set up and no one else has experienced these issues! Never mind, I will get around it. Also going to crack on refitting the loom again this week. Feeling enthusiastic about the car again which is good, and I am actually enjoying working on it too
Anyways, enough babble, here are some photos:
Doing it the old fashioned way (side note, if you don't own a vice, get one, best/most useful tool ever!!)
Getting there:
Motivational tunes to aid with the cutting!
Phew:
Done!
Refining the finish. Also used a file and sandpaper after this:
Complete:
Et voila, c'est parfait!
Tight, but, but she fits:
Small bit that I removed:
All tightened up (will come off again for cutting the arms down - arrgh!):
That's all for tonight!
Lewis
Thanks guys.
Ok, so it appears that I was being a muppet regarding the steering arms and confusing myself, after one of the smart chaps on the forum pointed out a mistake with my statement - DOH! (Thanks to Phillipm!)
So I managed to get everything on and the steering arms lined up (pretty much). Also setting the camber and messing about with the AST's wasn't an easy job, so it involved measuring from the edge of the strut to the edge of the nut using an allen key, marking with tape then trying to match it with the other side. I did have the idea of my mini magnetic spirit level on the brake discs, so may do that also to check they're equal. They look about right by my eye, although will get them set up properly once it's running.
So that sorted, started to put my loom back in. Bit of a fiddly job, and time consuming cable tying it all back together but it's getting there. Stupidly I did not take photos before removal, so there are a few connections i'm unsure of, for example the starter motor and the altenator one's (think the Altenator may be ok as the holes on the connectors and small and large so can match them easily, but I am a bit stumped with the one on the starter motor. May take some pics and see if any of you boys can assist.
A few unexciting pics of the work:
Steering arms adjusted:
Right wheel:
Left wheel:
Wiring:
Overall though I am enjoying working on it and feel quite stoked on it again. Really going to crack on with it and aim to get the thing working this year. I have been saying this since 2010 would you believe! Went through my thread today fully, cannot believe I have faffed on it for so long but money and other constraints haven't helped either!! Ho hum!
Ok, so it appears that I was being a muppet regarding the steering arms and confusing myself, after one of the smart chaps on the forum pointed out a mistake with my statement - DOH! (Thanks to Phillipm!)
So I managed to get everything on and the steering arms lined up (pretty much). Also setting the camber and messing about with the AST's wasn't an easy job, so it involved measuring from the edge of the strut to the edge of the nut using an allen key, marking with tape then trying to match it with the other side. I did have the idea of my mini magnetic spirit level on the brake discs, so may do that also to check they're equal. They look about right by my eye, although will get them set up properly once it's running.
So that sorted, started to put my loom back in. Bit of a fiddly job, and time consuming cable tying it all back together but it's getting there. Stupidly I did not take photos before removal, so there are a few connections i'm unsure of, for example the starter motor and the altenator one's (think the Altenator may be ok as the holes on the connectors and small and large so can match them easily, but I am a bit stumped with the one on the starter motor. May take some pics and see if any of you boys can assist.
A few unexciting pics of the work:
Steering arms adjusted:
Right wheel:
Left wheel:
Wiring:
Overall though I am enjoying working on it and feel quite stoked on it again. Really going to crack on with it and aim to get the thing working this year. I have been saying this since 2010 would you believe! Went through my thread today fully, cannot believe I have faffed on it for so long but money and other constraints haven't helped either!! Ho hum!
PhillipM said:
So, both my babies got some love today - Honda had it's new headlight and machine polished them both so they look new. Anyway, that's another blog so will update that too!
Finished putting the loom back into the Rallye tonight so that's all done. Also re-routed a few bits and made it even more tidy, so looks awesome now! Gotta put the exhaust back on, trumpets back and other bits back on, wire the wiper motor in, empty out the fuel tank (not looking forward to that), get a new battery, fit my speed sensor, sort out the rear calipers, and a few other bits, but not much left now!
Few snaps:
These pics are mainly for reference so if the engine blows up and I have to remove it then I can remember how things go back in!
Will update with a few more pics tonight, but have been cracking on with this recently. Still having grief with my steering arms. They are now wound all the way in following several attempts to get both wheels straight, and are still a touch long in that both the front wheels have a bit too much toe in. It's to do with the amount of camber set by the AST's. If you look at this picture of Dans you will see he has the camber set to the least aggressive setting, whereas mine somewhere in the middle moves the part of the strut that the track end bolts to quite far in which in turn means the steering arms are a bit too long. It's difficult to explain:
Dans:
Mine:
Anyway, will sort that later as trying to get it running first.
In the meantime I have been to Earls and got the brake line fittings I needed, made up the rear lines, fitted those, refitted the rear calipers, refitted the exhaust, refitted and tidied the loom, fitted the lambda sensor for the STACK AFR but but need to decide on a cunning method to route the wiring into the cabin to plug it into the actual connector block from the loom connected to the AFR. Also still need to wire that in, will need help with that. Got to empty the fuel tank and fill with fresh fuel (an arse of a job which I am not excited about), buy a new battery, fill engine with all fluids, and that's pretty much it. Mapping then.
I have a lot going on and the pressure is currently. We are buying a house and it has no garage so need to get this running so I can store it somewhere, either that or it will have to go to my brothers garage temporarily and then be sold or broken which I [U]REALLY[/U]do not want to do. We are getting married in August so trying to arrange that and sort it all out. My fiances father is extremely ill so we have been seeing him a lot recently and that takes time and is also very upsetting / stressful for all involved. Tough times and am gutted we could not find a property within budget that has a garage, but life has to move on. Seeing this illness destroy a mans life has made me think about the future more and kids, so that will be next on the agenda, although I am trying my hardest to ensure the Rallye features in these future plans. If we do have some offspring one day and it's a boy, I one day imagine taking him for a blast in the Rallye and introducing him to this hobby/obsession that has given me so much pleasure over the years, albeit with a lot of arse-ache in the meantime, but hey, that's all the fun of it right!?
Will keep you guys posted.
Dans:
Mine:
Anyway, will sort that later as trying to get it running first.
In the meantime I have been to Earls and got the brake line fittings I needed, made up the rear lines, fitted those, refitted the rear calipers, refitted the exhaust, refitted and tidied the loom, fitted the lambda sensor for the STACK AFR but but need to decide on a cunning method to route the wiring into the cabin to plug it into the actual connector block from the loom connected to the AFR. Also still need to wire that in, will need help with that. Got to empty the fuel tank and fill with fresh fuel (an arse of a job which I am not excited about), buy a new battery, fill engine with all fluids, and that's pretty much it. Mapping then.
I have a lot going on and the pressure is currently. We are buying a house and it has no garage so need to get this running so I can store it somewhere, either that or it will have to go to my brothers garage temporarily and then be sold or broken which I [U]REALLY[/U]do not want to do. We are getting married in August so trying to arrange that and sort it all out. My fiances father is extremely ill so we have been seeing him a lot recently and that takes time and is also very upsetting / stressful for all involved. Tough times and am gutted we could not find a property within budget that has a garage, but life has to move on. Seeing this illness destroy a mans life has made me think about the future more and kids, so that will be next on the agenda, although I am trying my hardest to ensure the Rallye features in these future plans. If we do have some offspring one day and it's a boy, I one day imagine taking him for a blast in the Rallye and introducing him to this hobby/obsession that has given me so much pleasure over the years, albeit with a lot of arse-ache in the meantime, but hey, that's all the fun of it right!?
Will keep you guys posted.
Edited by Track_Cit on Wednesday 9th April 14:30
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