Nut and Bolt rebuild - sensible mods

Nut and Bolt rebuild - sensible mods

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Discussion

Pete Mac

Original Poster:

755 posts

136 months

Tuesday 17th December 2013
quotequote all
I have been firing off various contributions to this forum over the last year or so but am now planning my ‘nut and bolt’ rebuild to start early January on my 1995, turquoise Griff 500. It’s got a serpentine engine with the T5 box.

I want to carry out ‘sensible’ mods to the car that will enhance it but not change its character. So far I have the following ideas:

  • Weld in reinforcing brackets/cold rolled steel profiles to reinforce the seat fixings
  • Weld in reinforcing brackets/cold rolled steel profiles to reinforce the battery fixings
  • Galvanise and powder coat the chassis – I’ve considered the pros and cons and I think the pros outweigh the cons. I’m interested to hear people’s experience of galvanising but not from the doomsayers who have had no first-hand experience. I think the chances of the chassis warping are minimal providing it is done properly and the structural advice I have had is that the stresses introduce to the chassis by drilling are small and should be outweighed by the integrity of the chassis following galvanising – experiences and recommendations gratefully received
  • Uprate brakes – my green Griff has grooved and drilled discs with Greenstuff pads. I think the callipers are standard. Unless I get any better ideas I will repeat as the braking is good with good feel.
  • Stainless braided hoses etc. for the brakes
  • Uprate suspension – my green Griff has Nitrons. I think they are quite old and may well need re-setting up. I don’t really have anything to compare against so suggestions gratefully received on this one
  • Polybush all round. I’ve read the pros and the cons and I think the pros outweigh the cons but they will need to be set up right. Suggestions/experiences?
  • Battery – I am planning to leave the battery where it is. I’m not that tall, 5’ 9” so it doesn’t give me or my family leg room problems but am planning to reinforce the fixings as well as drilling out the pop-rivets to the battery box cover and using rivnuts and stainless button screws – any other ideas?
  • ECU and Fuse Box – this has got to be moved, I can’t have that ECU rolling around in footwell but to where? It needs to be sensibly accessible. Behind the passenger seat seems sensible. Can anybody recommend a suitable housing for them?
  • 14CUX ECU – I’ve been following this thread but it is way beyond my knowledge and experience. I need to get into this, perhaps with the Rovergauge software and this may include re-chipping.
  • 100 Amp Fuse – I would like to move this to the under bonnet area. I also plan to upgrade the feed cables to minimise losses. Separate thread on this.
  • Fuel Pump – I was wondering whether there is a plastic cover out there to protect from water, road dirt and corrosion – something like a waterproof cable joint. Has anybody looked at this? Does the pump require airflow to cool it?
  • Brake and clutch master cylinder covers – I am planning to fabricate a cover for the brake master cylinder and re-fabricate the clutch master cylinder cover. I will fix using rivnuts and stainless button machine screws and make up gaskets either from sheet or foam silicone. I want to remove all those smears of silicone from under-bonnet. Has anybody done this and got a mould for the brake master cylinder? If not then when I’ve finished I should have a mould for both so if anybody else is interested..!
  • Gearbox – I was planning to rebuild myself. You can buy some very comprehensive T5 World Class rebuild kits
  • Differential – I would like to rebuild myself but kits don’t seem to be available. I can probably do it by buying individual bearings and oil seals and then it is down to the condition of the teeth on the various cogs
  • Engine – Get required machining done then rebuild myself. Sensible mods, probably camshafts only – suggestions?
  • Cooling system – I like those ACT stainless pipes and silicone hoses. Stainless clips and anodized hose finishers all round.
  • Radiator – not sure yet. It is currently aluminium. Probably just re-core/refurbish – 3-core
So what am I missing? Does anybody have any other modifications on their wish list? Contributions gratefully received.

I will document and take pictures of the re-build for all. Pete

spikep

468 posts

281 months

Tuesday 17th December 2013
quotequote all
If you have the outriggers replaced, make all the corner plate gaps bigger to enable easy cleaning and removal of stones. I would upload a picture but can't seem to do it from iPad (if it's possible please tell me).

swisstoni

16,845 posts

278 months

Tuesday 17th December 2013
quotequote all
Chimaera body.
xmas

GlynMo

1,140 posts

248 months

Tuesday 17th December 2013
quotequote all
swisstoni said:
Chimaera body.
xmas
You might not be able to make a silk purse out of a sow's ear, but you can make a sow's ear out of a silk purse tongue out

Podie

46,630 posts

274 months

Tuesday 17th December 2013
quotequote all
My list would add...

V8 GRF

7,294 posts

209 months

Tuesday 17th December 2013
quotequote all
7 " headlight upgrade.

Keeps the original looks, actually improves them imo as it makes the front look ;stronger' by filling the pods and the added bonus is you can actually see when you drive at night. biggrin

Pete Mac

Original Poster:

755 posts

136 months

Tuesday 17th December 2013
quotequote all
spikep said:
If you have the outriggers replaced, make all the corner plate gaps bigger to enable easy cleaning and removal of stones. I would upload a picture but can't seem to do it from iPad (if it's possible please tell me).
A good one. When you get the chance pictures would be welcome. Not sure I can help on the iPad though

swisstoni said:
Chimaera body.
xmas
I said sensible mods, I don’t think devaluing the car would be sensible…….. laugh

Podie said:
My list would add...

I shall check these all out. Side vents on the bonnet make sense. Not sure about the CliveF manifolds being available, I’ve read a lot about them and they look great
V8 GRF said:
7 " headlight upgrade.

Keeps the original looks, actually improves them imo as it makes the front look ;stronger' by filling the pods and the added bonus is you can actually see when you drive at night. biggrin
As above, makes a lot of sense.

One other thing I was going to do was to replace the bonnet stay. I’m thinking Steve Heath bonnet stay. I have some ideas but need to find a fabricator, not my top priority right now. Does anyone have a Steve Heath stay they want to sell me?

matt-man

2,665 posts

218 months

Tuesday 17th December 2013
quotequote all
Enjoy! Its a great experiance! Dont want to highjack your thread but hope this gives you some extra enthusiasm!

i'm just coming to the end of mine and its been (mostly!) great fun! Its frightening how much rust lurks beneath!!

I had my chassis zinc blasted and the powder coated...you cant really dip it as any weaknesses will fail and you need to drill loads of holes...the blasting is supposed to be super effective.

the powder coating over the top is actually unnecessary but its pretty so everyone does it. I went for red smile



The body went back on with no problems. I had the chassis work done by Southways Automotive and they were excellent - thoroughly reccomend them smile

The most upseting thing is when you put the body back it looks exactly the same... here is a before and after body off with the heavies who helped me lift the body off....WOW they are heavy!





Enjoy smile

Chilliman

11,990 posts

160 months

Tuesday 17th December 2013
quotequote all
New shiny heat shields on the inner wings? smile

cindydog3

158 posts

135 months

Tuesday 17th December 2013
quotequote all
Manual boot release to accompany electric one?

Why not battery AND fuses/relays in boot?

GlynMo

1,140 posts

248 months

Tuesday 17th December 2013
quotequote all
cindydog3 said:
Why not battery AND fuses/relays in boot?
That's only for people who don't go anywhere in their Griff, the boot's not exactly big in the first place!

anonymous-user

53 months

Tuesday 17th December 2013
quotequote all
cindydog3 said:
Why not battery AND fuses/relays in boot?
I'd consider battery behind passenger seat, and fuses behind driver's seat. If budget can stretch to it, then would replace both ECU and alarm system, which would significantly tidy up the loom and provide a reliable basis for any future upgrades.

Alexdaredevils

5,697 posts

178 months

Tuesday 17th December 2013
quotequote all
Reinforce the weakest part of the chassis around the gear stick area to stop any twist

Brembo upgrade front brakes

Braided fuel lines on a different route

Depends on budget..... How far you want to go

Pete Mac

Original Poster:

755 posts

136 months

Tuesday 17th December 2013
quotequote all
cindydog3 said:
Manual boot release to accompany electric one?

Why not battery AND fuses/relays in boot?
Should have said that I was planning to put fuses, ECU and relays
somewhere else, probably behind the seats. Still not sure about battery though but there again I've got relatively short legs and so has Mrs M.

eff eff

754 posts

203 months

Tuesday 17th December 2013
quotequote all

  • Brake and clutch master cylinder covers – I am planning to fabricate a cover for the brake master cylinder and re-fabricate the clutch master cylinder cover. I will fix using rivnuts and stainless button machine screws and make up gaskets either from sheet or foam silicone. I want to remove all those smears of silicone from under-bonnet. Has anybody done this and got a mould for the brake master cylinder? If not then when I’ve finished I should have a mould for both so if anybody else is interested..!
I would definitely buy the covers Pete

eff eff

754 posts

203 months

Tuesday 17th December 2013
quotequote all

  • Brake and clutch master cylinder covers – I am planning to fabricate a cover for the brake master cylinder and re-fabricate the clutch master cylinder cover. I will fix using rivnuts and stainless button machine screws and make up gaskets either from sheet or foam silicone. I want to remove all those smears of silicone from under-bonnet. Has anybody done this and got a mould for the brake master cylinder? If not then when I’ve finished I should have a mould for both so if anybody else is interested..!
I would definitely buy the covers Pete

eff eff

754 posts

203 months

Tuesday 17th December 2013
quotequote all

  • Brake and clutch master cylinder covers – I am planning to fabricate a cover for the brake master cylinder and re-fabricate the clutch master cylinder cover. I will fix using rivnuts and stainless button machine screws and make up gaskets either from sheet or foam silicone. I want to remove all those smears of silicone from under-bonnet. Has anybody done this and got a mould for the brake master cylinder? If not then when I’ve finished I should have a mould for both so if anybody else is interested..!
I would definitely buy the covers Pete

Pete Mac

Original Poster:

755 posts

136 months

Tuesday 17th December 2013
quotequote all
matt-man said:
Enjoy! Its a great experiance! Dont want to highjack your thread but hope this gives you some extra enthusiasm!

i'm just coming to the end of mine and its been (mostly!) great fun! Its frightening how much rust lurks beneath!!

I had my chassis zinc blasted and the powder coated...you cant really dip it as any weaknesses will fail and you need to drill loads of holes...the blasting is supposed to be super effective.

the powder coating over the top is actually unnecessary but its pretty so everyone does it. I went for red smile

The body went back on with no problems. I had the chassis work done by Southways Automotive and they were excellent - thoroughly reccomend them smile

The most upseting thing is when you put the body back it looks exactly the same... here is a before and after body off with the heavies who helped me lift the body off....WOW they are heavy!



Enjoy smile
Happy to be hijacked. Chassis looks great, can't say the same for your mates...! I'm still going for the galv. Not convinced on hot zinc spray, especially with that pile of road sh!t sitting between the body and the outriggers. To be inwardly debated over the next couple of months

Pete Mac

Original Poster:

755 posts

136 months

Tuesday 17th December 2013
quotequote all
cindydog3 said:
Manual boot release to accompany electric one?
I like it, nice one

Pete Mac

Original Poster:

755 posts

136 months

Tuesday 17th December 2013
quotequote all
eff eff said:
I would definitely buy the covers Pete
You don't need to buy, you just have to come and do your own fibreglassing but wait a few months, I'm not there yet. I will be posting when I am there...!