Terry's tale. (S3 resto ++)

Terry's tale. (S3 resto ++)

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Blue 30

Original Poster:

519 posts

117 months

Saturday 26th November 2016
quotequote all
As it was recently suggested to me that I document my (ongoing) S3 resto, here goes....
Where to start, Mmmm....

Me !
58yrs young, raised in a household where the piston rules, 42yrs in telecoms, & now recently retired.
My car based hobby breaks down into x2 main areas.
Driving & enjoying, plus being in the garage doing whatever.
Which has been so for as long as I care to remember.
And for the last 20yrs I've been pretty dedicated to Panther cars (no its not a kitcar). Where at the last count I have owned/restored x7 2.8 Kallistas, plus helping other owners projects too. You would be surprised how many similarities Kallista has with the 'S' !! So don't knock em unless you've tried one.
However lately I have got to the stage where Kallista doesn't really hold any challenges, so let's look for something new to get my teeth into.... My 'best' Kallista was one where I had taken it (engineering mods etc) to the max. But I still wanted to do more.
So what was out there (classic but also modern/old school), & suitable to be Terry-fied ?
The S seemed pretty well perfect.... (Lol).
Here's an image of one of my Kallistas (now sold).
Plus one of my S3 as purchased.
TerryB.
[url]
|http://thumbsnap.
com/iMduuo8Z[/url]

Blue 30

Original Poster:

519 posts

117 months

Saturday 26th November 2016
quotequote all
Oh, the S3 is planned to be an 'as well as' rather than an 'instead of'. Well that is, if my work pension will support both.
And don't get the idea that all I do is throw money at my projects. Or on the other hand, just bolt on someone else's clapped out, surplus parts. But I'll quickly agree with those who like/prefer 'originality', that I have been known to create a Frankenstein !!
Personally I like & appreciate both, as long as they're on the road, & out there doing it. And its my car, so I'll do with it what I want to.
TerryB.

Blue 30

Original Poster:

519 posts

117 months

Saturday 26th November 2016
quotequote all
Hi Barry..
You're most welcome, but don't expect to even walk around my garage !
As its only a modern single garage, full of broken down Tvr at the moment.
And in common with others, I just have to struggle with the space I've got. In fact I no longer see it as a problem, just something to work around... Literally.
TerryB.

Blue 30

Original Poster:

519 posts

117 months

Saturday 26th November 2016
quotequote all
Back to my tale...
And onto the purchase of...
Well, pockets checked. Mmm, not too deep, well not enough to buy a good example, but I don't want a good one anyway.
My early Tvr research revealed that I do like the 'M' models but there is no way I can afford one of those, however the S appears to have a similar style & character, & that'll do for me.
The S3 having longer doors (like Kallista does, over the Lima) will suit me. My research also imprinted on my brain, to check chassis, chassis, chassis. So off we went to look at a good car that requires a little tidying !!!!
The seats were shot, but the rest of the car was tidy, excepting the repaired hood. The 2.9 ran so so, but as I knew it would be replaced by ?? That wasn't an issue. Somehow I managed to get my little digit around the out rigger tubing, something didn't feel right, as in at least one place my finger dropped into a void.
All of these things created a mental list that I could negotiate with. Then then owner had only had the car for a few weeks, he being one of those from home traders, who had obtained the car in a bulk buy.
It had a massive file of history & receipts, so although work was required, it appeared honest & in molested.
So after a little debate, hands were shakes & it was mine.
Yes the S3 image above.
We were 100 miles or so from home, but came prepared for that.
No, it didn't break down, but my satnav quickly ran out of internal battery power (as the cars power outlet was US).
So I stuck my finger in the air, headed west until I recognised a road.
One home, over the following few weeks, we had couple of outings, including one to a local classic show.
At that point of getting to know the car, I knew enough it wasn't good enough to use 'as is', so it got parked up.
My original plan of action was to store it until I retired, some 18mths away or so at that point. But I could resist having a tinker with it, after all it wasn't going anywhere ! So once 2014 winter was over, I hatched a plan to lift the body off. Being a bit pig headed & one who prefers to do things my own way I did it on my own. Well, with a bit of over seeing from she who must be obeyed (& with rader on to make sure I cleaned up).
Oh, I hadn't been idle through the winter, as it gave me lots of thinking time.
I had informed various Panther friends of my purchase, one of which wanted first refusal on the 2.9 engine/g-box. So that was agreed. But what to replace it with....
Here's my one man body lifting kit, sorry health & safety, but its my drive, my rules.
TerryB



Blue 30

Original Poster:

519 posts

117 months

Sunday 27th November 2016
quotequote all
Cheers...
I'll get to the engine+ topic a little later into the thread.
I too had looked at the BOA & BOB engines, & came to your conclusion.
TerryB

Blue 30

Original Poster:

519 posts

117 months

Sunday 27th November 2016
quotequote all
I'm onto corrections already, sorry !!!
I must be an age thing.

Above, I said I was around 18mths away from retirement when I bought the S in 2014... That should have read 4yrs.
Plus I said I removed the S body in 2014.
I didn't, as it was late summer 2015 when I did that !
I know this because the S stood (in one piece) outside for its first year. My blue Panther being in the garage.
But later into 2014 I sold the blue panther, thinking that's now space ready for the S. Not so...
As a Panther friend told me about a low mileage but derelict 2.8 Kallista about to be sold.... Yes I bought it, so that went into the garage instead. The 2014 winter completed a mechanical resto on the Kallista ready for 2015 summer use, including a tour to the south of France. Not once did it miss a beat !
So now well into the summer of 2015, that's when I removed the body off the S.
Which in effect means I have now got x3 classics....
X1 Kallista on the drive, X1 Tvr S body on the drive, & X1 S rolling chassis in the garage. That plus a modern car, plus a works van. Good job I've got outside space.
TerryB.



Blue 30

Original Poster:

519 posts

117 months

Sunday 27th November 2016
quotequote all
So here's my first view of the chassis in full daylight.
Not such a pretty sight.


And worse on close inspection.
The good side is just rotted out.
The bad side is where some idiot had cut some 1/2 tubes and used filler to hold them in place, not a good idea or repair technique !! And those tube pieces had also rotted.
Anyway, who cares, its all going to be cut off.




Blue 30

Original Poster:

519 posts

117 months

Sunday 27th November 2016
quotequote all
Hi Barry..
Thanks for calling round & for the chat.
TerryB.

Blue 30

Original Poster:

519 posts

117 months

Sunday 27th November 2016
quotequote all
Hi guys...
Not wishing to go off topic too much.
And let this be a lesson for all...
Going down the perfection route IS great at first but soon becomes can burden. I know, I've been there.
This is my blue Kallista on the NEC Maguire's concourse stand (runner up to a mini !!). Don't get me wrong it was an accolade, & it topped off my trophy cabinet. But taking such a car out to shows etc, it soon gets a reputation which you have to live up to...
Plus not was wanting to leave it anywhere unattended.
My current gold Kallista has been much more fun to drive & own.
Here is the blue car..
TerryB




Blue 30

Original Poster:

519 posts

117 months

Sunday 27th November 2016
quotequote all
So let's get back on track & to reality !!
My better half had been a office person at a heavy metal fabricating company for years. Where she interacted with welding surly guys. On one occasion many years ago, they were offered a good deal on a mig welder. The company didn't want one.... But I did, so I do own a good reliable mig.
My skills taught by a friend who welded live gas mains !!!
Although I'm still not perfect, but an angle grinder works wonders....
I had worked out that it made sense to try to stabilise my chassis in the garage so that I could take laser measurements, & know the chassis wasn't going to move once the rot was cut away.
Its not costly but it is dirty work, & took most of the winter to complete.
And when I made a mistake, one simply grinds off the bad weld & starts again.
The chassis gained new full out riggers, and some repairs to the main chassis down tubes. Plus one new rear trailing arm tube.
That was done by welding the trailing arm solid, then cut away the rotten tube, then weld in the new one & adding new pivot brackets.
Sounds easy now, not so when it was done !!
And talking of trailing arms, one of the good points about my purchase, was that it had rust free trailing arms.
I must check my paperwork, as I suspect they had been previously changed.
Not too many photos during that stage, but here's the finished product.
Well, not quite, as I wanted it blasting clean of the old powder coating, & get it coated with a new zinc treatment ( not galv).
TerryB

Blue 30

Original Poster:

519 posts

117 months

Sunday 27th November 2016
quotequote all
Having thought about it for all of 2mins.
This isn't Wheeler Dealers, so here's a shot of my garage during its sh*t hole period.
Oh, all tube welds had sleeves inserted & plug welded in place for extra strength.
One of those B*sch lazer measuring devices is invaluable to ensure accuracy. Mine looks worse for wear now, but its done its job. $$$$$ saved & I have a great chassis.
This isn't a job for everyone to take on, but I guess you already knew that.
TerryB

Blue 30

Original Poster:

519 posts

117 months

Sunday 27th November 2016
quotequote all
Terry's tip...
Don't get doing any angle grinding at home anywhere near upvc !
I think you can guess the outcome....
If not, the least that happens is that the dust settles, then turns to rust, & leaves nice little orange spots.
Which isn't appreciated one little bit.
TerryB.

Blue 30

Original Poster:

519 posts

117 months

Monday 28th November 2016
quotequote all
Getting side tracked again...
I'm not going to mention (on a previous project) that a weld blob dropped into my shoe, I couldnt get it out quick enough, so ended up with a nice little scar on my ankle. And I didn't know I could dance so well. You don't forget things like that, so boots are now in order.
Oops I said I wouldn't mention that....
TerryB

Blue 30

Original Poster:

519 posts

117 months

Monday 28th November 2016
quotequote all
So now its the spring of 2016. The image above of the chassis on my drive is awaiting collection for it to be blasted clean of the old powder coating.
I had been informed by a mate, of a local company who do that plus they are specialists in metal coatings.
Applied Surface Treatments of Wolverhampton (Google that to know more). I agreed with them to collect, strip, zinc coat my chassis & associated parts, then deliver back to me.
Great guys & a great service.
Here's the finished and returned items.... That's better !
(Oh, no holes or corrosion revealed during the blasting)
TerryB



Blue 30

Original Poster:

519 posts

117 months

Monday 28th November 2016
quotequote all
The 'eagle eyed' of you may have noticed that the front of the chassis (rails) looks slightly different from standard !
Well, during the winter evenings after some of those after work cold garage sessions, my mind had been on the drive-train conversion rather than the resto.
As I said previously, my initial thoughts was to do yet another panther project, and it was during that period that I came across an idea to use a modern all alloy 24v V6, the Mondeo being the obvious choice. Research commensed.
Bugger, its front wheel drive.
Ah (light bulb moment) what about the Jaguar S type ?
Yep, that'll do for me. In fact its fitted into the XJ, the X350, & the F. The post 2003 engines being 3.0 240 bhp with VVT and other clever stuff.
Its a 60o Vee, so it should be okay...
To fit into the panther.
But then I had that mind shift, where I decided that this conversion was one step too far for the panther.
Step up, the S !
So once I had the S, it was obvious what I was going to use, no thought of whether it will fit in !!!
I can make it fit, and that's that.
So let's look for one. There is plenty of stock out there, but most are high mileage & stripped to the bare engine.
So I'll buy a whole car I thought. So I registered on one of those salvage auction sites.
No good, as the good cars sell for too high prices for me.
Then I noticed a guy on EB*y was selling brand new engine units. I contacted him, but they were just bare engines again. And I wanted everything as attached to an engine to make it run.... Back to the drawing board.
During more regular trawls of EB*y I saw a car salvage trader who was stripping a low mileage car. But on contact with the guy it was a X type (fwd). Our discussion included what my intentions were. Then he said, he had a rear end write-off undertakers limo..... I kid you not !!!
It was a very low mileage Jaguar X350 limo. He would just unbolt the front subframe, & I could have everything bolted to it.
That's the engine, g-box, suspension, steering, brakes.
This was a 2006 car with 1500 miles on it !!!! How could I refuse. The X350 IS rwd, but its an auto (manuals are available but a bit rare).
I bought it, then sold on everything except the engine.
This meant I have virtually paid nothing for the engine !!
It was complete with all of its ancillaries, plus the engine bay wiring loom. Perfect.
Oh. And that's why I did the chassis mods. Especially as I had saved a single image of what appeared to be a modern 24 valve engine in a Tvr chassis.
And at that time I didn't know anything more, but that image was precious. I later learned that this was Damian (who is part of the PH 'S' fraternity).
Many thanks to Damian since for a few more images, support & encouragement.
TerryB.

My engine as delivered...

Blue 30

Original Poster:

519 posts

117 months

Monday 28th November 2016
quotequote all
Of course, as I didn't need the engine at the moment, the best thing I can do is dispatch it to my dedicated parts storage facility (aka the garden shed).
But I didn't have a manual g-box !
Fortunately, during those hours of internet searching for the engine, I had seen a local trader (who buys bulk surplus parts of any description), that he had a brand new Getrag221 box for sale ( that's the correct red 5-speed unit). However that was weeks ago. Anyway I gave him a call. It turned out that he bought a stillage of these g-boxes from ?? He said (I believe him) that they were part of the JLR clear out of the Ford ownership era parts.
The truth is, is that these g-boxes were obviously thrown into the stillage. And what he had left were all damaged, but he would bring me x4 of the best to view... At a carpark, out of the back of his van, overlooked by a police station... You had to be there to believe it !!
Anyway, the outcome was that one had only broken sensors on it, and another had a cracked lug. So I bought both.
The sensors were swopped over from the cracked lug box, & hey presto I have a perfect box, brand new/never had oil in it. The other, I took to a welding specialist where the lug was repaired for 40quid.
You know what's coming next..... I sold that box on for the same price that I had played for both of them. Another part for the shed.
But now I need a clutch assembly, including flywheel !!!
And anything with a Cat stamped on it costs loads....
More searching required.
TerryB

Blue 30

Original Poster:

519 posts

117 months

Monday 28th November 2016
quotequote all
I hate auto spell correcting... Grrr !
Above posting...
Red = RWD
Played = payed
TerryB

Blue 30

Original Poster:

519 posts

117 months

Tuesday 29th November 2016
quotequote all
Cheers.
But remember, its not just the challenge of achieving such.
Its the responsibility and effort to maintain it....
It took me around 5yrs to climb that mountain, I stayed up there for another 10, then came back down.
My S resto & conversion is a new mountain !!
TerryB

Blue 30

Original Poster:

519 posts

117 months

Tuesday 29th November 2016
quotequote all
Back on topic...
The Jag S-type clutch is of DMF design (read stupid dual mass flywheel).
And because my engine had an auto box, I need everything including the flywheel to add a manual clutch.
Morgan used this engine in its roadster, but used a type9 g-box. But because the AJ-V6 engine has a unique bell housing pattern Morgan had bell housings made (no longer available). But from past experience, I don't think the T9 in standard form is up to the job of the AJ engine. So I didn't want to do that anyway. Then there's the kitcar guys, some have fitted MX5 6-speed boxes, but yet again lots to deal with in conversion terms.
My intention is to retain as many 'stock' parts as possible (as that should make life easier in years to come). So the Jag box & clutch gets fitted !
DMF flywheels are horrendous money on their own. And no better when bought as a full assembly.
Lady luck appeared again, that I won a brand new flywheel for about 1/2 retail via that auction site...
The clutch assembly was even a better buy, but I could only go into that verbally (no I didn't steal it).
So I have a drivetrain now, well that is except the propshaft, but that won't get custom made until the engine & box gets installed into the chassis.
Ah, onto the diff...
My resto (as others have done before me) just replaces like for like where required. And I'm doing the same... Mostly !
The Jag Getrag221 5th gear is lower than the T9, so if I left the 3.6 diff in, it would be a great sprint car, but not so good for touring.
Sierra did make a 3.14 diff but its a 7" not 7.5".
I found & bought one, although it was for push-in driveshafts, but it can be converted to flange type.
I talk to SierraRus. They have a complete 3.14 assembly already made up, & even better its had LSD added too. The original purchaser had dropped out. So I did a deal to include part-ex of my original S diff and the 3.14 that I had bought.

I'll talk about the installation of the new diff etc later.
TerryB.

Blue 30

Original Poster:

519 posts

117 months

Wednesday 30th November 2016
quotequote all
Sorry...
I'll announce when I get on my soapbox again.
TerryB.