I hate Spongy & Scotty thread (Peters Project )
Discussion
Initially my project was to refresh the steering as it had become a bit notchy,but that was only the start, the more i dug the deeper it has gotten. But I keep saying to myself it will be worth it in the end. As i do shift work i get a good set of four or five days straight on doing the bits to it, except this Monday with having to do rear springs and shocks on the girlfriends KA, but got that done and have been doing bits on and off over the last month or three, thinking about it i started before it showed. I polybushed all the suspension last year, but the deeper i have dug the more i want perfect, so all the suspension has been removed, and is currently being sand blasted and will be powder coated
So new track rod ends, painted and now fitted
Also removed all the coolant hoses and water pipes water rails and other than the hoses will be making my own water rails and pipes.
Made chassis out rigger guards to protect them getting sand blasted from the tyres these are now complete and ready to fit, just mounting holes need drilling. Started with a card template, then plasma cut them at work and folded
What my guards will be protecting, the metal is all solid, but will be stripped back and repainted and protected for the future
Thought i would give my calipers a fresh look, but wasn't happy with the finish, so got my spare set out and just went with black.
Front calipers are now done and will have stainless braided hoses.
One side of the front suspension, currently being refinished.
Also completed the welds on one of the drag links, shows before
I have moved the dipstick and redone the oil breather hose for better access
This is the hose joiner i made for the oil breather
I had the steve heath drop links for about a year or just a little bit more and they were seized solid so had to machine one end as the rose joint had sheared, and have fitted high performance stainless steel racing ones. You can feel the difference in them
Also added boots to protect them, something i never originally fitted, i have suggested to steve about included them in the price of the drop links
My car is an 04, with the chassis date of 03, but the surface rust where the powder coat has failed is horrible, so another good reason to tackle all this now
I've replaced all the cable heat shielding, mocal sell it for about £18 enough to do all the main battery cables, did get some on ebay at first and was £79, this stuff is the same, so very pleased to send it back to get my money back
Lots of brackets that i didn't know existed like the ones that hold the condenser to the car, so may get these remade in stainless, have found a laser cutting place near me which have made me some flanges, which you'll see later
Removed the rad, give me better access for painting and will add new waterproof plugs
Was easier to get out by removing the bigger of the two fans
One side of the engine bay heat shield has failed so got new, same stuff on racing greens website, but half the price
Bucket of powder coat remover, it works but needs to be left on as long as possible. I have also brought a compressor and sand blasting kit so can get all the hard to reach places removed of rust
Water rails have been removed to replace with new ones made my me
flanges for the water rails
I have an SPA dual gauge to install, this shows the boss for the water temp gauge
I'm going to drill the oil filter blank for oil temp gauge when i order one, you can by them ready done from mocal, but save a bit doing it myself.
Also have a oil stat to fit, so need to remove the oil hoses and get some made up either i'll do them at work has we have the hose and crimping machine, or use reusable ends.
So i have lots and lots to do, no end in sight at the minute, my aim is the may car show at duxford but that would only be the front end, but may say fook it and do everything this year and enjoy the car next year. we will see what happens.
Peter
So new track rod ends, painted and now fitted
Also removed all the coolant hoses and water pipes water rails and other than the hoses will be making my own water rails and pipes.
Made chassis out rigger guards to protect them getting sand blasted from the tyres these are now complete and ready to fit, just mounting holes need drilling. Started with a card template, then plasma cut them at work and folded
What my guards will be protecting, the metal is all solid, but will be stripped back and repainted and protected for the future
Thought i would give my calipers a fresh look, but wasn't happy with the finish, so got my spare set out and just went with black.
Front calipers are now done and will have stainless braided hoses.
One side of the front suspension, currently being refinished.
Also completed the welds on one of the drag links, shows before
I have moved the dipstick and redone the oil breather hose for better access
This is the hose joiner i made for the oil breather
I had the steve heath drop links for about a year or just a little bit more and they were seized solid so had to machine one end as the rose joint had sheared, and have fitted high performance stainless steel racing ones. You can feel the difference in them
Also added boots to protect them, something i never originally fitted, i have suggested to steve about included them in the price of the drop links
My car is an 04, with the chassis date of 03, but the surface rust where the powder coat has failed is horrible, so another good reason to tackle all this now
I've replaced all the cable heat shielding, mocal sell it for about £18 enough to do all the main battery cables, did get some on ebay at first and was £79, this stuff is the same, so very pleased to send it back to get my money back
Lots of brackets that i didn't know existed like the ones that hold the condenser to the car, so may get these remade in stainless, have found a laser cutting place near me which have made me some flanges, which you'll see later
Removed the rad, give me better access for painting and will add new waterproof plugs
Was easier to get out by removing the bigger of the two fans
One side of the engine bay heat shield has failed so got new, same stuff on racing greens website, but half the price
Bucket of powder coat remover, it works but needs to be left on as long as possible. I have also brought a compressor and sand blasting kit so can get all the hard to reach places removed of rust
Water rails have been removed to replace with new ones made my me
flanges for the water rails
I have an SPA dual gauge to install, this shows the boss for the water temp gauge
I'm going to drill the oil filter blank for oil temp gauge when i order one, you can by them ready done from mocal, but save a bit doing it myself.
Also have a oil stat to fit, so need to remove the oil hoses and get some made up either i'll do them at work has we have the hose and crimping machine, or use reusable ends.
So i have lots and lots to do, no end in sight at the minute, my aim is the may car show at duxford but that would only be the front end, but may say fook it and do everything this year and enjoy the car next year. we will see what happens.
Peter
Have a look on the Mocal website Scott. May have to search within the website as I think it's any other or accessories. I put heat shrink on the ends to prevent water getting in. The size was 14mm. Have fun getting the old stuff off. I'm still finding bits in my hand.
I'm also thinking of moving the big fuse. But not sure where to move it to for better access? Any ideas people
I'm also thinking of moving the big fuse. But not sure where to move it to for better access? Any ideas people
Been cracking on and made some good progress so far.
Getting new airbox brackets made after drawing them on a free cad program i found. hopefully see them this week
Had some parts in the rust removing tank at work and works great, got some more stuff to go in tomorrow. Had my front disks in it and they come out as good as new, although the tank was clean when they went in, rather dirty now.
Made some improvements to my jig for the water rails
Should allow me to get the angles correct
Made the bosses for the water rails on the lathe, they are 1/4 bsp if any one every needs to know.
Finished both the water manifold pipes, just need to pressure test them now and weld up any pin holes in the welds
Powder coat stripper doing its thing on the caliper that i painted yellow and didn't like, will paint in when i have finished the car since i'm putting my spare new ones on.
Both engine mounts off to re paint once all the rust has been removed.
New toy to help me
TO go with my new toy i made a blasting cabinet, the only cost was the perpex for the window, everything else was to hand.
Crack in my drivers side manifold
The welding on the manifolds is shocking
Passengers outrigger, surface rust, nearly all removed. funny that the passenger side has suffered yet the drivers is perfect
And nearly removed all the powder coat on the passenger side, dremel is great for getting in places, the powder coat remover softens it enough to be able to scrap it off then clean up with a handy sander and the dremel
Thats it for now, but hoping to get done before may and if any luck maybe chats, the rear is in much better condition, when i done the suspension last year it was really clean compared to the front so may do that later on in the year. really miss driving it now with such good weather
Getting new airbox brackets made after drawing them on a free cad program i found. hopefully see them this week
Had some parts in the rust removing tank at work and works great, got some more stuff to go in tomorrow. Had my front disks in it and they come out as good as new, although the tank was clean when they went in, rather dirty now.
Made some improvements to my jig for the water rails
Should allow me to get the angles correct
Made the bosses for the water rails on the lathe, they are 1/4 bsp if any one every needs to know.
Finished both the water manifold pipes, just need to pressure test them now and weld up any pin holes in the welds
Powder coat stripper doing its thing on the caliper that i painted yellow and didn't like, will paint in when i have finished the car since i'm putting my spare new ones on.
Both engine mounts off to re paint once all the rust has been removed.
New toy to help me
TO go with my new toy i made a blasting cabinet, the only cost was the perpex for the window, everything else was to hand.
Crack in my drivers side manifold
The welding on the manifolds is shocking
Passengers outrigger, surface rust, nearly all removed. funny that the passenger side has suffered yet the drivers is perfect
And nearly removed all the powder coat on the passenger side, dremel is great for getting in places, the powder coat remover softens it enough to be able to scrap it off then clean up with a handy sander and the dremel
Thats it for now, but hoping to get done before may and if any luck maybe chats, the rear is in much better condition, when i done the suspension last year it was really clean compared to the front so may do that later on in the year. really miss driving it now with such good weather
It's work doing Steve. Strip it all down doesnt take long to be fair. Get the wish bones etc shot blasted and re powder coated then whilst your waiting on your engine get the chassis welded and and either strip and repaint or just paint the bits that need doing
Best way of getting rid of the powder coat is a handy sander. Gets through it easy
Best way of getting rid of the powder coat is a handy sander. Gets through it easy
Bit of an update
Made a stainless steel battery bracket, one less thing to rust in the future, just need to add a stainless bolt to finish it off
I've welded up the crack in the exhaust, also had a good look and found what i think were a couple more so ground them out and reweld. The actual welding on the exhaust is erm to put it "Crap", don't think its a repair but Christ is crap
Managed to wrap one of the manifolds, just got to do the other side now, and the cable ties were temporary to get the wrap right before the proper metal ties.
Cleaned up more of the chassis, including sand blasting the outriggers, and where the end mount sits, and primed them, need to finish up this area, only primed the areas that where completely fnished, totally free from rust, i know in my heart that i'm not going to get it completely perfect and that will be when the time comes to do a body off, but for now this work will prolong the life or the chassis before more major repairs need to be carried out, hope i have a garage by then
Today i managed to clean up some of the spacers, engine mounts, and few little bits in my home made tank and ebay grit gun, doing a very good job so far, just need to find a platers for the spacers to be done again.
Booked easter off so got two weeks in total to get lots more done. Go see the powder coaters tomorrow and hopefully my stuff will be ready.
Made a stainless steel battery bracket, one less thing to rust in the future, just need to add a stainless bolt to finish it off
I've welded up the crack in the exhaust, also had a good look and found what i think were a couple more so ground them out and reweld. The actual welding on the exhaust is erm to put it "Crap", don't think its a repair but Christ is crap
Managed to wrap one of the manifolds, just got to do the other side now, and the cable ties were temporary to get the wrap right before the proper metal ties.
Cleaned up more of the chassis, including sand blasting the outriggers, and where the end mount sits, and primed them, need to finish up this area, only primed the areas that where completely fnished, totally free from rust, i know in my heart that i'm not going to get it completely perfect and that will be when the time comes to do a body off, but for now this work will prolong the life or the chassis before more major repairs need to be carried out, hope i have a garage by then
Today i managed to clean up some of the spacers, engine mounts, and few little bits in my home made tank and ebay grit gun, doing a very good job so far, just need to find a platers for the spacers to be done again.
Booked easter off so got two weeks in total to get lots more done. Go see the powder coaters tomorrow and hopefully my stuff will be ready.
Going to see a anodisers tomorrow to have my front hubs and caliper spacers anodised blue. Little things that help corrosion. Few spacers to make at work out of stainless again stop things rusting. Just need to find a local platers although may get a home kit for some of the suspension spacers. Laser cutters tomorrow for chassis guards and see if my suspensions been powder coated. Then snow forecasted this week which is very annoying
Well thanks to the lovely drought I haven't really been able to do much in the way of chassis prep. Also as I work for tube lines I've been on strike so not been able to get anything like welding my pipes up done.
Welded up the other exhaust manifold cracks. Started wrapping it then ran out of wrap so had to order some more
Pulled through the cabling for the sensors of the dual gauge. Managed to get the capillary gauge out in one and not broken
Order a oil temp gauge from speedy cables and have fitted this in the hole for the clock
Finished wiring them in today and powered them up to check them, all done except the sensors
Collected my hubs and calliper spacers from the aluminium finishers. £30 well spent
Shame that they have suffered from some corrosion already but given 8 years on the car is pretty good. New layer of protection
I was under the impression that they were helicoiled but they aren't.
Also getting a new steering wheel badge made. Noticed the production one was off centre so thought why not.
Got all my bits back from the powder coaters so all the main parts are ready. Just not the chassis. Hopefully may will bring better weather
Welded up the other exhaust manifold cracks. Started wrapping it then ran out of wrap so had to order some more
Pulled through the cabling for the sensors of the dual gauge. Managed to get the capillary gauge out in one and not broken
Order a oil temp gauge from speedy cables and have fitted this in the hole for the clock
Finished wiring them in today and powered them up to check them, all done except the sensors
Collected my hubs and calliper spacers from the aluminium finishers. £30 well spent
Shame that they have suffered from some corrosion already but given 8 years on the car is pretty good. New layer of protection
I was under the impression that they were helicoiled but they aren't.
Also getting a new steering wheel badge made. Noticed the production one was off centre so thought why not.
Got all my bits back from the powder coaters so all the main parts are ready. Just not the chassis. Hopefully may will bring better weather
With the weather not being so kind, i'm still working on getting the cerbera back together. Not long now and should be ready for the uxbridge show next week then the silverstone classic the week after, well thats the plan.
Started making new water rails. currently still welding these up so have used my originals for now until i have finished them
Made some stainless spacers for the ARB bolts on the top wishbone, one less thing to start rusting
Bit of sewing when the weather was rubbish, had the fabric badges for ages so thought time to use them on my new mats
More on the water rails
Managed to get the front primed ready for painting
adapter for the oil pressure sender for the SPA gauge. due to the new sensor i had to lift the coil packs up 10mm, so had a new coil plate laser cut and i welded on some threaded spacers.
New steering wheel centre
Chassis painted,
Although i have removed the original dual gauge for the SPA i have kept the fittings so can be replaced. i managed to remove the capillary without breakage so is very much usable
New UJ's, the thing that started the whole project
New track rods, i brought the longer ones when i needed the shorter, so cut them down and added some thread, M14 X 2.0 for reference
New heat shielding in the engine bay to replace the old stuff that had fallen apart
Powder coated bracket and cabling redone
Whilst i did start making new water manifolds and did finished them, when i leak tested them they needed attention, so will be going back to these in the future, but purchased the ACT ones, had to make an adapter for the sensor, turned out to be 5/8 unf for the 1/8th NPT sensor, luckily had the taps at work
All new oil lines, for the oil stat
Sandwich plate for the oil temp sensor
Not much access to the oil cooler, but got there in the end with a cut of spanner
Dual SPA gauge
Had new airbox brackets laser cut, i designed them on CAD and got them cut.
Exhausts wrapped and old water rails
Getting it all back together
Nearly there, just need top wish bones, some of the hoses to finish, oil change then test/MOT/tracking
Not that you'll see them, but made new hub back plates, ad scribed TVR into them, then anodized, amazing the local trades you find, pretty much covered for all my engineering needs that i can't do at work.
Thats it for now, hopefully on the road next week, although i checked my clutch fuild the other day and was empty, not sure if its to do with the car at the angle nose up, but one on the deck again will check it again and try bleeding it if needed. other wise. My next project will be with the master or slave, but i really hope not.
Peter
Started making new water rails. currently still welding these up so have used my originals for now until i have finished them
Made some stainless spacers for the ARB bolts on the top wishbone, one less thing to start rusting
Bit of sewing when the weather was rubbish, had the fabric badges for ages so thought time to use them on my new mats
More on the water rails
Managed to get the front primed ready for painting
adapter for the oil pressure sender for the SPA gauge. due to the new sensor i had to lift the coil packs up 10mm, so had a new coil plate laser cut and i welded on some threaded spacers.
New steering wheel centre
Chassis painted,
Although i have removed the original dual gauge for the SPA i have kept the fittings so can be replaced. i managed to remove the capillary without breakage so is very much usable
New UJ's, the thing that started the whole project
New track rods, i brought the longer ones when i needed the shorter, so cut them down and added some thread, M14 X 2.0 for reference
New heat shielding in the engine bay to replace the old stuff that had fallen apart
Powder coated bracket and cabling redone
Whilst i did start making new water manifolds and did finished them, when i leak tested them they needed attention, so will be going back to these in the future, but purchased the ACT ones, had to make an adapter for the sensor, turned out to be 5/8 unf for the 1/8th NPT sensor, luckily had the taps at work
All new oil lines, for the oil stat
Sandwich plate for the oil temp sensor
Not much access to the oil cooler, but got there in the end with a cut of spanner
Dual SPA gauge
Had new airbox brackets laser cut, i designed them on CAD and got them cut.
Exhausts wrapped and old water rails
Getting it all back together
Nearly there, just need top wish bones, some of the hoses to finish, oil change then test/MOT/tracking
Not that you'll see them, but made new hub back plates, ad scribed TVR into them, then anodized, amazing the local trades you find, pretty much covered for all my engineering needs that i can't do at work.
Thats it for now, hopefully on the road next week, although i checked my clutch fuild the other day and was empty, not sure if its to do with the car at the angle nose up, but one on the deck again will check it again and try bleeding it if needed. other wise. My next project will be with the master or slave, but i really hope not.
Peter
whilst it has been a great learning curve and fun doing it and seeing the results, its been very frustrating doing it out side, waiting for good weather, dodging showers, getting wet. think the rest of the car can wait till i get a garage. luckily when i rebushed it and done the diff bushes last year the rear was in better condition then the patches of rust on the front out riggers so should be okay to leave for a few years yet.
She's all back together now. Fired up first time. Although need a new battery. Took it for an mot not a Tvr friendly place and would have failed on the handbrake and emissions so got the handbrake to adjust slightly today. As for the emissions it melted his probe. It's over fueling a bit so going to look into this today also.
scotty_d said:
Question for you Peter in Regards to your Water Level Circuit on the expansion Tank. I had an Indecent some fool cross threaded the expansion cap after cheacking the Level before going for a drive 
First traffic I hit it dumped 8l of coolant before i could pull over. It never seen over 90 degrees so was very lucky.
Your idea is Great, I was just wondering how you have wired it all in have you tied it in to the Ignition or is it Permanent live? Is the Sensor in the Tank it's self or did you have to buy on and fit it?
Cheers Scotty
The sensor is in the bottle itself. But i haven't wired it in completely, but have the leads into the car should i want to. As others have said most cerb's seem to run with the coolant under the level line, so feel the sensor wouldn't work very well, and having observed mine recently it is the same, so would be always going off. Given it was designed for another vehicle where the cooling system probably needs that amount up there, but the cerb seems much differentFirst traffic I hit it dumped 8l of coolant before i could pull over. It never seen over 90 degrees so was very lucky.
Your idea is Great, I was just wondering how you have wired it all in have you tied it in to the Ignition or is it Permanent live? Is the Sensor in the Tank it's self or did you have to buy on and fit it?
Cheers Scotty
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