Terry's tale. (S3 resto ++)
Discussion
Hi...
If you look at the photo of my Blue 'S' on page4, that's when I refitted the body. So since then, all engine fitting work including designing & fabricating the exhaust manifolds has been done with the body on. The closest the exhaust manifolds piping gets is about 1/2" (13mm) inside of any chassis tubing. I have left the original heat proofing matting that was/is on the body/engine bulkhead side walls, plus I have over covered that with sheet aluminium, the type that ventilation/air-conn guys use on buildings. So that should be enough to protect the GRP, if that's what you were concerned about ?
The manifolds will connect to the original centre positioned large tubular silencer, so the ground clearance remains no closer to the ground than the original layout, plus it no longer runs under the engine.
TerryB
If you look at the photo of my Blue 'S' on page4, that's when I refitted the body. So since then, all engine fitting work including designing & fabricating the exhaust manifolds has been done with the body on. The closest the exhaust manifolds piping gets is about 1/2" (13mm) inside of any chassis tubing. I have left the original heat proofing matting that was/is on the body/engine bulkhead side walls, plus I have over covered that with sheet aluminium, the type that ventilation/air-conn guys use on buildings. So that should be enough to protect the GRP, if that's what you were concerned about ?
The manifolds will connect to the original centre positioned large tubular silencer, so the ground clearance remains no closer to the ground than the original layout, plus it no longer runs under the engine.
TerryB
Blimey was it really the 14th Dec 2016 when I did my last posting !!!
The reason being that around that time, my dads health took a turn for the worse, and passing away in Feb this year. So with that, & then dealing with his estate the year has just flown by.
In car terms, I have totally finishing the restoration of my latest Panther Kallista 2.8, which was a great distraction at times. Especially going out to shows etc. Which as you might guess, any progress on the S has been minimal. Other than completing the fabrication of the ancillaries brackets, including designing an adjustment facility of the drive belt. Over the last few weeks I have been tapping out & labelling the Jag engine loom, fitting the Emerald Ecu & doing the same with its loom. The 2 ends are now ready to be mated together.
But instead of getting on with that job, being as the winter is rapidly approaching, I don't want the shiny Kallista left outside in the cold !!
My garage is located in the front garden, of which can't be extended in either width or length. But what about going up ??
The roof was made up of engineered trusses, so I have converted those to a vaulted roof (under approval of a structural engineer). And now I've bought a 4-post lift (Automotech), currently laid out on the floor, but should be in situ this week. Then the Kallista can go up, and the Tvr will slot in below it. And if I've got things right, I should still be able to carry on with the wiring work etc, although I might need a hardhat when I've hit my head a few times !!
Is it too early to wish you all "a very merry Xmas" ?
Oh well, I've done it now...
TerryB.
The reason being that around that time, my dads health took a turn for the worse, and passing away in Feb this year. So with that, & then dealing with his estate the year has just flown by.
In car terms, I have totally finishing the restoration of my latest Panther Kallista 2.8, which was a great distraction at times. Especially going out to shows etc. Which as you might guess, any progress on the S has been minimal. Other than completing the fabrication of the ancillaries brackets, including designing an adjustment facility of the drive belt. Over the last few weeks I have been tapping out & labelling the Jag engine loom, fitting the Emerald Ecu & doing the same with its loom. The 2 ends are now ready to be mated together.
But instead of getting on with that job, being as the winter is rapidly approaching, I don't want the shiny Kallista left outside in the cold !!
My garage is located in the front garden, of which can't be extended in either width or length. But what about going up ??
The roof was made up of engineered trusses, so I have converted those to a vaulted roof (under approval of a structural engineer). And now I've bought a 4-post lift (Automotech), currently laid out on the floor, but should be in situ this week. Then the Kallista can go up, and the Tvr will slot in below it. And if I've got things right, I should still be able to carry on with the wiring work etc, although I might need a hardhat when I've hit my head a few times !!
Is it too early to wish you all "a very merry Xmas" ?
Oh well, I've done it now...
TerryB.
Here where I'm at today 14/02/18.
The 4-post lift is in, & the top bunk is occupied by the Panther Kallista for the winter period. I was just about able to use the top notch on the lift, so that leaves me about 3" to bump my head when working on the S. More if I climb aboard, but you only do it once... Or twice.
I have attached an led string under one of the platforms which gives me decent lighting, plus side mounted wall strip lights.
As I'm working on the wiring now (engine side & under the dash both sides) I have removed the nearside door, which makes access nearly as good as being outside, only slightly warmer.
Hopefully around Easter the Panther will be ejected, & the S will go on the lift so that I can do the under car wiring, fuel lines, pump, tank, gear linkage, prop shaft, etc etc.
Only once again I've been distracted !! As I'm now helping with the brother in laws new house purchase modernisation...
TerryB.
The 4-post lift is in, & the top bunk is occupied by the Panther Kallista for the winter period. I was just about able to use the top notch on the lift, so that leaves me about 3" to bump my head when working on the S. More if I climb aboard, but you only do it once... Or twice.
I have attached an led string under one of the platforms which gives me decent lighting, plus side mounted wall strip lights.
As I'm working on the wiring now (engine side & under the dash both sides) I have removed the nearside door, which makes access nearly as good as being outside, only slightly warmer.
Hopefully around Easter the Panther will be ejected, & the S will go on the lift so that I can do the under car wiring, fuel lines, pump, tank, gear linkage, prop shaft, etc etc.
Only once again I've been distracted !! As I'm now helping with the brother in laws new house purchase modernisation...
TerryB.
Edited by Blue 30 on Wednesday 14th February 23:01
Ah, tis 19/05/18 now.
The Panther is out there now being used in this luverly weather we're enjoying at the mo. And since my last posting I have been getting on with the S.
Boy have I had enough of fabricating custom brackets, but it is amazing what you can do with a welder, a grinder, and bits of mild steel !!
All of the ancillaries are now bolted in place, unique both to suit the S and the Jag engine.
On photo1, the alternator is bottom right, the pas pump is bottom left, x2 new idler wheels one with belt adjustment, and the idle air valve top right.
Photo2 shows the new gear selector linkage, yet to be adjusted to suit the driver (me) !
The 3rd photo is where I'm currently at with the exhausts. I will be using the 'standard' single silencer & twin outlet arrangement.
All of the ecu wiring is done, but with a fair few surplus wires still hanging about on the Jag engine loom, not required as they are foir such things as the cat sensors, variable pas, fly by wire throttle etc. I haven't cut them away yet, as I might be able to re use some of them (too late once cut off).
My neighbour has dropped a few serious hints now for my bonnet to be moved from his garage, so I am getting ready to implement my version of the wide open
bonnet mod. Oh, I'm also 1/2 way through doing the steering column refurb & bearing mod, plus a new Ford brake servo & ms, so I suppose I had better complete those next....
TerryB.
The Panther is out there now being used in this luverly weather we're enjoying at the mo. And since my last posting I have been getting on with the S.
Boy have I had enough of fabricating custom brackets, but it is amazing what you can do with a welder, a grinder, and bits of mild steel !!
All of the ancillaries are now bolted in place, unique both to suit the S and the Jag engine.
On photo1, the alternator is bottom right, the pas pump is bottom left, x2 new idler wheels one with belt adjustment, and the idle air valve top right.
Photo2 shows the new gear selector linkage, yet to be adjusted to suit the driver (me) !
The 3rd photo is where I'm currently at with the exhausts. I will be using the 'standard' single silencer & twin outlet arrangement.
All of the ecu wiring is done, but with a fair few surplus wires still hanging about on the Jag engine loom, not required as they are foir such things as the cat sensors, variable pas, fly by wire throttle etc. I haven't cut them away yet, as I might be able to re use some of them (too late once cut off).
My neighbour has dropped a few serious hints now for my bonnet to be moved from his garage, so I am getting ready to implement my version of the wide open
bonnet mod. Oh, I'm also 1/2 way through doing the steering column refurb & bearing mod, plus a new Ford brake servo & ms, so I suppose I had better complete those next....
TerryB.
Hi Damian...
My engine unit is a 2006 spec (with only 1200 miles recorded) so has the later type inlet manifold including IMTs. These are plumbed into the ecu. I bought an unbranded 65mm TB, it just needed the fixing holes modifying a little. Original Jag fbw tb was 60mm-ish, Ford 3.0 duratec used 62mm, with popular modified tb's being 65mm, so that's why I used that one, as it'll keep air velocity good (on standard cams).
As my car on purchase had a decent condition s-steel exhaust system, I plan to reuse the silencer & tail pipes. The silencer is twin in & twin out. Probably like you, I have no idea what it will sound like, or if acceptable to my (already degrading) hearing ! Or what power it gains/looses.
My master plan LOL, is that sometime in the autumn (say Oct) I will do an initial fire up, then carry on with the resto (brakes, pas, interior, hood, other mods, etc etc) through the winter (at my retired lazy pace). And get it to move under its own power. & get it road legal finished in the spring/summer 2019. After that we'll get some local miles on it, to gain confidence, reliability etc. With a second master plan to do an open ended Euro tour in 2020, following the coastline from northern Spain, Portugal, France, to at least the Amalfi, Italy, then head north slowly heading home via Austria, Germany, Netherlands.
Phew !!
TerryB.
My engine unit is a 2006 spec (with only 1200 miles recorded) so has the later type inlet manifold including IMTs. These are plumbed into the ecu. I bought an unbranded 65mm TB, it just needed the fixing holes modifying a little. Original Jag fbw tb was 60mm-ish, Ford 3.0 duratec used 62mm, with popular modified tb's being 65mm, so that's why I used that one, as it'll keep air velocity good (on standard cams).
As my car on purchase had a decent condition s-steel exhaust system, I plan to reuse the silencer & tail pipes. The silencer is twin in & twin out. Probably like you, I have no idea what it will sound like, or if acceptable to my (already degrading) hearing ! Or what power it gains/looses.
My master plan LOL, is that sometime in the autumn (say Oct) I will do an initial fire up, then carry on with the resto (brakes, pas, interior, hood, other mods, etc etc) through the winter (at my retired lazy pace). And get it to move under its own power. & get it road legal finished in the spring/summer 2019. After that we'll get some local miles on it, to gain confidence, reliability etc. With a second master plan to do an open ended Euro tour in 2020, following the coastline from northern Spain, Portugal, France, to at least the Amalfi, Italy, then head north slowly heading home via Austria, Germany, Netherlands.
Phew !!
TerryB.
To V8S4ME.
For our eurotour we plan to not plan too much, & wing it as much as we can.
We have done plenty of euro tours before, usually to one country per holiday, so this (in theory) will be just linking those together... Ha !
I guess she who must be obeyed will ensure some strategically placed decent hotels will be pre booked, but eurocamp & canvas holidays do good options too.
Oh, based on what Damian has said about the power of the AJ30 (so that I can swerve the blame)... Only if you can keep up....
TerryB.
For our eurotour we plan to not plan too much, & wing it as much as we can.
We have done plenty of euro tours before, usually to one country per holiday, so this (in theory) will be just linking those together... Ha !
I guess she who must be obeyed will ensure some strategically placed decent hotels will be pre booked, but eurocamp & canvas holidays do good options too.
Oh, based on what Damian has said about the power of the AJ30 (so that I can swerve the blame)... Only if you can keep up....
TerryB.
To Damian...
Thanks. Interesting on the exhaust note, I had surmised that with only one medium sized silencer it was going to be loud... Very Tvr !!
As I'm doing the full resto, plus the drive train swop, plus most of the sensible mods you guys have already done, plus my own Terry-isms, I have to have focus on whatever I'm doing on that day/session. Which means I do 'park' thoughts of 'what about'... 'how to' etc etc, until I actually get around to that job.
At the moment that includes the fine mapping of the ecu. I'm using an Emerald K6, of which has been pre mapped, as Dave Walker informed me that he has done the AJ30 before. Obviously it will need tweeking to suit my installation, plus our discussion included that they didn't use an IAV. But I've dealt with that before. Plus I have an Innovate data logger.... To have a play myself first.
But eventually it will go on a rolling road, to confirm & lock everything down.
I don't have any PDF info so would be grateful for any useful info....
As it saves buying too many rolls of wallpaper.
044 copy already bolted in, thanks.
Keep the info coming... Cheers.
TerryB.
Thanks. Interesting on the exhaust note, I had surmised that with only one medium sized silencer it was going to be loud... Very Tvr !!
As I'm doing the full resto, plus the drive train swop, plus most of the sensible mods you guys have already done, plus my own Terry-isms, I have to have focus on whatever I'm doing on that day/session. Which means I do 'park' thoughts of 'what about'... 'how to' etc etc, until I actually get around to that job.
At the moment that includes the fine mapping of the ecu. I'm using an Emerald K6, of which has been pre mapped, as Dave Walker informed me that he has done the AJ30 before. Obviously it will need tweeking to suit my installation, plus our discussion included that they didn't use an IAV. But I've dealt with that before. Plus I have an Innovate data logger.... To have a play myself first.
But eventually it will go on a rolling road, to confirm & lock everything down.
I don't have any PDF info so would be grateful for any useful info....
As it saves buying too many rolls of wallpaper.
044 copy already bolted in, thanks.
Keep the info coming... Cheers.
TerryB.
Update as of today 28/06/18
Fuel tank stripped of sump plug, gauge sender, and the in tank filter (which was as clean as a whistle), its not going back in so shout if you want it. I washed the tank out, again no debris. Then checked it over & scrapped the outside clean. As I had some Por15 tank sealant paint left over, I painted the outside of the tank with it, finished off with my Blue chassis paint. The sump plug refitted with a new seal & ring. A new Landrover disco gauge sender adjusted to suit & fitted, again using a new seal & ring.
The tank is a bit of a bugger to reinstall when the car is on a four-post lift and you're doing things on your own! Anyway its back in.
New big bore pipe from tank to new pump, plus i have fitted a before the pump in line filter, and a new after pump filter.
I have reused the plastic fuel lines, but with new R9 rubber ends to suit the yet to be fitted layout in the engine bay.
Having decided to re site the battery into the boot (drivers side) plus having loads of surplus 25mm2 cable lying about. I have now run in the main +Ve battery to starter motor & alternator cabling, plus what some might call 'a PME' earth cabling run,
thats from the battery to each of the welded chassis studs, a bit Ott, but it'll stop the bugger having bad earths for a while...
I have trial fitted the new bespoke prop shaft but removed it until the gear linkage is fully adjusted to suit me !! Plus I haven't re fitted the handbrake lever either yet.
Next, I'll be back head in the engine bay re fitting the steering column & mating it up to the pas rack, fitting the fiesta servo/ms, and associated pipework.
More trials to come, no doubt....
TerryB
[url]
|https://thumbsnap.com/lozASwJf[/url]
Fuel tank stripped of sump plug, gauge sender, and the in tank filter (which was as clean as a whistle), its not going back in so shout if you want it. I washed the tank out, again no debris. Then checked it over & scrapped the outside clean. As I had some Por15 tank sealant paint left over, I painted the outside of the tank with it, finished off with my Blue chassis paint. The sump plug refitted with a new seal & ring. A new Landrover disco gauge sender adjusted to suit & fitted, again using a new seal & ring.
The tank is a bit of a bugger to reinstall when the car is on a four-post lift and you're doing things on your own! Anyway its back in.
New big bore pipe from tank to new pump, plus i have fitted a before the pump in line filter, and a new after pump filter.
I have reused the plastic fuel lines, but with new R9 rubber ends to suit the yet to be fitted layout in the engine bay.
Having decided to re site the battery into the boot (drivers side) plus having loads of surplus 25mm2 cable lying about. I have now run in the main +Ve battery to starter motor & alternator cabling, plus what some might call 'a PME' earth cabling run,
thats from the battery to each of the welded chassis studs, a bit Ott, but it'll stop the bugger having bad earths for a while...
I have trial fitted the new bespoke prop shaft but removed it until the gear linkage is fully adjusted to suit me !! Plus I haven't re fitted the handbrake lever either yet.
Next, I'll be back head in the engine bay re fitting the steering column & mating it up to the pas rack, fitting the fiesta servo/ms, and associated pipework.
More trials to come, no doubt....
TerryB
[url]
|https://thumbsnap.com/lozASwJf[/url]
Hi Mike...
Sorry, been away again !
They worked from my made up plastic manifolds.
But even then, the finished S steel items required fine adjusting, plus some subtle grinding away of surplus alloy on both the engine & the bell housing areas.
As mine exit rearwards, they really do have to hug the engine contour, with very little room for error.
IE. A thick finger gap in some areas between exhaust piping and the chassis is all there is.
TerryB
Sorry, been away again !
They worked from my made up plastic manifolds.
But even then, the finished S steel items required fine adjusting, plus some subtle grinding away of surplus alloy on both the engine & the bell housing areas.
As mine exit rearwards, they really do have to hug the engine contour, with very little room for error.
IE. A thick finger gap in some areas between exhaust piping and the chassis is all there is.
TerryB
No, my S3 project hasn't fell by the wayside, its just that this retirement malarkey is very time consuming !!
What with proper holidays plus short breaks, added to those there are such things as sorting my brother's brakes out, finding the brother in law a new car, project managing the neighbours garage conversion, etc etc. And now I'm readying my Panther Kallista to be show ready for this weekends NEC classic car show.
However some S progress has been made...
All new/modified brake parts now fitted & piped up (left dry for now).
Remote oil filter & oil cooler fitted
The Jag V6 now has a full water cooling system in place (left dry for now).
I didn't intend it being blingy blue, but no stockist could supply everything it needed in black.. Oh, the green plastic pipe is just a mockup until I get some alloy pipe swagged.
Mondeo V6 main cooling fan added engine side of the alloy radiator.
Pas rack now fully piped up (left dry for now).
Modified bonnet hinges fabricated & fitted to give wide opening.
Of course, there's still plenty to do through the winter..
Next to do is positioning the new fuel regulator & associated fuel hose to the engine, although I have already renewed the tank hoses through the new filter & pump up to the engine bay.
Then there's concluding the rest of the engine bay wiring to the sensors etc.
After that Haha, I might treat myself to a change of scenery... By working inside the cockpit, loads of cosmetic upgrade work to do there...
The work continues...
TerryB.
What with proper holidays plus short breaks, added to those there are such things as sorting my brother's brakes out, finding the brother in law a new car, project managing the neighbours garage conversion, etc etc. And now I'm readying my Panther Kallista to be show ready for this weekends NEC classic car show.
However some S progress has been made...
All new/modified brake parts now fitted & piped up (left dry for now).
Remote oil filter & oil cooler fitted
The Jag V6 now has a full water cooling system in place (left dry for now).
I didn't intend it being blingy blue, but no stockist could supply everything it needed in black.. Oh, the green plastic pipe is just a mockup until I get some alloy pipe swagged.
Mondeo V6 main cooling fan added engine side of the alloy radiator.
Pas rack now fully piped up (left dry for now).
Modified bonnet hinges fabricated & fitted to give wide opening.
Of course, there's still plenty to do through the winter..
Next to do is positioning the new fuel regulator & associated fuel hose to the engine, although I have already renewed the tank hoses through the new filter & pump up to the engine bay.
Then there's concluding the rest of the engine bay wiring to the sensors etc.
After that Haha, I might treat myself to a change of scenery... By working inside the cockpit, loads of cosmetic upgrade work to do there...
The work continues...
TerryB.
In direct reply to fefeu52...
Simply put, it was due to my ignorance that such spherical bushes are available as replacements for the AVO poly bushes.
At that time I just did the obvious (to me anyway) in contacting AVO to order 'same as' replacements.
But of course, now knowing this new info, I will be swooping over to spherical bushes as soon as the poly bushes show any signs of wear etc.
Thank you for that info.
Oh, the rears are GAZ with spherical bearings !
TerryB.
Simply put, it was due to my ignorance that such spherical bushes are available as replacements for the AVO poly bushes.
At that time I just did the obvious (to me anyway) in contacting AVO to order 'same as' replacements.
But of course, now knowing this new info, I will be swooping over to spherical bushes as soon as the poly bushes show any signs of wear etc.
Thank you for that info.
Oh, the rears are GAZ with spherical bearings !
TerryB.
Yes, you're right about doing an update... So here it is.
Thanks for the reminder.
Nov18.. Went to the Nec classic show (Panther stand attendee).
My Panther Kallista on show, mainly to get it sold.
Then I saw this... Simply stunning. It tells me I should get back to working on my S.
Jan19... My Panther has sold. So that's a bit less to think about...
Jan19... Converted our neighbours garage into a dance studio for their daughters.
Feb19... Went on winter holiday.
Feb/March 19... Completed a total strip/refit of our bathroom.
Back in time credit now, so car work comes next...
TerryB
TerryB
Thanks for the reminder.
Nov18.. Went to the Nec classic show (Panther stand attendee).
My Panther Kallista on show, mainly to get it sold.
Then I saw this... Simply stunning. It tells me I should get back to working on my S.
Jan19... My Panther has sold. So that's a bit less to think about...
Jan19... Converted our neighbours garage into a dance studio for their daughters.
Feb19... Went on winter holiday.
Feb/March 19... Completed a total strip/refit of our bathroom.
Back in time credit now, so car work comes next...
TerryB
TerryB
March/April... Now I can see into my garage, it needs an urgent cleanse.
Panther parts get sold on, storage shelves rebuilt into a storage/work bench, with down lighting, a vice, and a pillar drill no less. I've never had such an organised facility, but will I be able to find anything !!!
Now I've got the S outside, and we're into the spring. It might as well stay out, and I can work in the sun & fresh air.
Oh, that's also because our 20yr old Merc Slk needs some TLC, on the 4-post.
So doing all that we're now at the end of May19...
The Merc's underbelly... Pretty clean eh ?
Panther parts get sold on, storage shelves rebuilt into a storage/work bench, with down lighting, a vice, and a pillar drill no less. I've never had such an organised facility, but will I be able to find anything !!!
Now I've got the S outside, and we're into the spring. It might as well stay out, and I can work in the sun & fresh air.
Oh, that's also because our 20yr old Merc Slk needs some TLC, on the 4-post.
So doing all that we're now at the end of May19...
The Merc's underbelly... Pretty clean eh ?
June19...
As I said previously, I wanted to work outside on the S, so that I could complete the front brakes, the steering set up, and the suspension.
But guess what... Our great British summer bites back, and decides to pee down.
Oh well, back into the garage the S goes.
But on shifting it, there's a puddle on the floor !!
There are no fluids in the engine, so ??
Its one of the AVO front shocks (they were on the car when I bought it in 2014).
So they come off the car (again). And now they're with AVO to repair/refurb.
Okay,
I'll finish off the front brakes (557/8 calipers & 278mm discs). I had bolted those on a while back. The calipers were used, but in good order. So now its time to add the pads, tighten down the hoses etc, and get ready to add fluid and bleed. The back already been fitted with new parts. And then I break off a bleed nipple !!!!
Every trick tried to extract the remains. Nope.
But thanks to Mick P, for suggesting a drill out, re thread, add an insert repair kit. The only thing is the cost (around £60). Mmmm.
So I do some searching for a another caliper. Used ones currently on eBay look pretty grotty. But there is a trader selling new ones in pairs (non OE) for around £70. But it didn't exactly list them for Fiesta ST150 fitment. So I made direct contact, still no good as they work from Reg or Vin No's... Only I ain't got either of those...
Light bulb moment... Find ST150 for sale, give them that Reg, and we're onto a winner... Fingers crossed.
Anyway they arrive PDQ, and they're spot on.
So that's one job down...
As I said previously, I wanted to work outside on the S, so that I could complete the front brakes, the steering set up, and the suspension.
But guess what... Our great British summer bites back, and decides to pee down.
Oh well, back into the garage the S goes.
But on shifting it, there's a puddle on the floor !!
There are no fluids in the engine, so ??
Its one of the AVO front shocks (they were on the car when I bought it in 2014).
So they come off the car (again). And now they're with AVO to repair/refurb.
Okay,
I'll finish off the front brakes (557/8 calipers & 278mm discs). I had bolted those on a while back. The calipers were used, but in good order. So now its time to add the pads, tighten down the hoses etc, and get ready to add fluid and bleed. The back already been fitted with new parts. And then I break off a bleed nipple !!!!
Every trick tried to extract the remains. Nope.
But thanks to Mick P, for suggesting a drill out, re thread, add an insert repair kit. The only thing is the cost (around £60). Mmmm.
So I do some searching for a another caliper. Used ones currently on eBay look pretty grotty. But there is a trader selling new ones in pairs (non OE) for around £70. But it didn't exactly list them for Fiesta ST150 fitment. So I made direct contact, still no good as they work from Reg or Vin No's... Only I ain't got either of those...
Light bulb moment... Find ST150 for sale, give them that Reg, and we're onto a winner... Fingers crossed.
Anyway they arrive PDQ, and they're spot on.
So that's one job down...
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