S3 winter project - advise would be gratefully recieved.

[trickjohn]

Hi all,

I am currently doing up my S3, so far what I need to do is :

1) Partial body lift (excellent links on how to do this on this site), I have dug around with a small screwdriver and have found a couple of small holes close to the chassis on the outriggers, new outriggers where fitted a couple of years ago, however there was approx 6 inches of original tube left which the new outriggers where welded too. I have ground out and removed the poor area and will fill the hole with metal plate cut to the correct shape and mig weld - does anyone know what spec of material this is and gauge?
2) I am losing a small amount of water, my radiator has seen better days and looks rusty / corroded, the original engine has been replaced with a cosworth 2.9 V24 BOA engine - should I get my radiator reconditioned (£130) in Cheltenham or I am considering buying a second hand Scorpio radiator (original to the engine or the later frogeye Scorpio) and see if I could persaude it to fit, hopefully thin enough. I am not sure if the radiator angle will have an impact on this.
3) The steering feels lumpy, when going from lock to lock it goes slightly tight then back to smooth again in a couple of places.
4) The bonnet needs a blow over - stone chips and a few scars - to be expected of a car this age. I live in the Cirencester area, if anyone has got any hints in the Glos - Wilts area.

I would be very grateful if anyone could offer me any advice on any of the above questions.

Thanks in advance for any help.

[jls]

Hi recently replaced the outriggers on my s2 - chassis tube was ERW 1.5 inch dia 16 gauge. I also bought some 33.7mm od tube which I inserted inside tube prior to welding to sleeve the joint for extra strength.
I purchased this from Fred R Powell in Bristol
Good luck

[Jed-S]

For the ohe outriggers on mine I used 38mm x 1.6mm ERW. It is quite cheap from a steel stockist - around a tenner for a 6M length.

[Barkychoc]

trickjohn said:

3) The steering feels lumpy, when going from lock to lock it goes slightly tight then back to smooth again in a couple of places.

Almost certainly the steering UJ just the other side of the bulkhead - and just behind/above the drivers side front wheel - probably covered in crud & rust.
You may be able to free it off but more likely you'll have to replace it, if you do try and enclose it in a steering gaiter packed with grease to keep the rubbish out.

Chris

[trickjohn]

Thanks for the info -

I will order some material.

I have just been out to the garage and given the UJ joint a good dose of WD 40, it is moving much smoother, therefore it needs to be disconnected prior to the partial body lift I will give it a good clean and see if good enough to re use. Hopefully I may get away without replacing it.

Thanks again