Terry's tale. (S3 resto ++)

Terry's tale. (S3 resto ++)

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mentall

239 posts

65 months

Monday 28th November 2016
quotequote all
mycroft said:
Oh come on , cant be just me , hasn't everybody set themselves on fire angle grinding rolleyes.
Yep: me too. Trousers. But that was many years ago!

Blue 30

Original Poster:

244 posts

52 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:

244 posts

52 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:

244 posts

52 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...

Graham

16,278 posts

219 months

Monday 28th November 2016
quotequote all
[quote=Blue 30]
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./quote]


They did my Chim chassis and also my single seater chassis :-)

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Blue 30

Original Poster:

244 posts

52 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:

244 posts

52 months

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

glenrobbo

12,066 posts

85 months

Monday 28th November 2016
quotequote all
I have the same trouble with autocorrect and fat finger typos.
I just click on 'Edit' at the top of my post and correct the bloody autocorrects. irked
But you can't correct a title of a new topic once you've submitted it, so be warned. Only the mods can do that for you.
HTH Terry. smile

Kitchski

5,970 posts

166 months

Tuesday 29th November 2016
quotequote all
Blue 30 said:
Now that, is how you do an engine bay clap

Blue 30

Original Poster:

244 posts

52 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:

244 posts

52 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.

Kitchski

5,970 posts

166 months

Wednesday 30th November 2016
quotequote all
Blue 30 said:
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
Ok mate, calm down laugh

Blue 30

Original Poster:

244 posts

52 months

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

DamianS3

1,712 posts

117 months

Wednesday 30th November 2016
quotequote all
Hello there

A couple of observations if I may...

You must have got a good price for your DMF, I have this on my to do list, i.e. Replace with light flywheel and clutch.. the D MF works ok perhaps even well but I personally don't thing our little cars need the mass.

You don't technically have to modify the top rails to fit the duratec but I'm sure it will make exhaust work easier.. I had to modify mine at the bottom to fit the huge S type sump, I believe you have fitted either an X type or st220 sump to avoid this.? Either is possible.

The next challenge after fitting and the diff is the inlet manifold, I am not sure of your plans in this area but options are Throttle Bodies for mega power and £££ fancy ECU to run the IMT valves in the Jaguar version of the manifold or with a little work a conventional ST220 item. Removing IMT issue.

Then the throttle body, I have a Jenvey 70mm unit to replace the FBW Jaguar unit.. ST220 is also an option but will probably need a new TPS as the ford unit is a bit binary. I have also seen bike TBs and custom manifolds used here.

This is not a cheep conversion but it is loads of fun

Thanks

Damian S3 the first S3 Duratec

Blue 30

Original Poster:

244 posts

52 months

Wednesday 30th November 2016
quotequote all
Hi Damian...
Like you I'll use the DMF for now, its a good reference point if nothing else.
Plus mass is good for torque, I don't want it too snappy. Although I agree it is a bit ott, in weight terms even just picking the damn thing up.
For the others benefit, a few Jaguar engine layouts have a growth on their sumps which just adds oil capacity. I can only think its for extended service intervals. Yes, I have changed mine for one without it, which also needs the matching oil pickup pipe. The slight change of the top & bottom (in front of the engine) chassis cross rails were not required for the AJ V6. But when I did those I hadn't finalised my engine choice. At least I have maximum spanner space in front of the engine. And the triangulation maintains the chassis strength.
The rest of the detail as you raised, I believe I have resolved &/or got in hand. But I doubt it ! All good fun.
I'll try to keep some kind of order to the thread of my progress, so some details will appear later on...
But you're always welcome to interject etc.
TerryB

Alan Whitaker

1,928 posts

117 months

Thursday 1st December 2016
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Looking good,

Alan

Blue 30

Original Poster:

244 posts

52 months

Thursday 1st December 2016
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With the major conversion parts (plus other reqd items) safely squirrelled away, I am still continuing with the rebuild of the chassis. I really don't know if the zinc coating is meant to be a final finish, but the guys did say it can be over painted. Good !
Because that's what have done, in a contrasting blue to complement the body colour. Loads of red oxide primer, then top costs of coach/engine enamel, all brushed on.


Blue 30

Original Poster:

244 posts

52 months

Thursday 1st December 2016
quotequote all
Now that the paint is dry, its time to get it into a rolling chassis state.
Hard brake lines are changed to cupro-nickel. The flexi's are changed to Ssteel braided. All brake line threads are changed to metric. The original rear shocks look tired & as I had bought a pair of good used rear Gaz gold pro, I fitted those but with new pivot bearings & new springs.
The trailing arm bushes are very good so they stay. The diff carrier bushes are changed to poly.
That looks better...


glenrobbo

12,066 posts

85 months

Thursday 1st December 2016
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Now you're showboating Terry!

But I'm loving it!!! cloud9

Blue 30

Original Poster:

244 posts

52 months

Friday 2nd December 2016
quotequote all
True, it does look a little bit matter of fact, so far.
But I haven't got any piccies of me sitting on my garage floor checking/replacing my spherical bearings smile
Which is something you gents should be doing on a regular basis.
But seriously, all shock absorbers mounting point bushes or bearings should be checked periodically. As they do take as much impact as the internals of the shock absorbers.
These were the bushes in my front AVO adjustable shocks (see below). Now replaced with new ones. The AVOs were already on the car when I bought it, so I don't know their age, but they appear to work okay, & the adjusters too.
I'll get onto the front end shortly...
(I know... Don't call me shortly) smile