My kit car (re)build

[hugh_]

I bought this back in late September. The previous owner had started a conversion to a 2.1 Pinto, but had run out of enthusiasm for the project, it had a seemingly short to do list:

• Ignition wiring,
• Final fit bucket seats,
• Gear linkage,
• Fit dashboard,
• Fit exhaust and air filters
• Bonnet modifications to allow for carbs & exhaust.

It turned out not to be that way and very quickly I had a list as long as my arm so things I wanted to do. The front suspension was shocking (no pun intended) and would have been dangerous if driven, the radiator did a good impersonation of a colander, the interior carpets and panels (originally plywood :/) were a state, and with the big valve head I had got with the car, the standard dizzy and points were going to be a limiting factor, so I bought a MegaJolt kit for it. With the (hopefully) 170hp ish that will give me I don't want to rely on escort brakes, so I've got new bigger disks on the front and 4pot Wilwoods, and as I was doing that it made sense to fit a bias adjustable pedal box. The wipers were dead, and windscreen on these things are effectively a big air brake, so that went. You get the idea...

I was doing 5-8hours a day on it initially, often still in the garage at 3 in the morning; and after a few weeks I was exhausted, wanted it running and had generally had enough of the thing. I tried to encourage myself by getting some nice wheels (Team Dynamics Pro Race 1.2s in black), smart small headlights and small motorbike indicators but it didn't work, and truth be told I've hardly touched it since late October when I hit a problem that I couldn't easily overcome.

Over the last few weeks I've been mulling over some ideas which have re-ignited some enthusiasm for it. I intend this to be a sort of build diary, and while I haven't taken many photos to date, I'll put up those that I have.


With previous engine (before I owned the car)


As I bought it


As I bought it

During my initial few weeks of work I managed to sort:
• Interior (floors, side panels, dash, tunnel top and seats)
• Floor mount bias adjustable pedal box & MCs
• Replumb front brake lines, new braided hoses, discs, callipers, pads etc.
• New gear linkage and quick shift kit;
• Air filter backing plates
• Front wheel bearings,
• Speedo cable adaptor and new cable
• Exhaust
• Rewire rear of car

I also had a go at the front wiring, but it was mainly resurrecting old wiring and I wasn't happy with it, so that has come out again.
The dash still isn't wired which along with wiring the ECU are the 2 jobs I'm least looking forward too!

I haven't been very good at taking photo's to date, but here are some from this evening, as much as anything as a benchmark from which I can measure progess, some encouragement wouldn't go amiss either!

[Barkychoc]

Looking good Hugh.
I took my TVR to bits last year - then had some surgery and driving isn't allowed for a year - so I know about the lack of motivation!
I have a potter in the garage with a bit of a push sometimes, other times I haven't looked at it for a few weeks.
It will get there - I'm nearly finished now just an engine rebuild to go!

Chris

Taking apart

Rebuild

Edited by Barkychoc on Thursday 5th February 21:50

[hugh_]

The V8S looks good Chris, other than changing the head I've no engine work to do as the engine was rebuilt only a year ago and hasn't run since. I've just been back out to the garage and the replacement radiator that I have will be easier to mount than expected (its rather larger and I was slightly worried about fitting!)

I think I only have the following left to do:
• Finish fitting replacement front suspesion
• Fit crank position sensor
• Refit dizzy minus gubbins (it won't be used, but houses the bearings for the oil pump)
• Makes mounts for new headlights, fit new indicators
• Mount radiator and plumb.
• Make bulge (to clear cam cover) in nose cone and spray

• Build MegaJolt
• Fit oil catch tank

• Repair and spray scuttle
• Fit aeroscreen and mirrors
• Patch (old airfilter hole), cut (new airfilter and exhaust holes), reinforce and spray bonnet
• Fit latches for boot lid

• Wire it all in

Then at a later date I will fit the new big valve head, respray rear tub and possibly the side panels.

[sniff diesel]

Suprised you needed to go for 4 pots on the front, my mate's Tiger with 180bhp and 600 kgs copes fine on Cortina calipers and solid discs.

[hugh_]

When I had the Fury (which was ~135hp and 500kg) I had brake fade issues on track (Lydden) after 10-12 minutes with escort calipers (with spacer) Capri disks, Mintex 1144s and Automec silicon fluid. So on a heavier, more powerful car I thought something more beefy wouldn't go amiss.

I have today off work to focus on the car, some more pics so far (haven't done anything other than tidy yet!)







The last one shows where the dizzy mounts. I had removed it and made up this blanking plate as the dizzy won't form part of the ignition system once the MegaJolt is on. However, and very fortunately, I discovered that the oil pump runs off the same drive, and therefore the dizzy bearings are required.

[Contaminated]

Not bad Hugh. One small point though - too much typing, not enough work (he says as he avoids heading into the garage!)

[madrob6]

Good stuff, I'm also suffering from a lack of motivation with my project but that's been brought on by a lack of funds and the fact that several months later the engine is still not much closer to starting.

[hugh_]

Get your arse out there Dan, what's todays task on yours?

Yesterday afternoon and this morning have been frustrating and fairly non-productive. Alternator and dizzy back on, and probably 6hours spent making, adapting and remaking a mount for the crank position sensor. Nevermind, its on done now, and once I've got some slightly longer bolts can be attached.

[hugh_]

The new dominator headlights are on temporarily pending painting of the brackets, they look so much better than the previous 7" chrome ones.

Edited by hugh_ on Sunday 8th February 13:14

[Contaminated]

Those lights do look better mate. Regards the radiator issue I think this one should fit. It would on mine if I mount it in front of the chassis uprights.

http://cgi.ebay.co.uk/A-VOLKSWAGEN-POLO-Mk2-1-1-19...

[hugh_]

Yeah. I found the same for £38 with free postage from an independant supplier. If we can get them to combine postage that would be worth pursuing though, were you thinking of replacing yours during this phase of work?

[hugh_]

I've managed a bit more this evening. Most of the modification to the bonnet is done, except a extending a both apertures slightly to give better clearance (over no.4 header and the forward air-filter). The panel to cover the old air filter hole is mark up and drilled, just waiting getting my jigsaw back before fitting. The cycle wings are now cut and drilled, but I won't permanently attach them until the painting is done.

















The pinto sits higher than the previous x-flow, while there is enough give in the bonnet that it can be accommodated , the nose cone needs butchering, there will be a tiger avon-esque bulge on the nose cone to clear the cam pulley.

[Andy_sx]

And yet another car of yours I really like Hugh, good work so far mate.

Keep the motivation up, I know that if I had the cance I would be out there alot myself.

Hoping to get a 7 esq car myself later this year if possible, will probably be my only car aswell so thinking car engine rather than BEC.

Knowing you the finished article will look rather damn smart mate, keep up the graft!

Dan, get your tiger sorted mate!!!

[Contaminated]

It's nearly there mate. Some pics here:

http://www.photobox.co.uk/album/95290220

How's things anyway?

[hugh_]

Cheers Andy, we must all meet up again come the summer, when all being well this will be up and running. If it isn't be a must poorer man...

A status check, no more photos yet because I left the camera in the garage, I'll upload them tomorrow. Anyway, she rolls again , the mare that was the front suspension hangers is finally sorted. The previous (positively lethal) front shocks/spring were supported with M8 bolts onto hangers which must have been pre-drilled prior to welding to the chassis, and the way the chassis tapers towards the front meant that I couldn't have drilled them at 8mm again, let alone 12... In short I drilled 2 2mm holes then filed the rest out, which took ages.

The plate filling the hole for the previous air filter has been cut and riveted in place, the oil catch tank is in but as yet unplumbed as the oil pressure sensor is in the hole it will use, and the bolt in the hole where it will relocate to is seized, not very impressive for a block that was completely rebuilt less than a year ago.

I also started butchering the nose cone to include a 40mm bump over the cam pulley.

[hugh_]

No real progress tonight, just a tidy up, some painting and think about how to do things.

A photo of how the old shock was mounted the black band on the right is a cable tie around 4 washers...

[Andy_sx]

Dan, keep it up mate, love your Tiger!

Hugh, that shock mouting is a little worrying to say the least, no wonder you spent ages rectifying the issue! I wouldnt be happy with that at all personally (which says quite alot ghiven the current issues with my HGT...)

Things arent too bad this end, changed jobs, girls, lost plenty of dosh and now wondering what car i want next after getting a pay cut! good job the missus is a petrol head too....

Do you have any tips on finding a locost or similar motor that needs some tlc, i think that will be the best way for me to get one given the lower purchase price, i can do what needs be as i go sort if thing. I was building one with a mate, but when i lost my job in August I had to pull out as i couldnt afford it... regret that a bit now if im honest!

[hugh_]

I light of my experience with finishing off someone elses build I really wouldn't bother unless you can find bare chassis with lots of bits. I have spent a lot of time and money rectifying or replacing bits that I wasn't happy with. That said a car that has already been sva'd is a huge benefit with the imminent arrival of IVA so it's swings and roundabouts.

Locostbuilders.co.uk and eBay are worth keeping an eye on for part built kits if you do decide to go that route

[Andy_sx]

Thanks for that Hugh, I realise it may not be the best way of doing things in many respects, but my thoughts are to get the car itself cheaper with a blown engine / needing finishing / who knows... then fixing it up as i go little by little. I dont have the funds to go in and buy a working example straight away (not for a while either) but I'm impatient and child like when i get a bee under my bonnet

Failing that ill come and pinch yours once its finished will make sure i head over in the stealth Astra estate and not the HGT though as you may hear me 'sneak' up!

[hugh_]

Right another little update. My Polo Rad (VW302 from a 83-90 1.0 Polo) turned up, will do the job nicely.



I decided that instead of having the hassle of painting the side panels and scuttle I would just black vinyl cover them. Enough vinyl (2.5x1.2m) was £20 from Iden Signs so maybe a decent budget choice if it avoids buying a compressor and spray gun. It was slower than expected, but only due to fiddly bits around the suspension; I opted to apply the side in 3 panels, from the rear to about the midpoint of the front carb, then two bits, one either side of the rear wishbone mounts. The finish on the flat bits is fantastic, but I'm not entirely pleased with it around the front, despite managed to get rid of all the air bubbles eventually.






The joins aren't anything like as obvious as they appear in the last photo.

I still need to change the rear shocks, which I was planning to do after it was back on the road, but as I have the rear arch off for the vinyling I will do them now, and probably paint the arches too!