3 Year Rebuild - Complete!
Discussion
So you'll excuse me for indulging in what I think is about to be a long post... It's 2 years, 11 months and a week (ish!) since I took the decision to take my 1989 S2 off the road for a complete rebuild. I bought the car intending to do this, but then accidentally drove it for 3 years before finally deciding that even though it was passing it's MOT that the chassis was in need of serious attention!
It's been a long hard road, and having set out to do as much as I could myself (with no previous experience or real mechanic skills) I'm chuffed to bits with the result. I have ended up 'outsourcing' more and more of the work as the project went on, partly due to the skills needed and partly due to the time required.
All credit goes to the companies I've used to complete the clever stuff:
Chassis rebuild: Southways Automotive
Bodywork and respray: Surface and Design
Interior trimming and roof: D&C Trim
Engine bay completion, setting up the suspension, getting it an MOT and generally fixing stuff I'd done wrong: X-Works Service
Now for some photos....
Sorry there are no pictures of the Chassis Rich - I need to get it on a ramp before it's too dirty!!
Things I'm especially pleased with!
- High lift bonnet hinges (Surface and Design)
- Secure petrol cap hidden in boot (design copyright of Philpot!)
- Quickshift gear lever (Southways Automotive)
- Rocker covers (JR Cast) with adapted alternator bracket (Southways Automotive)
- Modified roof storage - really pleased with this so far. Time will tell, boot space is compromised but much easier to store the panels compared to in the boot and more space for luggage in the car if necessary with the roof on
-Digital odometer by not-so-speedy cables
- Interior colour scheme (me!) and general standard of work on Chassis, Bodywork and Interior trim
Things left on the 'to-do' list (the project that will never be finished!)
- The dipstick is broken
the handle is snapped off. Temporary measure in place but if anyone has a spare I have beer tokens or if anyone has successfully replaced theirs please let me know what with as the originals seem like rocking horse poo
- Engine running well but only getting 23mpg
and there is a 'dead spot'. If revving the engine from tickover if you slowly press the throttle the revs die before they pick up. Also very little power below about 1400 rpm. Currently being fixed by an enthusiastic right foot. Once over this it's pulling really well
- Throttle cable/response/return is cr*p. Need to get this modified but it's fine for now
- Rev meter not reading correctly. Reading correct at tick over but never exceeds 3000rpm?! Sender fault possibly. Currently using ears instead
- Wheels - going to have them powder coated in shadow chrome once I've saved a bit more money. Dunlop blue-rinse on order for this Saturday so I am on legal tyres though!
- The clock doesn't keep time properly
- Replace window winders, they're cr*p. Some on order!
I've done 400 miles in it since getting it back - work and back and a trip one weekend to York. Not broken down yet....!!
Overall I'm over the moon. Booked a short 4 night trip to Bruges in October with the patient Mrs Robert who suggested we go away in it. Chunnel booked and fingers crossed it doesn't break down... Oh and Monaco/Spa booked for May.
As with most projects it took me twice as long and twice the budget I originally planned. With what I have finally outlaid, I could have bought a modest V8S(!) but I've learned a lot along the way, I now understand most of how the car is put together and this was part of the goal for me. I also have a near perfect car which is exactly the way I wanted it, and I hope will last me a very long time!
Thanks to those of you along the way that have provided advice (especially Philpot and Kitchski) and support and also for everyone having put up with me chasing them in my MG on S Tour's while it was off the road. Really looking to being able to keep up on the motorway down to Monaco
Bring on the driving!!!
Previous threads documenting the rebuild
And so it begins...
The engine is OUT!
Chassis Strip Complete
Rebuild Updates!
Engine Rebuild
Body back on
Almost there....
It's been a long hard road, and having set out to do as much as I could myself (with no previous experience or real mechanic skills) I'm chuffed to bits with the result. I have ended up 'outsourcing' more and more of the work as the project went on, partly due to the skills needed and partly due to the time required.
All credit goes to the companies I've used to complete the clever stuff:
Chassis rebuild: Southways Automotive
Bodywork and respray: Surface and Design
Interior trimming and roof: D&C Trim
Engine bay completion, setting up the suspension, getting it an MOT and generally fixing stuff I'd done wrong: X-Works Service
Now for some photos....
Sorry there are no pictures of the Chassis Rich - I need to get it on a ramp before it's too dirty!!
Things I'm especially pleased with!
- High lift bonnet hinges (Surface and Design)
- Secure petrol cap hidden in boot (design copyright of Philpot!)
- Quickshift gear lever (Southways Automotive)
- Rocker covers (JR Cast) with adapted alternator bracket (Southways Automotive)
- Modified roof storage - really pleased with this so far. Time will tell, boot space is compromised but much easier to store the panels compared to in the boot and more space for luggage in the car if necessary with the roof on
-Digital odometer by not-so-speedy cables
- Interior colour scheme (me!) and general standard of work on Chassis, Bodywork and Interior trim
Things left on the 'to-do' list (the project that will never be finished!)
- The dipstick is broken
the handle is snapped off. Temporary measure in place but if anyone has a spare I have beer tokens or if anyone has successfully replaced theirs please let me know what with as the originals seem like rocking horse poo- Engine running well but only getting 23mpg
and there is a 'dead spot'. If revving the engine from tickover if you slowly press the throttle the revs die before they pick up. Also very little power below about 1400 rpm. Currently being fixed by an enthusiastic right foot. Once over this it's pulling really well- Throttle cable/response/return is cr*p. Need to get this modified but it's fine for now
- Rev meter not reading correctly. Reading correct at tick over but never exceeds 3000rpm?! Sender fault possibly. Currently using ears instead
- Wheels - going to have them powder coated in shadow chrome once I've saved a bit more money. Dunlop blue-rinse on order for this Saturday so I am on legal tyres though!
- The clock doesn't keep time properly
- Replace window winders, they're cr*p. Some on order!
I've done 400 miles in it since getting it back - work and back and a trip one weekend to York. Not broken down yet....!!
Overall I'm over the moon. Booked a short 4 night trip to Bruges in October with the patient Mrs Robert who suggested we go away in it
. Chunnel booked and fingers crossed it doesn't break down... Oh and Monaco/Spa booked for May.As with most projects it took me twice as long and twice the budget I originally planned. With what I have finally outlaid, I could have bought a modest V8S(!) but I've learned a lot along the way, I now understand most of how the car is put together and this was part of the goal for me. I also have a near perfect car which is exactly the way I wanted it, and I hope will last me a very long time!
Thanks to those of you along the way that have provided advice (especially Philpot and Kitchski) and support and also for everyone having put up with me chasing them in my MG on S Tour's while it was off the road. Really looking to being able to keep up on the motorway down to Monaco
Bring on the driving!!!
Previous threads documenting the rebuild
And so it begins...
The engine is OUT!
Chassis Strip Complete
Rebuild Updates!
Engine Rebuild
Body back on
Almost there....
Kitchski said:
Bet you're itching for the next Euro-tour now!
If you go to ferry/chunnel via here, swing by for a cuppa. Happy to stick it on the dyno for you & see where your flat spot is.
Definitely would love to get it on a dyno at some point and see what's going on under the bonnet! May not be time when I come to the chunnel with crossing times but I'm definitely up for a trip down at some point - will let you know. So happy with the gear lever. I also need to let you have the spare alternator bracket back and while I'm there you could get measurements off the one that now fits :-)If you go to ferry/chunnel via here, swing by for a cuppa. Happy to stick it on the dyno for you & see where your flat spot is.
Absolutely itching for the Euro tour!!!
lfsv8 said:
Hi OP, I'm only an occasional S forum viewer/visitor but your efforts caught my attention and the standard of your work looks so impressive, that I felt moved to pass comment accordingly. Many projects must flounder due to cost and associated economic/domestic pressure. I also suspect that the cabin colours may represent 'Marmite' to some but, personally, I think the combination looks very effective indeed and justifies the bravery of your selection! Quite an achievement because such projects are always going to be far easier to contemplate/talk about than actually complete, so very well done indeed and have fun tackling remaining minor fettling/finishing of items!
Thanks very much!!! 
RayTVR said:
Andrew, looks brilliant.
Revs dying at beginning of throttle travel and dead spot sounds like throttle pot issue. Mine had exactly that when I acquired it.
Interesting as I had 2 TPs in the draw, one good and one suspect... will see if I guessed wrong and switch it out to see if it makes any difference. Thanks!Revs dying at beginning of throttle travel and dead spot sounds like throttle pot issue. Mine had exactly that when I acquired it.
LawrieS said:
Great work, love the interior!
Where’d you get the battery from and what size is it?
http://www.optimabatteries.co.uk/en/red-top/17-red...Where’d you get the battery from and what size is it?
Click the more info button and it's got all the dimensions etc.
Andrew
Update! 3 and 1/2 months since I got the car back on the road and I'm still really pleased! Done just over 1500 miles including a trip to Bruges, York, Leeds and lots of commutes through the Peak District taking the longer way to work 
. I've also managed to replace the window winders and sorted out my broken dip-stick. Car runs up to temp and the fan cuts in and the Evans Waterless Coolant seems to do the trick well, keeping the temp at 90 degrees once it's fully warmed up.
Having done this milage it does still need a bit of engine work. I've got an oil leak which I can't figure out if it's engine or gear box (or both). I've also still got a complete lack of power very low down the rev range and I need to get some better locking washers for my rocker covers as the screws keep working loose, leaking oil onto the manifold....
I'm going to try and get it on a rolling road in Feb/March to sort out - plan to contact X Works soon but can't remember if they have one. If anyone can recommend a garage with a rolling road that they'd recommend as someone who knows their way around the 2.9 V6 cologne engine please let me know - I know a few have used various places for the more common rover V8 but keen to have someone that knowns what they're doing with the ford engine. I'm in Manchester so looking for somewhere I can get to within a couple of hours.
I'm also on the look out for a drivers side wheel arch - the part that fits to the body (as oppose to the bonnet). Mine was missing when I bought the car and I got a piece of Norman a few years ago. It doesn't really fit properly and there is a big gap to the piece that fits to the bonnet so it's letting loads of cr*p into the engine bay, which means lots more cleaning than I would like and the spray is going directly on to the servo...
All in all still very happy. Also using it for work this last couple of weeks as the CRX has an ignition problem which is proving tricky to fix!
Andrew
. I've also managed to replace the window winders and sorted out my broken dip-stick. Car runs up to temp and the fan cuts in and the Evans Waterless Coolant seems to do the trick well, keeping the temp at 90 degrees once it's fully warmed up.Having done this milage it does still need a bit of engine work. I've got an oil leak which I can't figure out if it's engine or gear box (or both). I've also still got a complete lack of power very low down the rev range and I need to get some better locking washers for my rocker covers as the screws keep working loose, leaking oil onto the manifold....
I'm going to try and get it on a rolling road in Feb/March to sort out - plan to contact X Works soon but can't remember if they have one. If anyone can recommend a garage with a rolling road that they'd recommend as someone who knows their way around the 2.9 V6 cologne engine please let me know - I know a few have used various places for the more common rover V8 but keen to have someone that knowns what they're doing with the ford engine. I'm in Manchester so looking for somewhere I can get to within a couple of hours.
I'm also on the look out for a drivers side wheel arch - the part that fits to the body (as oppose to the bonnet). Mine was missing when I bought the car and I got a piece of Norman a few years ago. It doesn't really fit properly and there is a big gap to the piece that fits to the bonnet so it's letting loads of cr*p into the engine bay, which means lots more cleaning than I would like and the spray is going directly on to the servo...
All in all still very happy. Also using it for work this last couple of weeks as the CRX has an ignition problem which is proving tricky to fix!
Andrew
MisterTee said:
Have you checked the area around the distributor? Mine was leaking oil from the back of the engine which was then running down the bellhousing and off the gearbox onto the exhaust. Like you, I wasn’t sure where it was coming from and eventually traced it to the o-ring on the distributor shaft.
Always worth a look as it’s a really cheap fix!
Your car looks great, by the way.
Enjoy it!
Andy
This is definitely the right sort of area, I'll check it out thanks!Always worth a look as it’s a really cheap fix!
Your car looks great, by the way.
Enjoy it!
Andy
Update!
Cause of the lack of power at low revs was 2-fold:
1) valve clearances adjusted - 1 was very out so hardly opening, the plug was very black when removed. Heath at X-Works has adjusted them all.
2) fuel pressure regulator replaced. Fuel was approx half the pressure it should have been at
In addition Heath has done the ‘Philpot’ throttle mod - different cable and much more stiffly sprung. Feels so much more controllable.
And now? The car feels absolutely superb - I’m over the moon!! Starts easily hot or cold, idle is spot on and the torque and power are back!
Time for a full road test I think! Good job I’m writing this from Longers’ conservatory then....see many of you in France or Belgium!!!
Cause of the lack of power at low revs was 2-fold:
1) valve clearances adjusted - 1 was very out so hardly opening, the plug was very black when removed. Heath at X-Works has adjusted them all.
2) fuel pressure regulator replaced. Fuel was approx half the pressure it should have been at
In addition Heath has done the ‘Philpot’ throttle mod - different cable and much more stiffly sprung. Feels so much more controllable.
And now? The car feels absolutely superb - I’m over the moon!! Starts easily hot or cold, idle is spot on and the torque and power are back!
Time for a full road test I think! Good job I’m writing this from Longers’ conservatory then....see many of you in France or Belgium!!!
Edited by AndrewS2 on Wednesday 9th May 06:35
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