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LE 30 Project Thread #1458305
15/11/2013 20:58
15/11/2013 20:58

K
KBT
Unregistered
KBT
Unregistered
K



Hi folks. Time to get this underway - whatever the outcome.
Here she is, a lovely looking car.
click to enlarge

Now I have cleared the garage, work can begin. There is barely room to swing a cat, so until I move the Lancia out, going will be slow.
click to enlarge click to enlarge

As you can see i`ve removed the wipers, scuttle cover and wiper assembly.
Inside, I found this sat on the chassis rail.
click to enlarge
Fortunately the rail is undamaged, but further back there is a large hole.
Considering how good the car looks, the amount of corrosion i`m finding at the back of the car beggers belief. I have seen rustier coupe pictures though so maybe all is not lost.
I have this weekend off so I hope to get some pictures to post. In the meantime, here is a picture showing one of the cars good bits.
click to enlarge
From inside I have seen the colour that the centre should be, I don`t really want to paint them though.
Thanks for looking, more soon.
Jon smile

Re: LE 30 Project Thread [Re: ] #1458410
16/11/2013 14:54
16/11/2013 14:54

K
KBT
Unregistered
KBT
Unregistered
K



Just found this, lucky the car isn`t in the pit.
click to enlarge
Been under the car today and found to my relief that what I have seen is nearly all surface rust. No pictures of underside yet or behind O/S Pininfarina badge, here is some of the rear end. Will be a bit busy now cleaning out the pit and sawing timber.
click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge
....................................................filler behind here....

Re: LE 30 Project Thread [Re: ] #1458577
17/11/2013 19:06
17/11/2013 19:06

K
KBT
Unregistered
KBT
Unregistered
K



Not a great deal done today.
Removed door seals, dash ends, o/s one has 2 of the plastic lugs missing, removed blitz, widget, pillar pod and guage - didn`t like the way they had been wired in, neutral connections just wire twisted together at dimmer connection. Removed metal strip also, only mildly toasting the badge - it had some dings anyway and will be replaced.
o/s sill cover came off fine, hardly any rust bubbles underneath. n/s ones screw heads are gone, will have to drill them out - might be some corrosion below.
No pictures today except for this one, it`s amazing just how much stuff fits into a car - there are loads more bits lying around in the garage.
click to enlarge

You can see the centre console on the seat, no longer carbon wrapped, will be painting it black I think. wink

Re: LE 30 Project Thread [Re: ] #1458874
19/11/2013 12:59
19/11/2013 12:59

K
KBT
Unregistered
KBT
Unregistered
K




Re: LE 30 Project Thread [Re: ] #1458953
19/11/2013 17:25
19/11/2013 17:25

K
KBT
Unregistered
KBT
Unregistered
K



click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge

To think when I bought this car I had concerns that there wasn`t much left to do. I really dislike the way the cables and pressure feed have been routed, butchering the rubber between body and door that carries wiring. The fan switch installation looks ok, but i`ll redo the ends with gold plated and heat shrink, I dislike crimp connectors. One wire was falling out of the widget. (loose)

If any one is wondering why I decided to strip/rebuild a car I only just bought, the answer is simple. The car is a deathtrap. Front pads seized in caliper - pads have bent to make contact, ground and hammered in job. I suspect the car is on its original dampers, wishbone bushes are worn. Rear subframe bushes are so worn I can move sub. with finger and thumb. Not a very good pic in scuttle but you get the idea, dash needs to come out for decent repair without fire.
Will try to get image of the corrosion behind rear quarter badge o/s tomorrow. sick

Last edited by KBT; 19/11/2013 18:57. Reason: spelling
Re: LE 30 Project Thread [Re: ] #1459053
19/11/2013 21:59
19/11/2013 21:59

K
KBT
Unregistered
KBT
Unregistered
K



Just finished for today.
Discovered o/s engine mount is tired, o/s arch is broken and the sealing rubber appears to have been rubbing on the tire at some point. O/S repeater has slight crack. Can probably mend the arch. Replacing some of the small pipes. Car has those booster hoses which seem to need replacing as some ends are leaking!
Taking small parts off Alfa 145 which are common with the Coupe, like the body to door concertinas - think they are the same.

Re: LE 30 Project Thread [Re: ] #1495749
26/06/2014 01:05
26/06/2014 01:05

K
KBT
Unregistered
KBT
Unregistered
K



They weren`t, but that`s so last year.

I still don`t have a picture of the corrosion in the offside rear quarter, the panel forming a floor where water ingress from the pininfarina badge has pooled is perforated. A quality repair is needed and then the car will be no worse for wear - but access is limited.

I have decided to not do a blow-by-blow account of how I replaced this nut, and then that one, etc. It isn`t very interesting. I also won`t be posting pictures until a section is complete.

I am in the tenth week of work now. I have restored any rubber that needed attention and was worthy of the effort. Notably the door seals, 3 hours on each and now look new. The boot seal is knackered, cut to ribbons for some reason.

Headlights got sanded and polished but I switched papers after doing a really good job on the nearside unit, with the intention of doing a `better` job on the offside, only to find that the finer paper had a stiffer back and the edges have caused some scratching. This isn`t very noticeable, but I have become a bit picky. Offside unit had a broken tab, which has resisted my first repair effort, which being invisible lacked strength. So i`ll pin it.

I removed the HIDs, I didn`t like the way the ballasts were mounted, the straps were corroded, they weighed half a kilo per side and after I removed them the bonnet didn`t fall on my head twice so no reperconcussions. Spell checker didn`t like that one. The headlights were not designed to illuminate a road at night but to look very pretty in car photographs and i`ll stick to daytime driving. I have some difficulty with my eyes anyway as a result of `thyroid eye`.

I also removed the underbonnet sound-deadening. It was torn, oil impregnated, weighed 1691 grammes plus clips and also prevented the engine being reflected by this amazingly shiny painted surface. Noise will have increased too. Bonus.

I spent ages cleaning the insides of the fog driving lamp assemblies, then I also bought some new ones which look better again. I now have ducting to the oil cooler. Seems like a good idea eh.

Except for the oil and intercooler brackets, all the sub panels at the front have either been refinished or are about to be. I decided to paint them myself, a few people have viewed the car and thought they were seeing factory fit and finish. Car enthusiasts so..

The front end is being repainted but again I have some thyroid related problems causing me to vomit when I smell anything from sewage, coal smoke, paint etc. Very tedious.

I am in the process of an engine bay re-work. New induction pipework and layout, modded loom, obviously the battery has vanished as has the washer tank. Did you know that full up it weighs 6.5kg? The expansion tank may swap sides to de-shrould the cambelt cover. The engine is a masterpiece and should be showcased. (I`ll finish this update at the weekend)

Re: LE 30 Project Thread [Re: ] #1496297
29/06/2014 23:32
29/06/2014 23:32

K
KBT
Unregistered
KBT
Unregistered
K



Family stuff blew up in my face, I miss having pictures and i`m getting some new nuts and bolts so a very different update very soon.

July 5th is our first anniversary, I had hoped to be further ahead with the rebuild than I am. I had to redo some of the painting as I wasn`t satisfied, very glad that I did as these cars are worth finishing well.
A car is made up of so many parts, I have wondered a few times if i`ll ever stop seeing bits that require attention.

TTFN

Re: LE 30 Project Thread [Re: ] #1503791
19/08/2014 23:33
19/08/2014 23:33

K
KBT
Unregistered
KBT
Unregistered
K



Finally, here are some shots of work in progress - the good, bad and ugly.

click to enlarge click to enlarge click to enlarge click to enlarge

Underneath is less good..

click to enlarge click to enlarge click to enlarge click to enlarge
click to enlarge click to enlarge click to enlarge

Fortunately, I have these.

click to enlarge

Much more soon.
Jon

Re: LE 30 Project Thread [Re: ] #1504643
25/08/2014 21:15
25/08/2014 21:15

K
KBT
Unregistered
KBT
Unregistered
K



To be complete, here is the fuel tank leak again.
click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge
Only a short-term job so the car can be started, even the original feed cable is damaged almost to the drivers seat. The fuse has been running hot, relay undamaged due to better materials. I decided my job looked a bit tractor like so I have upgraded my electrical department somewhat - you`ll have to wait and see. The connectors are bomb proof though, you can grab and yank without causing damage as I layered them up with silicone, flexible glue and heatshrink.

I used an extreme enviroment glue to seal the tank.

Re: LE 30 Project Thread [Re: ] #1504645
25/08/2014 21:21
25/08/2014 21:21

K
KBT
Unregistered
KBT
Unregistered
K



More of the previous owners handywork.
click to enlarge
So, what is wrong? The clue is in the brake pipe flexible and the fact that this is the front of the car - the hose should be fitted at the rear and is massively bound as it is fitted, o/s calliper was also loose, that was the clonking noise.

Re: LE 30 Project Thread [Re: ] #1504867
26/08/2014 22:32
26/08/2014 22:32

K
KBT
Unregistered
KBT
Unregistered
K



The bonnet release cable was damaged so I cut out the section and used a frankly dreamy 9mm 3:1 shrink to make a repair, ends then glued and a full length again over the top - now my cable is a better colour and functions smoother as the outer is slightly stiffened. I haven`t fully recovered the length so no finished picture as yet. The heatshrink is from a u.k. supplier with a product range to rival industry leaders, they don`t do boots but pricing is good and a trial quickly turned to using their entire range.
click to enlarge click to enlarge

A couple of shots of the front end progress - i`m about to fit the engine mounts (fast road version) and painted/new bracket.
Own up - just how many people have done a FMIC conversion and NOT swapped the bracket?
click to enlarge click to enlarge click to enlarge click to enlarge

I have started work at the back of the car and I will focus my efforts on her tender rear. I need to check a section of chassis between the subframe mounting points on the offside a.s.a.p. - other than this last one unknown area the car is going to live, and then some.

I`m doing development work towards a race type ecu loom, currently recycling F1, LMP and Indy car wiring loom sections to upgrade the slightly consumer rated tec. on the car like the Blitz. This is a half-way step towards producing work using the Deutsch Autosport range of connectors - there is a painful tooling cost of about £400 to £800 plus depending on crimper brands and number.

All the wiring I have done already got removed for something decent to replace it. I think there will be about three slightly woeful updates coming as there are 3 things that have happened to relate - one of them was done by me or while in my care. Sob!

Pictures from the o/s back so far.
click to enlarge
click to enlarge

Re: LE 30 Project Thread [Re: ] #1506436
05/09/2014 22:40
05/09/2014 22:40

K
KBT
Unregistered
KBT
Unregistered
K



I just noticed that the image of the damaged area in my previous post is misleading as the repair length is only about 110mm.

I have also reproduced here my post about suspension pre-load from another thread. This is relevant to my build as I will follow my own advice, any doubters are welcome to try and keep up.

Failure to pre-load front will promote early failure in wishbone bushes and arb to body bushes, the effect on the bushing arb to drop link may be less but...in performance, you chase even fractions of a percent so no compromises - things are assembled correctly.
The base point of pre-load should be roughly with the wishbones in the horizontal position in relation to the subframe.

Now, that last statement is very inaccurate - you will note that I said "base point" and "roughly".

The reason for doing this pre-loading is to limit the twisting forces which the bushes are subjected to during suspension movement, so in theory you would only fully tighten wishbone mounting bolts, arb to body bolts and arb to drop link nuts with the suspension damper at 50 percent of travel between rest and full compression.

Road cars are expected to rarely see full suspension compression so a lower percentage is used. Obviously, using lowered springs changes the maths, but here is the theory.
I have the famous brace of O on the car which makes a good starting point for reference(wish the adjuster wasn`t bent though).
I will probably make a tool when I see how, there are many titanium F1 suspension parts coming on the market and I would hope to have a bolt on part. Bolt on, jack up to reference mark, tighten fixings. I might even use a torque wrench. smile

p.s. I doubt I could find a garage for a hundred miles that would understand the term - they would bullshit you, take your money and say "yeah, we changed the springs"
p.p.s. I forgot to mention that correctly pre-loaded bushings exert, an admittedly limited, 2-way controlling influence over movement as opposed to 1-way resistance and t`other way assistance. The lighter the vehicle the more noticeable the performance increase/degradation - again in my view.

Some other parts of interest have arrived from the Red Bull F1 cars! woohoo

Re: LE 30 Project Thread [Re: ] #1506895
09/09/2014 01:39
09/09/2014 01:39

K
KBT
Unregistered
KBT
Unregistered
K



At the weekend I managed to get a few bits done.
Engine mounts fitted, even though i`m not happy with the nearside unit. Oil cooler refitted - I added a couple of rubber washers as the mounts are tired. Wing extensions fitted and the towing eye leg. Looks almost like a car again.

I managed to spray carb. cleaner in my eye as I sprayed the throttle body. I have taken a dislike to the throttle linkage. I think on the LHD version this would have been smoother and I hope to improve mine or at least stop the creaking.

Why do we heat the throttle body on a turbo engine? Having just cooled the inlet charge down it would seem silly to then heat it. Is the CSV temperature sensing? If it is I see an electric `choke` button on the horizon.
Re. CSV issues, mine didn`t respond to the clean but i`m hoping with a fully cleaned TB some improvement may be seen.

I also removed the fuel rail for a clean and polish and noticed that the injectors don`t appear to be a set, just a collection of odd ones. I have toyed with the idea of replacing them. I have more than toyed with the idea of changing the fuel lines, even thinking of adding dry-break fittings as they are cheap second hand.
Moving to the plenum to plan the wiring I found this - which I take to be the inlet air temp. sensor -
click to enlarge

loose in the thread so another small pressure leak fixed.

I`m fighting my way in to replace the CHOD with an ally pipe. The car won`t have a heater or air-con. She will only be used in summer and the car is so complicated I am going to slim down to bare essentials so as to make maintenance easy. All parts will be stored for refit if necessary at some point.
My mate is a bit gutted about the air-con going, I had to promise to fit a stereo or he would have sulked for days.

So I have drained the cooling system, all over my pit lights as it happens and myself. I did all the painting with a roller with the rad. and drier in place so I will have another go when all is removed.

I tried to get a cfc cambelt cover but so far no joy. There is a guy locally who works with the stuff, he is a friend of a friend but I doubt this will happen.

Nearly all for now but while i`m at it.
I lined up the timing mark on the cover by rotating the engine, moved the engine across and removed the cover to find the belt is slack and exhaust cam seems to be 4 teeth retarded. When I last drove the car she went like a dream, didn`t stop like it but I think??? I don`t know what to think, i`m glad I didn`t rev the car hard.

p.s. I also tested the stickers supplied by Kayjey by drenching in coolant, by accident and phew - no harm done. thumb

Last edited by KBT; 09/09/2014 01:42. Reason: p.s.
Re: LE 30 Project Thread [Re: ] #1507043
10/09/2014 00:39
10/09/2014 00:39

K
KBT
Unregistered
KBT
Unregistered
K



Managed to get the plenum chamber off today.

CHOD close to splitting at the o/s end and leaking somewhat though not visible on the floor as yet.
Generally, nothing tight at the back of engine, lots of signs of incorrect tool usage so some fixings to replace.
Not exactly fun to work in this area of the car so now i`m in there I will have to have the most colossal blitz.
Donuts from group buy trial fitted and they are really nice. I think i`ll get another set!

Obviously, doing my competition wiring makes the back of engine more straightforward and i`m blowed if i`m doing this twice so that mod is back on.
Some of the water pipes including CHOD replacement come from RB3.

Blower has made its way into the workshop now so development is underway.

I saw some race car thread and the owner has this crazy rear wing, I think i`m going to get one on my road car just to disgust you all.
Jon

Re: LE 30 Project Thread [Re: ] #1507560
13/09/2014 15:20
13/09/2014 15:20

K
KBT
Unregistered
KBT
Unregistered
K



I started doing research into fuel injectors and have discovered that injector swaps are a can of worms involving pressure and ignition timing adjustment. I have to talk to a specialist regarding mapping as I don`t know enough to make an informed decision as yet.

Despite this week being chaos I managed to de-gas and remove most of the air-con. components. Drier, separator and forward 3 pipes weigh 3575g plus refrigerant.

Now the front end is clear I suppose I can do some more painting.

I have noticed the plenum chamber seems to have been internally re-modelled, I have no idea if this has been done by someone with know-how or just a dude with a dremel. It has also been painted as has the inlet manifold, I don`t want to remove the manifold if I can help it at this point but I hope to get the plenum some kind of heat-proof coating that also looks the business.

I only just woke up and decided to write this, now i`m going out to get started - hoping to get a few things done and some pictures.

Re: LE 30 Project Thread [Re: ] #1507624
13/09/2014 23:59
13/09/2014 23:59

K
KBT
Unregistered
KBT
Unregistered
K



Progress today.
click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge click to enlarge

Re: LE 30 Project Thread [Re: ] #1507648
14/09/2014 11:36
14/09/2014 11:36

K
KBT
Unregistered
KBT
Unregistered
K



Hopefully, you can see my statement as to the ultra-fishyness of this car. I have known this car has some secrets for a while, I just didn`t know how to phrase my thoughts and suspicions. Now I don`t give a damn either way, the truth will out.

As far as I am concerned this vehicle won`t ever be what I had hoped for because of her dirty dp`ing past.

If the owner/driver who may have been involved in a collision with a motorcycle would come forward that would be a start.

I noticed the o/s wing mirror bore a trace of the colour of ultimate evil.
Broom Yellow. laugh
It also has 2 extra wires and a stub, compared to the N/S.
One wire is frayed - exposed copper.

O/S door glass also replaced, interestingly this glass was then trashed during re-spray prep. at a guess. I don`t think the door was replaced but until I can remove the card I can`t be sure. Can`t remove card without some effort due to the state of the fixings.

Door bottom seal also doesn`t match the N/S.
Damage at front end of sill area, underneath o/s footwell and to a greater extent the n/s.
Possible signs of a dent pulled from bonnet.
Damage to headlight.

I called in a friend to look at this and another area which I will cover in my second book. I pointed him towards the areas in question, didn`t mention my thoughts, in fact I went and made the tea. tongue

Regarding this area he said, has this hit a motorbike?

Re: LE 30 Project Thread [Re: ] #1508122
17/09/2014 07:30
17/09/2014 07:30

K
KBT
Unregistered
KBT
Unregistered
K



Engine number does not match V5C.

Copied from gov.uk -

1. Changes you'll need to update

You must update your registration certificate (V5C) if there are any mistakes on it, or if you make any of the following changes to your vehicle:

colour
engine
cylinder capacity (cc)
fuel type
replacing or modifying the chassis or bodyshell
seating capacity
weight of a goods vehicle
tax class changed to ‘disabled’
So I guess i`m in the frame to inform of the change which previous owners have failed to notice.
The insurance policy on the car since the unrecorded engine swap has been technically void as a result I believe.

Has the individual responsible for not recording the change not committed a crime?

Where is engine number 1161030?

Last edited by KBT; 18/09/2014 01:02.
Re: LE 30 Project Thread [Re: ] #1508744
21/09/2014 12:29
21/09/2014 12:29

K
KBT
Unregistered
KBT
Unregistered
K



Well, i`m over it!
There seems no need to maintain any outward sign of the cars identity any further. What a relief.
I have engaged secrecy mode for a while as I have decided to further buck current trends, I sort of needed my life back so have returned a lot of removed parts to the car - regular mock ups keep the enthusiasm high and mean I don`t design into spaces which are already occupied.
I have very nerdily weighed many parts of the car, I will include the list here in time - over 100kgs gone now including the seats so there will have to be a weight added list later on.
Should have a few pictures later today as a parting shot - the doctor is telling me to stop, or die, a break is inevitable now.

Re: LE 30 Project Thread [Re: ] #1508809
21/09/2014 23:07
21/09/2014 23:07

K
KBT
Unregistered
KBT
Unregistered
K



As promised, a few photos before I sign off.
click to enlarge click to enlarge click to enlarge


If you look very close at the image below you can see the 1mm cfc rods i`m using to toughen up the grille.
click to enlarge

I can say that the car will return with a fixed limit of 350bhp based on air flow in the induction system. Not much lag though. A change of induction parts, turbo, pistons, rods etc. would support 650bhp.
I met a guy with a 600bhp gtr, he also has a coupe!
Thanks for looking. Back soon.
Jon

Re: LE 30 Project Thread [Re: ] #1510300
04/10/2014 11:42
04/10/2014 11:42

K
KBT
Unregistered
KBT
Unregistered
K



What a difference two weeks can make!

Project 30 has gone off on a wild tangent and I don`t know how to begin to relate. You`ll see glimpses and clues in the coming weeks.

In the meantime here is something dull.
click to enlarge click to enlarge

Craig had not made the best of jobs in the cutting of the front bumper. His shape was more ambitious than mine though. After these pictures I removed more material to enlarge the cutout beyond where the knife must have slipped.(pic2)
In the first image you can see the cfc rod which cures droopy mouth syndrome.

Some work is going into the front bumper/spoiler which I will add when I get it all done.
Here is the mesh again - since this shot I painted it black.
click to enlarge

If the w/e goes well I might manage some updates - I have to go and do some ugly jobs behind the engine and don`t want to even start.
Jon

Re: LE 30 Project Thread [Re: ] #1510505
05/10/2014 20:56
05/10/2014 20:56

K
KBT
Unregistered
KBT
Unregistered
K



Sorry no pictures.

I didn`t get as much done as I would have hoped for due to an extensive mock-up then removal of the charge cooling bits.
:-re a cc setup - yes I saw the type of system employed on coupes in the past, I expect they didn`t work at even lowly factory power.

ABS mostly removed.
Pipes to front brakes removed.
Build your own braided stainless pipes emerging from master cylinder.
ECU loom labelled and coiled on floor in front of car.
Front end stripped (again) for paint and some design work.
Engine mount sub-brackets removed for custom made substitutes.

In line with what i`m doing I envisage a re-site/replace of the brake/clutch res. - I have a nice one from a low heat output car!
All brake, fuel and clutch lines in stainless. (HEL byo service)
Some electrics may move into the passenger space.
The battery might join them from the boot - depends on regs.
Dash comes from F1 car I think.
Interior fan fits below cabin filter.
Told my mate the stereo might be a hand held.

This is just for starters, as the car will have extensive mods. from the from front lips to exhaust tips - even the front undertray has a mod or two envisaged!

Having read the 4wd elements of the thread by Josip I see an easier way to handle the engine move. Also a sequential box would be nice, I have to stop myself from left footing as it is. Too much time in rally sim.

I have totally failed to mention the major news - what a muppet I must be eh?
More soon.
Jon

p.s.
Much as it is nice to get what we want, especially when we have paid for it, the fact that this car was a disaster has proved to be the best motivation I could have had to rebuild her into the earth-shattering LEmental she secretly knows herself to be.

Re: LE 30 Project Thread [Re: ] #1511093
09/10/2014 20:30
09/10/2014 20:30

K
KBT
Unregistered
KBT
Unregistered
K



I actually took the day off work today but failed to do any work on the car as I spent the whole day watching videos of Spa!

Myself and my workmate are being transferred under TUPE legislation to another firm. I`m sure that things will work out ok but can`t help worrying about what the future employment prospects are likely to be. As a result of this I can`t concentrate and my work on the car is suddenly rubbish.

I decided to go back to my original plan for the car with work to be completed in phases.

Phase 1 - make repairs where necessary. Replace all suspension components. Rebuild callipers, remove ABS and fit stainless lines. Change intercooler - now charge cooler - less lag and lighter pipework as my stainless was heavy.
Get MOT and enjoy car for a time.
So I have to pull back from some mods. already in progress. These are too many to list but big obvious ones are race-type wiring loom and twin charge setup. The twin charge implementation is so shocking that I can`t not do it, but I don`t have the fabrication skills/facilities right now and it seems sensible to plan to build a second lump with forged internals when circumstances allow.
As for the wiring I will make some compromise initially so work done already isn`t wasted.

The best news about this thinking is that I don`t even need to think about Phase 2 and can regain some concentration.

In the height of my brainstorming I also realized why I had so much difficulty swallowing my medication which I stopped taking -the pharmacy had been giving me an un-branded product which dissolved really fast and made me throw. I hope to be able to take the branded stuff and should become less crazy as a result.

Re: LE 30 Project Thread [Re: ] #1511559
13/10/2014 20:51
13/10/2014 20:51

K
KBT
Unregistered
KBT
Unregistered
K



I hope this post is the last of the bad news and me bitching at previous owners. (Don`t hold breath)

This is my bad. The bonnet spat out its prop and fell to the closed position. The catch was mis-aligned and two spot welds tore. Circled. Love the scratchy paintwork too, roll on paint correction week.
click to enlarge
I am probably just going to stick some dreadful decal over it for a temporary measure. I may well do some other naff things too so to save anyone the bother...
Note to self - You utter ricer, I would s*it on your head for this!

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Damage to glass, I have been told that T-cut may improve it.

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Whoever did this is going to hell.

Now, last year I posted a picture of an anomaly at the rear screen. I was told all coupes have this - it`s a braze line.
I didn`t believe a word, sorry. I always trust my instincts and so far haven`t been eaten by any sabre toothed tigers.(just bitten by dodgy sellers)
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This repair occurred after the car was hit by a van. I believe the sale was already agreed between Roger Chapman and Steve Duke. There was no money in it for Roger and I imagine the work could have been done much better if someone had paid for it.
As it is, it looks as though the repair was undertaken with the B/C pillar cover held out of the way with wood-I even found painted wood slivers behind bonnet sound deadening amongst other places. The reason this was done is because one of the fixings was knackered, I had a devil of a job getting the trim off without visible damage.

The car has also been rear-ended so the n/s quarter and rear is all out of line. Expensive repairs or just say whatever/track orientated car.

Nismo may be right, and the colour matches my eyes, but does this really need to be so complex? I can`t help but wonder if the vapour line could simply be plumbed in pre-turbo.
click to enlarge

I have come to realize that I like having the car in bits, I just need another one now to drive.
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Your thermostat`s gone, and then some.
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I have 9 inches to play with.
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Custom plenum required though. I have no idea how this will come about, I can`t weld as I have tremor and i`m crap at it to be honest.

Re post before last, HEL service doesn`t cover fuel lines, i`m hoping Joe will come to the rescue on that bit once i`ve sourced the dry break fittings etc.
Jon

Re: LE 30 Project Thread [Re: ] #1511784
15/10/2014 22:49
15/10/2014 22:49

K
KBT
Unregistered
KBT
Unregistered
K



Quick update.
It turns out that my tremor relates to Graves Disease.
I cut my smoking by 60% to save 500 quid a year and stop looking like a goldfish that`s about to keel over - smoking exacerbates Graves. After just 5 days of the new regime my eyes are so much better and tremor lessened. Result.

I also found a mobile gas welder who rates himself? Good start but i`ll have to see some results, I had hoped an old friend from the docks would be on hand but he is lost in Didjabringabeeralong or somewhere that sounds like it.

I`ll make all the panels to save money and ensure they are made well. Decided to not muck about so the underside will get epoxy coated. I`ll have to do front end the same, I live a quarter mile from North Atlantic coast and if the car is to last I must use the best products.

So now I have the welding penned in I must get on and strip the fuel tank and running gear. Rear sub will also get the epoxy treatment, bushes from Ferrarist?, Boge Dampers and probably new springs. I might be tempted to keep AR bars standard till phase 2 which will include a change to coil overs. I won`t know which way to jump till I can test the car.
The rear discs look silly so they may get an upgrade. I have some vented carbon in 280mm which may become an option with some cross-grade parts from VAG/Audi. Lots of worried Audi drivers round here as been under S3, S4 and several TTs with tape measure etc.

As it has stopped raining i`m going out to get started.
yipee

Re: LE 30 Project Thread [Re: ] #1511927
17/10/2014 00:22
17/10/2014 00:22

K
KBT
Unregistered
KBT
Unregistered
K



Overnight a couple of things fell into place.
I`m really, really chuffed. So characteristically i`m not saying anymore.

Underneath the car is foul, I almost envy those with a lift and air tools.

Managed to remove h/brake cables, exhaust system, and heatshields. The main tunnel shield is ok but the rear sections are in poor condition.
The downpipe seems to be broken at the pre-cat., if that is what it is - the mini silencer by cat. Pipe is very loose fit at rear end.

Should there be a metal strap around cat.?
None present but there are unused hangers.

I`m not happy with the position of the car, seeing as she may be up on blocks for a few months. I need to move the Beta but it`s not really the right time of year.

I think the chassis is ok, not 100% but i`ll know for sure this weekend.
Haven`t decided whether to go aluminium or oxide red underneath, suspect i`ll go for the ally but I do tend to change my mind.

Praise goes to JBT whose application of underseal to the brake lines has saved the underbody in those areas.
He changed the cam belt 5 years ago too. I wonder if the inlet timing marks were made at this time?
I have a problem with the engine timing and the tensioner is slack but I realize now that the tension backed off when I rotated the engine backwards by a small amount. Exhaust cam appears to be 4 teeth retarded. I know I need the locking tools and proper approach to find TDC, but I really hope that I can get the engine timed without taking head off. If it comes to that, i`ll have the engine out too for a full clean etc.

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The day will come when the bits you can`t see will outclass the bits you can.
I`ll post a video soon from her last cruise, next time on the road will be very different.
Jon

Re: LE 30 Project Thread [Re: ] #1512198
19/10/2014 12:11
19/10/2014 12:11

K
KBT
Unregistered
KBT
Unregistered
K



I have put myself out of action for a few days, old injury - always happens when working under car.

The HEL build your own service seems to have been updated since I last used it.
Prices have gone up. A 5m used to be 40 quid, now max length seems to be 3.5m at 55 quid.
They also do oil and fuel lines.
This service is pretty cool if you like to go it alone. I used to get bits made at a local firm which involved a 60 mile drive, now I just click a mouse button and they turn up day after next.

ps. I knew there was something I forgot to mention.
I just got fed up mending the grille so I glued some mesh behind. It doesn`t look too bad and is only till I find a better one, highlight was managing to glue my phone to it in the process.

Last edited by KBT; 20/10/2014 00:30. Reason: ps
Re: LE 30 Project Thread [Re: ] #1513140
26/10/2014 22:20
26/10/2014 22:20

K
KBT
Unregistered
KBT
Unregistered
K



I haven`t managed to get any pictures today, but I got a bit done and I`m off out to carry on after typing this bit.

I decided to put off the welder till I can get the car in the centre of the garage, if he is uncomfortable he might not be able to do the best of jobs.

Also, the car is not in a good position to block up and access all the areas I need to get at. So more compromises.
The front end is now up in the air, I didn`t have the right type of blocks so I used a couple of spare Lancia alloys and a couple of bearers running the length of the front subframe. This is going to limit what I can do at the front for the time being but I hope to have the car supported safely as I expect to be fighting with some of the rear end fixings.

Where I have to block up at the back also limits the areas available to work on but I can at least refurb. the rear subframe and maybe with tank and rear sub removed I may be able to then deal with the chassis in that area and perhaps block there to deal with the area below the rear seats.

I planned to uprate the fuel system but it`s hard to know which way to go as I might change the fuel tank. chinny hehe

More soon. Very soon.

Re: LE 30 Project Thread [Re: ] #1513159
27/10/2014 01:38
27/10/2014 01:38

K
KBT
Unregistered
KBT
Unregistered
K



A friend stopped by today and had a look at the car.

He was amazed at how clean the front end and engine bay is looking, it just looks how it should as far as i`m concerned considering i`ve bare metalled the problem areas and painted. I have been working on it for 6 months and I seem to have made little impact.

Just been attacking the inner front o/s wing area. There is some corrosion, not the worst I have seen and I don`t think the chassis by the forward subframe mount has been affected. Some welding will be required here, I think the n/s is similar.

Tomorrow I hope to really make some progress, with a little extra bravery I should be able to remove the front struts, wishbones, uprights and driveshafts.

In my porch I have 2 sets of Brembos to refurb, one set to read Brembo and the other LEmental - local GfX dude is doing the decals for me.

In my bathroom we have wheels, n/s/f came off finally, it`s only taken 15 months - just slightly longer than it took to find the oil filter. crazy

I have to have a remote filter, probably from Canton Racing Products. The mutts absolute nuggets.

I also whipped off the pas drivebelt, there seems to be some play in the idler which looks about as sophisticated as a reel of fishing line. That`s not very good, if you hadn`t realized.

No Stuart, it isn`t a Volvo engine.
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