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R803CGP / C20VTJ restoration thread #1661134
11/10/2022 08:15
11/10/2022 08:15
Joined: Dec 2005
Posts: 1,071
Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Drakelow
Hi all,
As I’ve now taken ownership of what was GrahamL’s car, I’m planning to bring the car back to factory fresh condition.

Graham has done a great job in either fixing the nuances of a coupe and/or doing a number of jobs just right (wishbones being one of them tongue :P)

My aim is to not really touch the engine/turbo, other than maintenance, it’s more to improve the standard suspension and brakes, along with with fixing some cosmetic stuff.

So onto the brakes, whilst Graham has recently done brakes and discs all round, they are decidedly average, which is just how they are from factory. So at this stage I’ve bought some PFC pads that I’ll fit at some point before Xmas.

I’ve bought a complete new set of brake lines and flexi hoses from JBT, and have some ATE200 brake fluid ready to go.

I’m going to refurb the calipers all round and paint them red as the silver always looked a bit understated to me.

For the suspension stuff, I’d initially ordered a full Koni set up, but when I found out you needed to butcher existing struts at the front to fit them, I’ve cancelled and bought the OSRAV shock absorbers, and then a set of Eibach springs with a 30mm height reduction.

Albeit these are made to order and I won’t get them until November ish

I’ve ordered a Ultra Racing rear ARB (23mm), again made to order but that should be with me in the next couple of weeks

Finally for suspension I’ve got the subframe bushes and rear arm bearings from FCSS, as I’ll drop the whole rear end and deal with tarting up the arms and get them painted.

For obvious reasons whilst I have all this stuff off the car I’ll check the chassis over and as a minimum I’ll treat all the underside to simply preserve what appears to be a rock solid chassis floor pan.


I have as a belt and braces approach , bought a new oil cooler and pipes from JBT which I’ll fit in the next couple of months….


Onto cosmetics……

I need to refurb the leather seats due to age related wear, so I’ll post pictures in the next few weeks

The Eiffel towers are cruddy bit appear solid so I’ll repaint those, or if they are scabby, I’ll change them out for some new ones

I’ve fitted a special head unit off Amazon for £90, just so I have Bluetooth for hands free calling, but I’ll put some pictures up and tell you a bit more about it

That’s it to start with, I’ll endeavour to post pics/progress and fix anything else I see along the way

Cheers Jamie


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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1661285
15/10/2022 18:28
15/10/2022 18:28
Joined: Dec 2005
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Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Drakelow
I should have replied here….

Anyway so my Eibach springs have turned up today.

I might have an hour tomorrow to fit the new bonnet latch I’ve bought from JBT, if I do I’ll post some pictures afterwards.

I’m still waiting for the Ultra Racing anti roll bar (23mm), which should be here in the next week or so, and then a couple of weeks later the OSRAV shocks are due to arrive.

I’m busy for the next couple of weeks doing some dads DIY at both my kids houses, but then it’s payback when they help me drop the rear end of the car including taking off the calipers all round and start to refurb those as well

Attached Files

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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1661303
16/10/2022 16:01
16/10/2022 16:01
Joined: Dec 2005
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Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Enjoying the ride

Joined: Dec 2005
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Drakelow
Today I’ve been faffing around with replacing the bonnet catch, also I found the cable for the bonnet release somewhat frayed. So a trip to Halfords for a bike cable is needed.

Jamie

Attached Files

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Re: R803CGP / C20VTJ restoration thread [Re: Edinburgh] #1661369
22/10/2022 19:57
22/10/2022 19:57
Joined: Dec 2005
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Drakelow
So I’ve degreased the entire underside of the car today including all the wheel arches in readiness to drop the rear subframe in a few weeks time. At present I’ve got the car SORN so it will stay ‘clean’.

I noticed whilst under the car at some point someone has jacked the car up on the floor area, so I’ll try and pull the metalwork back out.

Also bought a new inner cable for the bonnet release, if it’s not raining tomorrow I’ll refit that

Also bought some cable to do the fuel pump wiring mod along with the relay.

Also chasing ultra racing for the new anti roll bar, as it’s been 4 weeks and counting….

Cheers Jamie

Last edited by Edinburgh; 20/11/2022 10:37.

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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1661522
30/10/2022 16:16
30/10/2022 16:16
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Drakelow
Not much done this weekend due to Dads DIY for my daughter


Anyway changed I’ve done the bonnet release cable, which with my crappy eyesight took an eternity of squinting in order to find the hole (ooer)

The Ultra Racing anti roll bar has arrived, so I’m just waiting for a couple more weeks before I start to dismantle the rear end.

I’ll try to take as many before and after piccies , so anyone doing similar stuff can either get the idea or I shout up for help!

Cheers Jamie

Last edited by Edinburgh; 20/11/2022 10:37.

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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1662010
19/11/2022 16:01
19/11/2022 16:01
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Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Posts: 1,071
Drakelow
Quick update, my Osrav shocks have just arrived, so now I have everything to start with.

Jobs to do


Wire the fuel pump mod

Overhaul and rebuild front and rear brake calipers inc fresh paint job

Replace all solid brake pipes both front and rear, also replace the flexi hoses

Flush brake fluid system with ATE200 brake fluid

Fit new oil cooler and pipes from MCS (Jonny bravo)

Fit new Osrav shocks, Eibach springs, top mounts and camber bolts for the front end of the car.

Fit PFC pads to the front brake calipers

Remove rear axle and trailing arms, derust and paint Matt black

Obviously there are a number of tasks linked to the above, so fuel tank, rear shocks, exhaust off etc

Whilst the rear end is stripped off, I’ll check and treat the floor and chassis where needed, then stone chip seal it to make it look factory fresh

Fit new 23mm ultra racing rear anti roll bar

Fit new Osrav rear shocks

Change the bearings and bushes in the rear arms (FCSS).

Go to my mates garage and get the tracking and camber set up

I’m sure I’ll have some surprises along the way, but I’ll fix anything else that crops up

Cheers Jamie

Attached Files

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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1662335
11/12/2022 14:55
11/12/2022 14:55
Joined: Dec 2005
Posts: 1,071
Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Enjoying the ride

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Posts: 1,071
Drakelow
Firstly will post a load of pictures later, but had a full day of working on the coupe, and strangely remembered from 20 years ago the sequence of how certain things come off

Anyway the aim of the day was to get the turbo off, and get it checked as it’s a bit smoky at times. What I found was the manifold was cracked on the 5th branch as well as on the collector area. So turbo will be done via a local specialist and the manifold will get repaired at work as we have the skills onsite to do this kind of repair

Depending on what the turbo people say will determine if I modify the unit further as it’s got an Owen Developments logo on it, or if I just get the bearings/o rings done to stop the smoke, as there’s only a small amount of play on it

What I do remember is the poxy 8mm Allen key to loosen the idler pulley to get at the coolant bolt, so after sacrificing the crapiest 8mm Allen key I own it’s quite easy to do.

I also drained the oil as the plan is to fit the aftermarket oil cooler and pipes, however Grahaml must have the strength of a gorilla as the sump bolt took all the effort of 2 of us to shift it, anyway it’s out and oil is drained.

Eiffel towers on the front look a bit crusty but salvageable, so I’ll take the bumper off and treat those along with some other metal areas whilst it’s all exposed

Anyway pictures will be later


Cheers Jamie


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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1662502
21/12/2022 16:49
21/12/2022 16:49
Joined: Dec 2005
Posts: 1,071
Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Drakelow
Hi all,
Couple of pictures of the manifold repair for now

It had been repaired previously, so I hope that it will last

I have noticed that the face isn’t totally flat so I’ll get it machined to avoid stressing it and promoting the chance of further failures

Cheers Jamie

Attached Files
image.jpg (446 downloads)
image.jpg (442 downloads)
image.jpg (441 downloads)

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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1662548
25/12/2022 11:41
25/12/2022 11:41
Joined: Dec 2005
Posts: 1,071
Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Enjoying the ride

Joined: Dec 2005
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Drakelow
A few Santa prezzies

Attached Files
image.jpg (419 downloads)

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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1662561
26/12/2022 12:44
26/12/2022 12:44
Joined: Dec 2005
Posts: 1,071
Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Joined: Dec 2005
Posts: 1,071
Drakelow
Fitted both sets of led lights this morning to replace the dipped and main beam bulbs

Pretty easy to do, I found it easier to just remove the whole headlamp unit and change the bits over in the warmth of my kitchen

Massively brighter than the halogen bulbs that were in, as you can see from the attached photo

I did plan to put the Osram nightbreakers from the dipped fitment and put them into the driving/fog light units, but they are super fragile and both filaments broke just by removing them

I will buy a new set as I want to get as best I can for night driving


Cheers jamie

Attached Files
Last edited by Jamiepm; 26/12/2022 12:45.

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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1662673
31/12/2022 15:25
31/12/2022 15:25
Joined: Dec 2005
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Drakelow
Made a electrolysis tank today to clean up some parts whilst I’m waiting for the turbo and manifold to come back


After 30 mins you get something that looks like a scene from the gremlins movie (see picture attached ), so it’s doing something

Anyway as some parts were too big to be fully submerged, I’ll turn those around tomorrow to get the other halves done over the next day or so

Then it’s a wash down, brush any last bits off and then prime and paint the bits

Cheers Jamie

Attached Files

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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1662688
01/01/2023 15:13
01/01/2023 15:13
Joined: Dec 2005
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Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Drakelow
I cleaned a few parts off this morning, but found some of the bits need more time to get rid of all the rust

On the coolant pipe that runs near the alternator, I noticed it was cruddy to start with. After 8 hours of being in the tank it’s cleaned up nicely, however there are now a few pinholes, so I’ll get those welded up at work

Cheers Jamie


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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1662753
04/01/2023 18:07
04/01/2023 18:07
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Drakelow
Quick picture of the heat shield for the turbo/manifold after a coat of VHT paint

The electrolysis takes a a fair few hours, but it saves you that time from grinding etc

Cheers Jamie

Attached Files

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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1662762
05/01/2023 15:39
05/01/2023 15:39
Joined: Dec 2005
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Drakelow
Just got the turbo back, so it’s had a new shaft, 360 bearing and a staggered piston ring and then all balanced up.

So that will have cured the blue smoke and oil consumption

Cheers Jamie

Attached Files

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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1662964
13/01/2023 21:04
13/01/2023 21:04
Joined: Dec 2005
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Drakelow
Firstly I haven’t loaded many pictures due to the 2mb limit, so hopefully below is a link that people can use to see pictures etc

https://drive.google.com/drive/folders/1bv_IyVF6GCa8Iy3VzYooOsIdeRZLHG4R?usp=sharing

So hopefully I’ve done the link correctly

Cheers Jamie


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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1662976
14/01/2023 16:59
14/01/2023 16:59
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Drakelow
More pics from today

Had fun with misaligned manifold holes which meant some unplanned work , but the turbo and manifold are back on

That poxy bolt for the water rail :mad:, as I’ve removed the oil cooler bracket, I found it easier to remove the 3 bolts for the tensioner and then the m6 water rail bolt is super easy to get at

I’ve bought a new gasket for the water rail as a leak there means a whole chunk of work to rectify, and I used some RTV sealant to be sure that it will never leak!

In terms of drivers side wheel arch, I’ve acid etched primered everything that’s been cleaned up. There are a couple of bits such the drivers wing that need filling and painting properly, but I didn’t want surface rust to form overnight .

I’ll try and get paint and stone chip done tomorrow, so I can then fit the new suspension stuff and new brake line

I’ve got the caliper off and all bolts and fittings loose, so during the week I’ll try and do the seal and paint overhaul

Cheers Jamie


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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1662980
15/01/2023 10:56
15/01/2023 10:56
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Drakelow
Just uploaded a couple of pictures of the new oil cooler pipes that I’ve give a quick coat of paint

As these things seem to eat themselves over time, and the aftermarket cooler and pipes aren’t the cheapest thing to buy, I’ve painted them to preserve them

I’ve painted up some other bits and bobs that I’ll load the photos onto the google drive later

Cheers Jamie


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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1662985
15/01/2023 15:55
15/01/2023 15:55
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Drakelow
Not done too much today as the weather has been not the best

I’ve put all the air con, belt tensioner and associated gubbins back together

Noticed the shroud/heat shield that protects the silicone return pipe which feeds back into the sump was somewhat rusty, so in the electrolysis bath it’s gone with a few other crusty bits

Also fitted the oil feed pipe onto the turbo, but I had a brain freeze moment as to regards which water pipe and banjo bolt goes to which side of the turbo. So I’ll come back to this next weekend

I’m going to try and strip the brake caliper during the week and see if I can get it all refurbed and painted.

https://drive.google.com/drive/folders/1bv_IyVF6GCa8Iy3VzYooOsIdeRZLHG4R?usp=sharing

Cheers Jamie

Last edited by Jamiepm; 15/01/2023 15:59. Reason: Google drive link added

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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1663104
21/01/2023 18:31
21/01/2023 18:31
Joined: Dec 2005
Posts: 1,071
Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Enjoying the ride

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Drakelow
Spent a few hours today finishing off some bodywork and started to put the aftermarket oil cooler and some coolant pipes around the turbo

All being well, I should get on the car tomorrow to be able to at least start the engine and check for leaks before I then start on the Shock absorbers the following weekend

A few pictures in the drive to nosey over

Cheers Jamie


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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1663114
22/01/2023 17:16
22/01/2023 17:16
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Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Drakelow
Just left the engine running for 30 minutes to do the obvious check for leaks etc.

So far so good

Just got to stone the drivers side wheel arch area, replace the brake line back to the abs unit, fit the wheel arch liner, fit the new shock and spring, paint and overhaul the caliper, bleed the caliper, put the wheel on…….


And then do the passenger side……..

Cheers Jamie

And a few new pics via google drive


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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1663236
28/01/2023 17:53
28/01/2023 17:53
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Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Enjoying the ride

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Posts: 1,071
Drakelow
Spent the day removing the whole rear axle,subframe assembly

I've knocked out all bushes and trailing arm bearings etc

The smaller subframe bushes needed a bit of violence, but the hammer won

Likewise putting the new ones back in was a similar story, the larger bushes refit quite easily, but I had to use a puller to fit the smaller ones

Got the electrolysis tank set up again so derusting the rear brake guards and some other bolts etc

Some of the brake lines failed the minute I touched them, so a worthwhile task to change all the lines

I'll upload some photos later, but feels like a lot done today

Cheers Jamie

Drive uploaded with a few photos

Last edited by Jamiepm; 28/01/2023 18:15. Reason: Photos

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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1663251
29/01/2023 15:44
29/01/2023 15:44
Joined: Dec 2005
Posts: 1,071
Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Enjoying the ride

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Drakelow
Couple more photos from today

Basically got both trailing arms and the beam derusted and painted today

Whilst it’s been a good day it just took a long time to clean and prep the bits

Cheers Jamie


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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1663252
29/01/2023 15:51
29/01/2023 15:51
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Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Enjoying the ride

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Drakelow
I also should think about changing the thread title as I have have a private plate on the car…….


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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1663255
29/01/2023 17:46
29/01/2023 17:46
Joined: Dec 2005
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Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
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Drakelow
Plan for next the next at night is to continue with caliper refurbishment, and then at the weekend I have some surface corrosion on a few places around the underbody that I plan to clean up, apply rust treatment then stone chip the underside of the car

Cheers Jamie


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Re: R803CGP / C20VTJ restoration thread [Re: Jamiepm] #1663295
31/01/2023 22:23
31/01/2023 22:23
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Drakelow
Primed the brake caliper tonight, then will flat it tomorrow before painting yellow , photos in the link

Cheers Jamie

https://drive.google.com/drive/folders/1bv_IyVF6GCa8Iy3VzYooOsIdeRZLHG4R?usp=sharing


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Re: R803CGP / C20VTJ restoration thread [Re: Edinburgh] #1663349
02/02/2023 22:03
02/02/2023 22:03
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Enjoying the ride

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Drakelow
Quick update for tonight

Couple of coats of paint stripper applied to the strut brace, so I’ll see how it cleans up tomorrow after work

Wire brushed the rear calipers, which is pretty fiddly to be honest, but they clean up pretty well

I’ll post some pictures tomorrow

Cheers Jamie


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Re: R803CGP / C20VTJ restoration thread [Re: Edinburgh] #1663359
03/02/2023 19:02
03/02/2023 19:02
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Drakelow
Whatever the paint on the strut brace, it’s pretty tough

Anyway all cleaned up and an etch primer coat applied

See the google drive for piccies

Cheers Jamie


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Re: R803CGP / C20VTJ restoration thread [Re: Edinburgh] #1663374
04/02/2023 17:09
04/02/2023 17:09
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Drakelow
Painted the strut brace and one caliper today, will try and clear coat them tomorrow if time permits….

Also finished with final paint for the rear arm assembly’s

Main job for today was to go over the entire floor and chassis and prep any rust found

I took the time to literally touch even the smallest of blemishes to be sure I won’t need to come back to this job later

I’ve then put rust treatment on anything I found, then finally degreased the floor area and pressure washed it all

Hopefully tomorrow I can apply stone chip to all of the underside and again that’s job done I hope!

Finally link for all photos below

Cheers Jamie

https://drive.google.com/drive/folders/1bv_IyVF6GCa8Iy3VzYooOsIdeRZLHG4R?usp=sharing


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Re: R803CGP / C20VTJ restoration thread [Re: Edinburgh] #1663383
05/02/2023 12:16
05/02/2023 12:16
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Drakelow
Jamiepm Offline OP
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Jamiepm  Offline OP
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Drakelow
I ve just done the underbody treatment with upol

Really impressed with how it covers,so would highly recommend 👌

Will post some pictures later

Cheers Jamie


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Re: R803CGP / C20VTJ restoration thread [Re: Edinburgh] #1663388
05/02/2023 17:27
05/02/2023 17:27
Joined: Dec 2005
Posts: 1,071
Drakelow
Jamiepm Offline OP
Club member 1989
Jamiepm  Offline OP
Club member 1989
Enjoying the ride

Joined: Dec 2005
Posts: 1,071
Drakelow
Good weekend of progress on the car

Fit new bearings into the rear trailing arms and then fit them to rear beam(bought the kit from Joe @FCSS, nice quality and pretty easy to install) wink

Prepped and protected the whole underside of the car, including all wheel arch areas and behind the liners(that should last another 25years laugh

Refurbed and repainted the whole rear beam and arm assemblies , albeit I can’t find the lovely plastic end caps I’ve bought from joe grr

Installed new bump stops, new Osrav rear shock absorbers (set at 4 clicks having read other people’s experience) and the Eibach uprated springs love love

Refit the repainted rear disc guards and refitted the rear discs

Tried to fit the ultra racing rear anti roll bar, but the brackets are oversized compared to the 23mm bar, why? Anyway I’ll get some shimmed material to compensate for this tomorrow I hope grr grr

I’m planning a day on Tuesday, where I’ll plan to refit brake lines from the rear brake bias, and hopefully sort the anti roll bar out. If time permits I’ll finish the overhaul on the rear calipers

Assuming that goes to plan I’ll then at the weekend put the rear arm back on, along with the petrol tank and exhaust tongue

Cheers Jamie


Google drive has some new pictures to look at for those interested


She's alive!
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