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R803CGP restoration thread #1661134
11/10/2022 08:15
11/10/2022 08:15
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
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Jamiepm  Online Yippee OP
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Hi all,
As Iíve now taken ownership of what was GrahamLís car, Iím 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, itís 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 Iíve bought some PFC pads that Iíll fit at some point before Xmas.

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

Iím 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, Iíd initially ordered a full Koni set up, but when I found out you needed to butcher existing struts at the front to fit them, Iíve 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 wonít get them until November ish

Iíve 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 Iíve got the subframe bushes and rear arm bearings from FCSS, as Iíll 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 Iíll check the chassis over and as a minimum Iíll 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 Iíll fit in the next couple of monthsÖ.


Onto cosmeticsÖÖ

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

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

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

Thatís it to start with, Iíll endeavour to post pics/progress and fix anything else I see along the way

Cheers Jamie


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Re: R803CGP restoration thread [Re: Jamiepm] #1661285
15/10/2022 18:28
15/10/2022 18:28
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
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Drakelow
I should have replied hereÖ.

Anyway so my Eibach springs have turned up today.

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

Iím 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.

Iím busy for the next couple of weeks doing some dads DIY at both my kids houses, but then itís 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 restoration thread [Re: Jamiepm] #1661303
16/10/2022 16:01
16/10/2022 16:01
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
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Enjoying the ride

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Drakelow
Today Iíve 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 restoration thread [Re: Edinburgh] #1661369
22/10/2022 19:57
22/10/2022 19:57
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
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Drakelow
So Iíve 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 Iíve got the car SORN so it will stay Ďcleaní.

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

Also bought a new inner cable for the bonnet release, if itís not raining tomorrow Iíll 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 itís been 4 weeks and countingÖ.

Cheers Jamie

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

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Re: R803CGP restoration thread [Re: Jamiepm] #1661522
30/10/2022 16:16
30/10/2022 16:16
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
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Not much done this weekend due to Dads DIY for my daughter


Anyway changed Iíve 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 Iím just waiting for a couple more weeks before I start to dismantle the rear end.

Iíll 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 restoration thread [Re: Jamiepm] #1662010
19/11/2022 16:01
19/11/2022 16:01
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
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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, Iíll 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

Iím sure Iíll have some surprises along the way, but Iíll fix anything else that crops up

Cheers Jamie

Attached Files

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Re: R803CGP restoration thread [Re: Jamiepm] #1662335
11/12/2022 14:55
11/12/2022 14:55
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
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Enjoying the ride

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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 itís 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 itís got an Owen Developments logo on it, or if I just get the bearings/o rings done to stop the smoke, as thereís 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 itís 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 itís out and oil is drained.

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

Anyway pictures will be later


Cheers Jamie


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Re: R803CGP restoration thread [Re: Jamiepm] #1662502
21/12/2022 16:49
21/12/2022 16:49
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
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Enjoying the ride

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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 isnít totally flat so Iíll get it machined to avoid stressing it and promoting the chance of further failures

Cheers Jamie

Attached Files
image.jpg (281 downloads)
image.jpg (277 downloads)
image.jpg (277 downloads)

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Re: R803CGP restoration thread [Re: Jamiepm] #1662548
25/12/2022 11:41
25/12/2022 11:41
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
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Enjoying the ride

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Drakelow
A few Santa prezzies

Attached Files
image.jpg (254 downloads)

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Re: R803CGP restoration thread [Re: Jamiepm] #1662561
26/12/2022 12:44
26/12/2022 12:44
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
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Enjoying the ride

Joined: Dec 2005
Posts: 610
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 restoration thread [Re: Jamiepm] #1662673
31/12/2022 15:25
31/12/2022 15:25
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
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Drakelow
Made a electrolysis tank today to clean up some parts whilst Iím 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 itís doing something

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

Then itís 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 restoration thread [Re: Jamiepm] #1662688
01/01/2023 15:13
01/01/2023 15:13
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
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Enjoying the ride

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Posts: 610
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 itís cleaned up nicely, however there are now a few pinholes, so Iíll get those welded up at work

Cheers Jamie


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Re: R803CGP restoration thread [Re: Jamiepm] #1662753
04/01/2023 18:07
04/01/2023 18:07
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee 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 restoration thread [Re: Jamiepm] #1662762
05/01/2023 15:39
05/01/2023 15:39
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
Club member 1989
Enjoying the ride

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Posts: 610
Drakelow
Just got the turbo back, so itís 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 restoration thread [Re: Jamiepm] #1662964
13/01/2023 21:04
13/01/2023 21:04
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
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Enjoying the ride

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Posts: 610
Drakelow
Firstly I havenít 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 Iíve done the link correctly

Cheers Jamie


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Re: R803CGP restoration thread [Re: Jamiepm] #1662976
14/01/2023 16:59
14/01/2023 16:59
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee 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 Iíve 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

Iíve 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, Iíve acid etched primered everything thatís been cleaned up. There are a couple of bits such the drivers wing that need filling and painting properly, but I didnít want surface rust to form overnight .

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

Iíve got the caliper off and all bolts and fittings loose, so during the week Iíll try and do the seal and paint overhaul

Cheers Jamie


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Re: R803CGP restoration thread [Re: Jamiepm] #1662980
15/01/2023 10:56
15/01/2023 10:56
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
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Enjoying the ride

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Drakelow
Just uploaded a couple of pictures of the new oil cooler pipes that Iíve give a quick coat of paint

As these things seem to eat themselves over time, and the aftermarket cooler and pipes arenít the cheapest thing to buy, Iíve painted them to preserve them

Iíve painted up some other bits and bobs that Iíll load the photos onto the google drive later

Cheers Jamie


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Re: R803CGP restoration thread [Re: Jamiepm] #1662985
15/01/2023 15:55
15/01/2023 15:55
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
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Drakelow
Not done too much today as the weather has been not the best

Iíve 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 itís 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 Iíll come back to this next weekend

Iím 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 restoration thread [Re: Jamiepm] #1663104
21/01/2023 18:31
21/01/2023 18:31
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
Club member 1989
Enjoying the ride

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Posts: 610
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 restoration thread [Re: Jamiepm] #1663114
22/01/2023 17:16
22/01/2023 17:16
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
Club member 1989
Enjoying the ride

Joined: Dec 2005
Posts: 610
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 onÖÖ.


And then do the passenger sideÖÖ..

Cheers Jamie

And a few new pics via google drive


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Re: R803CGP restoration thread [Re: Jamiepm] #1663236
28/01/2023 17:53
28/01/2023 17:53
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
Club member 1989
Enjoying the ride

Joined: Dec 2005
Posts: 610
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 restoration thread [Re: Jamiepm] #1663251
29/01/2023 15:44
29/01/2023 15:44
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
Club member 1989
Enjoying the ride

Joined: Dec 2005
Posts: 610
Drakelow
Couple more photos from today

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

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

Cheers Jamie


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Re: R803CGP restoration thread [Re: Jamiepm] #1663252
29/01/2023 15:51
29/01/2023 15:51
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
Club member 1989
Enjoying the ride

Joined: Dec 2005
Posts: 610
Drakelow
I also should think about changing the thread title as I have have a private plate on the carÖÖ.


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Re: R803CGP restoration thread [Re: Jamiepm] #1663255
29/01/2023 17:46
29/01/2023 17:46
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
Club member 1989
Enjoying the ride

Joined: Dec 2005
Posts: 610
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 restoration thread [Re: Jamiepm] #1663295
31/01/2023 22:23
31/01/2023 22:23
Joined: Dec 2005
Posts: 610
Drakelow
Jamiepm Online yippee OP
Club member 1989
Jamiepm  Online Yippee OP
Club member 1989
Enjoying the ride

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Posts: 610
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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