Fiat Coupe Club UK
R803CGP / C20VTJ restoration thread
Posted By: Jamiepm
R803CGP / C20VTJ restoration thread - 11/10/2022 08:15
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
: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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 15/10/2022 18:28
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 16/10/2022 16:01
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 22/10/2022 19:57
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 30/10/2022 16:16
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 19/11/2022 16:01
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 11/12/2022 14:55
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 21/12/2022 16:49
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 25/12/2022 11:41
A few Santa prezzies
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 26/12/2022 12:44
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 31/12/2022 15:25
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 01/01/2023 15:13
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 04/01/2023 18:07
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 05/01/2023 15:39
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 13/01/2023 21:04
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=sharingSo hopefully I’ve done the link correctly
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 14/01/2023 16:59
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 15/01/2023 10:56
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 15/01/2023 15:55
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=sharingCheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 21/01/2023 18:31
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 22/01/2023 17:16
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 28/01/2023 17:53
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 29/01/2023 15:44
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 29/01/2023 15:51
I also should think about changing the thread title as I have have a private plate on the car…….
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 29/01/2023 17:46
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 31/01/2023 22:23
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 02/02/2023 22:03
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 03/02/2023 19:02
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 04/02/2023 17:09
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 05/02/2023 12:16
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
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 05/02/2023 17:27
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)
Prepped and protected the whole underside of the car, including all wheel arch areas and behind the liners(that should last another 25years
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
Installed new bump stops, new Osrav rear shock absorbers (set at 4 clicks having read other people’s experience) and the Eibach uprated springs
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
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
Cheers Jamie
Google drive has some new pictures to look at for those interested
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 05/02/2023 18:23
Just emailed ultra racing about their useless brackets, so let’s see what they say…..
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 07/02/2023 17:06
So another good day of stuff done today
So fitted the the anti roll bar with the shims (I’ll post a video in the google drive link)
Fitted the brake lines and flexi hoses to and from the brake bias valve assembly
Repacked the rear wheel bearings with some fresh molybdenum grease
Started painting the rear calipers , and will try and finish them at night during the week
Question for the forum, can someone confirm the correct torque setting for the rear wheel bearing?
Thanks Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 11/02/2023 18:27
Got the rear axle assembly all bolted back in along with the fuel tank
Then decided to change the front anti roll bar bushes for some strongflex jobbies
The actual point of changing the original bushes is easy, but you have to drop the whole subframe in order to get at it
Also I fitted new drop links as the rubber bushes were cracking, and that's as you have to release them anyway to get at the bushes it's pretty straightforward
Finally put together the front shock absorber and spring along with the new top mount and bearing assembly
Will try and take a few photos tomorrow, as I wanted to simply get stuff done today
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 18/02/2023 16:22
Been a bit busy over the last 2 weekends with non coupe stuff
However got a few hours in today
So fitted the drivers side suspension strut assembly, and wheel arch liner
Tarted the front cross member paintwork up,
Refitted the repainted strut brace
Painted the rear calipers
Done the decal and lacquered the front drivers side brembo caliper
A few bits of touch up here and there
I will get photos uploaded tomorrow, and try and do the seal kits for the calipers so I can refit them
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 19/02/2023 17:50
Just uploaded a few pics and a few videos with some commentary
I’ll do another post later to show work done and jobs left to do
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 25/02/2023 18:33
Finished off doing both near side wheel arches today, so removed the liners, checked for rust, of which it was only surface. Then upol everything after rust treatment
Also fitted the first brembo caliper and flexi pipe to the drivers side of the car, then whipped off the old suspension on the passenger side and put the shiny new stuff in. Unsurprisingly the shock absorber on the passenger side was totally knackered in that there was no pressure keeping the piston at maximum, so I hope weekend after next I can start to drive it again.
Fitted the 2nd set of dust covers for the rear axle, I must have thrown the others away, anyway it makes for a tidy job
Fitted new seal kits to the rear calipers as the last job, word of warning to anyone planning this job,there is a technique to getting the dust seal back in. Basically smoother the seal and piston in silicone grease and fit the seal over the piston and extend it so it’s proud of the end of the piston. Then you can after some fiddling get the other end of the seal into the groove
I will say the seals were ready, as now the movement has far lest resistance, so a good but fiddly job done
Plan for tomorrow is fit the 4 remaining pieces of brake lines for the abs unit to the the front end
Get the exhaust assembly back together, and try and get the cooling fans and bits around that area bolted back in
Not so many new photos from today, so click the google drive to view
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 25/02/2023 18:35
Just emailed ultra racing about their useless brackets, so let’s see what they say…..
Radio silence from Ultra Racing……
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 26/02/2023 18:01
So got the brake lines done, albeit cut 2 lines wrong
so will have to replace those next weekend
Got the exhaust all back on
Refitted the remaining wheel arch liners
Refitted the rear plastic undertray with new self tapping fixings as the old ones were totally crusty
Routed the fuel pump wiring mod live supply from front to back
And then fired her up, no smoke from the new turbo, so happy with progress apart from cutting the wrong pipes
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 28/02/2023 11:54
quick update folks
It appears the fuel pump has packed up as it now won't start
So I've ordered a KEMSO pump which seems to have good reviews and at £48 seems pretty cheap
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 03/03/2023 17:59
Took a day off work to get some more stuff done….
So fitted the aux belt guard after taking some advice from Joe
Also fitted a new aux belt, just to be doubly sure of no surprises
Fitted the pu right hand engine mount and put the trims back in place
Fitted the KEMSO fuel pump (I’ll change the fuel filter tomorrow), which requires the same mods as per the uprated Walbro pumps. The fiddliest task is reseating the rubber gasket when putting the assembly back into the tank.
Fitted the turbo heat shield, but will fit the fans tomorrow
Started to remove the brake calipers all round and strut brace as I’m just not happy with the finish, so they’ll get a professional job done on them over the next few days.
As I’ve taken the battery tray out to do the brake lines, I’ve cleaned and painted that as well
Only a couple of photos today, as I’m nearly finished
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 04/03/2023 18:32
So bolted in a set of brake pipes that I’d cut by mistake, that’s not a fun job with the engine getting in the way
Unbolted the rear calipers to be painted by someone who knows what they are doing
Got another screen wash pump and then inadvertently sat on it and bust that one (fml), so I’ll have get another ……
Topped the coolant up having lost some fitting the turbo heat shield
Fitted the cooling fans
Went over the floorpan to upol treatment just to get any bits that I’d missed in the previous coats.
Started to refit the front bumper and side light assembly, weather permitting I’ll finish this tomorrow
Started her up, and did the usual checks for leaks/noises etc, but everything was good
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 04/03/2023 18:37
Should be wheels on the ground and tootle around the block next weekend, assuming I don’t have any dramas bleeding the entire brake system
I’ll still have a few nice to do type jobs, but it should be stuff I can ticker with as the nights start to draw out
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 05/03/2023 21:37
Only spent a couple of hours today underneath the car
Basically went round all nuts and bolts and made sure they were tight
Finished off fitting the bumper
And dropped the calipers to get painted properly
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 18/03/2023 19:30
Been a bit quiet for the last couple of weeks, as I needed to wait for the calipers to be repainted
Anyway I’ve now got them back along with the strut brace, and they look brill
Weather forecast is dry for tomorrow so I should get them reassembled and bolted back on, then bleed the brakes and then a quick test around the block
Google drive has a brief video showing the pained goodies
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 19/03/2023 14:33
So close, yet so far
So put the calipers etc back on
Set the brake bleeder up,decided to do the clutch first,and then tried at the rears....
After 10 minutes of nothing, I decided to try the fronts,which worked a treat
So decided to crack the pipes near the brake bias valve to make sure fluid was at least getting to that point. Confirmed that fluid was there, so it appears the valve is seized up.
I've been faffing around for an hour, but no success, so I'll try and whip it off tomorrow after work, and see if I can free it up
I did test the brake and clutch pedal, and pedal feels great
Fingers crossed I can get it sorted in the week and then Road test it
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 22/03/2023 22:21
New brake compensator valve fitted, and brakes have been bled, albeit I will do them again as the pedal feels a bit soft
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 24/03/2023 15:34
so I've rebled the brakes, and pedal feels good now
I've put the repainted battery tray and re-secured the battery itself along with the various looms clipped back into place.
I've refitted the side lights, and put the piece of heat shield near the muffler back into its fittings
Finally put the rear wheels on the ground!!
Plan for after work tonight is to fit the undertray and put the front wheels down
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 24/03/2023 18:11
She lives
Brakes need a rebleed as there's still too much pedal travel, maybe because the pistons weren't fully seated? Anyway it's easy enough to push more fluid through
Albeit only a short drive, but no knocks and bangs and the ride is brilliant
Will post a bit more over the weekend
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 26/03/2023 18:19
Had a brief drive in the car
Pulls like train,handling is pretty neutral, albeit it needs the tracking doing
Brakes are still a bit soft, so I’ll bleed them again
The only thing I’ve got to investigate is a knocking at the rear end. It’s coming from both sides, so my immediate suspicion is something to do with the anti roll bar and the brackets I had to pack out, which I know means a few things off to get at it
I’m on holiday early next week, so I won’t get chance until next weekend
Quick walk round video in the google drive for those interested
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 02/04/2023 07:36
Just having a cuppa, and then I’ll have a look at the clonking on the rear of the car and hopefully bleed the brakes for the final time
Then put some fuel in and go for a bit of a drive
Fingers crossed
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 02/04/2023 09:26
Brakes pedal feels good now, I took Joe’s advice and bled them with the engine running. Must have been some air around the abs pump
Onto the knocking…….
I checked the bolts holding the anti roll bar, one side had a bit of movement so I nipped it up, I then proceeded to the other side and the bolt head snapped
Anyway I’ll try loosen the fittings so I can pivot the whole anti roll bar and see if I can mole grip out the bit of threaded stud showing
I’ll put a comment in the discussion about bolts needed
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 02/04/2023 17:16
After a surprise breakdown (fuse for the fuel pump blew), which I’m presuming is linked to the higher flow fuel pump I’ve fitted
I’ve had a good hours drive, and honestly nothing to note of any significance
Tracking definitely needs doing as at higher speeds the understeer is still there, but at low speeds the turn in is great
Likewise for those interested, the pfc brake pads are a good upgrade over the standard brembo pads. The initial press is a bit lacking, but after a couple of presses and they have a decent amount of bite
Tomorrow will be a trip to the body shop to see when I can get it touched up
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 04/04/2023 20:43
Well another surprise breakdown tonight
Tonight’s drive was short lived, so after buzzing around the country lanes near me, the car suddenly died, just as I was coming onto boost. It cut out quite abruptly, so my immediate thought was something electrical
As I’d faffed around with fuses from earlier in the week, I’d got a few spare ones with me, so I get out of the car , cocksure the fuse had gone and I’d just pop another one in
Anyway it wasn’t the fuse
I popped the bonnet and the negative connection on the battery felt a bit warm, so I thought some kind of short
Then I tried to start it, but it turned over without firing.
The injector light stayed on, so I knew it would not start
When I tried again the ignition just clicked, like when your battery is flat , and I could hear something crackling/buzzing in the drivers footwell, so I turned it off and got the car towed back home
Anyway got the car home, had a nosey around, with nothing obvious
After an hour the car had cooled down and would turn over but not fire
So the code and injector light comes on and goes off, so for me this is correct. I hear the fuel pump prime for a second or two, again I’m sure this is normal
But it won’t fire up
I’ve tried the inertia switch several times
I’m not sure about the 2 relays in the passenger footwell, and the fuel gauge is showing about a 3rd of a tank.
I will to be sure check there’s actually fuel in it tomorrow, and given I put about 50 quids worth of fuel and haven’t done more than a 70 miles I hope it’s not just fuel now for why it won’t start
However I still wonder what was going off with the electrics
Any pearls of wisdom that anyone can think of ?
Ps big thank you to joe for taking messages tonight
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 22/04/2023 08:46
Took the opportunity to freshen up the window wiper arms and the mesh on the scuttle panel
Again I've just used the hammerite satin black to paint them
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 18/05/2023 20:29
Decided to buy the 2 pu bushes that connect the engine mount to the drivers side suspension turret
They take a fair hammering to get the old ones out, but fitting the new pu bushes is a doddle
Considering this should be the last time I touch any of these bolts, I’ve threadlocked them all up including the strut brace bolts
Also the new track rod ends from alternative autos have turned up, weather permitting I’ll fit those at the weekend
Finally the new rear brembo brake pads also turned up today, but as I have another track day at curborough in a few weeks I’ll use what’s in for now and them change them before I make my way to the ring
Cheers jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 20/05/2023 17:10
Just finished the track rod ends, had to basically cut them off/open to get them off the threaded rods
Although I bought them from alternative autos they were shorter than the original ones I cut off, so as always tracking definitely needs doing now
A quick drive confirmed no knocking, so just do the fuel pump wiring tomorrow, then over to my mates garage for tyre fitting and tracking
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 21/05/2023 16:52
Fuel pump wiring mod now done
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 21/05/2023 22:01
Just thinking about what jobs I’ve got left to do this year
Fit the zestino Gredge 07rs tyres and have the car retracked
Before Nurburgring, fit another set of Brembo rear pads as I’ve about done the set that Graham had fitted
Fit some aftermarket led footwell lights
Fit some better front door speakers
Detail the car inside and out
Contemplate the jobs list for next year
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 31/05/2023 20:30
Tyres and tracking all done tonight
I can only say these Zestino tyres are night and day difference (in a good way) compared to the standard offering
Also set the negative camber at -1.5 degrees
The challenge right now is adjusting my own threshold for the Trackday at curborough , as already the speed difference in corners is sizeable with zero tyre squeal
NB: Joe hope you and your lad can make it to curborough
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 01/06/2023 21:18
Latest tracking set up
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 02/06/2023 21:31
So after a day at curborough, the car performed brilliantly.
After trying a few settings for the front shock absorbers, I ended up with a 2 full turns from soft, that seemed to keep the car nice and flat through the tight bends
Can highly recommend the zestino tyres, they are soft but they get rid of any understeer and give a nice predictable drive
Also got the chance to drive Joes coupe whilst there, and compare visco drive vs the quaife diff. Put simply the viscodrive doesn’t compete, but given it’s about a £1000 I’ll wait for now before thinking about buying one.
End of the month will be at the ring, so really looking forward to that, as the corners are far more open, which plays to the coupe’s strengths
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 29/06/2023 14:41
Just a quick update, trip to Nurburgring starts tomorrow, so they'll be videos to share afterwards.
Hopefully tears of joy and not tears of sadness, considering the efforts/forum advice from folks to get me to this point
Cheers Jamie
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 24/07/2023 20:01
Hi folks, it’s been a while…….
Anyway one of my next jobs to do will be to fit the Alfa gta subframe braces
I read Per’s thread about this and thought that’s a great mod to do, so I’ve bought a 2nd hand set off eBay
Instead of welding captive nuts, I think I’m going to use a rivet gun with either M6 or M8 inserts, as some of the undertray fittings are knackered, so I can do both jobs.
Whilst I mount the nut inserts I’m going to try and straighten out the floor where someone prior to grahaml or myself has incorrectly jacked the car up.
Also having looked at Per’s thread, I saw his bottom strut brace, which I think I can improve upon his idea with an aluminium version.
Cheers Jamie
Posted By: Cyclone
Re: R803CGP / C20VTJ restoration thread - 27/02/2024 06:03
Superb thread and very informative.
Posted By: Jamiepm
Re: R803CGP / C20VTJ restoration thread - 25/03/2024 17:53
Quick update, took the car to be fleamapped a couple of Fridays ago……
I took some VXR injectors with me and changed them over for Leighton to do his thing. (NB there will a be a OEinjectors for sale thread on the forum shortly).
Anyway I asked for torque over power, and pleased to report peak torque of 300ft lbs with 270 hp as an end result.
Drive ability wise, it simply comes ‘on power’ much sooner in the rev range, making it ultimately a faster car
Cheers Jamie