My fire burned rebuild

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21-09-09, 12:41 PM
spanishfly

I then wired up and fitted the side repeators (I said repeators)
http://img190.imageshack.us/img190/1...illbonnet5.jpg http://img190.imageshack.us/img190/w...jpg/1/w640.png

I then made a mount for the wiper motor assembly, no longer do I have a bolt through the scuttle. Notice the egg like mount:)
http://img193.imageshack.us/img193/2...llbonnet10.jpg http://img193.imageshack.us/img193/w...jpg/1/w640.png

http://img24.imageshack.us/img24/515...llbonnet16.jpg http://img24.imageshack.us/img24/wip...jpg/1/w640.png

Then it was onto mounting the bonnet. I liked the way Lee303 of Germany mounted his so I decided to do it the same-ish way:)
Flatout cut the holes for the bonnet, remember now I got no generator it's all cordless drills.
http://img190.imageshack.us/img190/8...illbonnet6.jpg http://img190.imageshack.us/img190/w...jpg/1/w640.png

http://img12.imageshack.us/img12/413...llbonnet15.jpg http://img12.imageshack.us/img12/wip...jpg/1/w640.png

I made brackets to go onto the bonnet, notice the strength plate on the otherside.
http://img40.imageshack.us/img40/404...llbonnet19.jpg http://img40.imageshack.us/img40/wip...jpg/1/w640.png
http://img196.imageshack.us/img196/8...llbonnet23.jpg [URL=http://g.imageshack.us/img196/wipergrillbonnet23.jpg/1/]
21-09-09, 12:41 PM
spanishfly

It's handy as the bonnet can be removed OR tilted up.
http://img33.imageshack.us/img33/808...llbonnet27.jpg http://img33.imageshack.us/img33/wip...jpg/1/w640.png

We put the pins where they needed to go, however as I'm re-spraying the bonnet I haven't screwed them in yet.
http://img24.imageshack.us/img24/749...illbonnet2.jpg http://img24.imageshack.us/img24/wip...jpg/1/w640.png

I then made a bracket for the grill
http://img24.imageshack.us/img24/801...llbonnet13.jpg http://img24.imageshack.us/img24/wip...jpg/1/w640.png

The masters workshop...
http://img24.imageshack.us/img24/193...illbonnet3.jpg http://img24.imageshack.us/img24/wip...jpg/1/w640.png

Once I get the oil pump it's engine in:):D
21-09-09, 12:41 PM
spanishfly

So, now that I have the zLET pump in my possesion I decided to have a quick look at the differences. I got the pump 2nd hand so also wanted to make sure all was ok. It is good as you'll see from the pics. I took it apart and gave it a clean and regrease.
The inside of the pump are majorly different, you can tell the metal is stronger due the thickness on the thinest part.
http://img119.imageshack.us/img119/9178/dscn3339.jpg http://img119.imageshack.us/img119/d...jpg/1/w640.png

Cogs out...
http://img24.imageshack.us/img24/3703/dscn3338v.jpg http://img24.imageshack.us/img24/dsc...jpg/1/w640.png

I then cleaned it all up and taped up the important parts, took out the PRV and all other bits and pieces, gave it all a clean. The oil cooler take off has a massive allen key bolt holding it on, reckon it's a 10mm.
http://img269.imageshack.us/img269/1487/dscn3340i.jpg http://img269.imageshack.us/img269/d...jpg/1/w640.png

What it look like roughly on the block
http://img269.imageshack.us/img269/455/dscn3337k.jpg http://img269.imageshack.us/img269/d...jpg/1/w640.png

As you can see the zLET pick up is alot different than the cXE one. The shape is the obvious thing, however the bore on the zLET one is twice the size of the cXE one. Should be fun modding something to fit.
http://img102.imageshack.us/img102/4435/dscn3335.jpg http://img102.imageshack.us/img102/d...jpg/1/w640.png
http://img49.imageshack.us/img49/2295/dscn3336.jpg http://img49.imageshack.us/img49/dsc...jpg/1/w640.png

I then moved on to the sump, gave it a good clean and also removed the oil level sender in prep for it to be baffled.
http://img24.imageshack.us/img24/573/dscn3342y.jpg http://img24.imageshack.us/img24/dsc...jpg/1/w640.png

[URL=http://img49.imageshack.us/i/dscn3341.jpg/]http://img49.imageshack.us/img49/5592/dscn3341.jpg
21-09-09, 12:42 PM
spanishfly

Went back to dry the car so got some pics:D

Silver pump
http://img132.imageshack.us/img132/4719/dscn3343.jpg

Silver dipstick tube and matt black fuel cap to replace the silly metal one!
http://img220.imageshack.us/img220/1056/dscn3345l.jpg http://img220.imageshack.us/img220/d...jpg/1/w640.png

Matt black wiper arm.
http://img43.imageshack.us/img43/83/dscn3346i.jpg http://img43.imageshack.us/img43/dsc...jpg/1/w640.png
21-09-09, 12:43 PM
spanishfly

So my calipers turned up, and I painted them! The army green was nice, just not on my car. I love the new 997 911 turbo with there yellow standout 4 pots, so I decided that was the way I wanted to go... me and flatout then had the idea that instead of using black for the 'wilwood' I would use red, which makes it match the car, but more importantly it's the Spanish flag!

I think they look great and should look good behind my matt black wheels:) Standout-tastic
http://img38.imageshack.us/img38/5601/dscn4242z.jpg http://img38.imageshack.us/img38/dsc...jpg/1/w640.png

http://img41.imageshack.us/img41/2331/dscn4243s.jpg http://img41.imageshack.us/img41/dsc...jpg/1/w640.png
21-09-09, 12:47 PM
spanishfly

Thats the pics sorted: Now for the talk.
Basically i've been hestitating on what cam to go for, I want a nice spread of power, that starts at about 3000rpm and continues to 8500rpm. After buying (QED 450V's, Kent 1623's) /speaking to various people (SBD, QED, Bowyer) I decided to go for some Bowyer spec'd cams. Hopefully get these in the next month along with my +1mm valve seats cut. I'm hoping for around 230bhp, anything more would be great:) This will hopefully mean my engine can go together:D I'm waiting on a baffled and gated sump, which Hellier performance are making for me.
21-09-09, 12:51 PM
dj_wudgey

glad this is getting rebuilt!! i loved this car well youve been cracking on mate which is good to see!! well mate keep up the good work!
21-09-09, 01:53 PM
spanishfly

Quote:

Originally Posted by dj_wudgey

glad this is getting rebuilt!! i loved this car well youve been cracking on mate which is good to see!! well mate keep up the good work!

:thumb::thumb:Cheers mate:)
21-09-09, 05:10 PM
scott.parker

Awesome progress dude! Sump/pump combination looks interesting, should be nice to see the outcome, also like they idea with the bracket for the AX setup, might have to steal that one, as mines still bolted through the scuttle.

Scott
21-09-09, 05:27 PM
spanishfly

Quote:

Originally Posted by scott.parker

Awesome progress dude! Sump/pump combination looks interesting, should be nice to see the outcome, also like they idea with the bracket for the AX setup, might have to steal that one, as mines still bolted through the scuttle.

Scott

Thats how I did mine before but as i'm going for concours... well I had more time anyway lmao

Yeah, sump will be great. He has made one before but that engine isn't running yet, so i'm gonna trial it and go from there, if they work well then he'll sell the kit to others and laser cut it all! It's cheap bearing in mind what's involved! The pump, as you can see has better designed gears, the zLET pump also comes with a Nylon PRV, so getting this pump works out about the same price as getting the SBD steel gears and NPRV, only this way round it doesn't cavitate at 8xxx rpm.
21-09-09, 07:14 PM
peester

nice one mr fly, evolution not just repair...
wilwoods have a 'my first wilwoods' kinda look to them lol
a good idea tho, if stopping 230bhp.. no nos anymore??
21-09-09, 07:18 PM
Adam

Nice work Fly
21-09-09, 07:49 PM
spanishfly

Quote:

Originally Posted by peester

nice one mr fly, evolution not just repair...
wilwoods have a 'my first wilwoods' kinda look to them lol
a good idea tho, if stopping 230bhp.. no nos anymore??

I'm hoping the 230bhp+ will be enough to not want nitrous. lol SCCR also means nitrous isn't ideal.
21-09-09, 08:28 PM
peester

ah ha - to catch mr lee of germany..?
22-09-09, 07:45 AM
spanishfly

Quote:

Originally Posted by peester

ah ha - to catch mr lee of germany..?

Well if we're going to be doing team shonky trackdays, it's more entertaining being next to each other hitting into eachother!
22-09-09, 09:29 AM
tony k

hello mate good to see your getting far now,did you find out a day when you can pop down,to have a look at mine cheers
22-09-09, 10:39 AM
spanishfly

Quote:

Originally Posted by tony k

hello mate good to see your getting far now,did you find out a day when you can pop down,to have a look at mine cheers

I'm in Germany next week and working till then, apart from tomorrow when I have to do the shower room. Can sort something when I'm back?
22-09-09, 01:05 PM
tony k

Quote:

Originally Posted by spanishfly

I'm in Germany next week and working till then, apart from tomorrow when I have to do the shower room. Can sort something when I'm back?

yeah mate thats okay,got a few odds and sodds to do to the car till then lol,let me know when you can mate thanks tho:thumb:
22-09-09, 02:17 PM
spanishfly

Quote:

Originally Posted by tony k

yeah mate thats okay,got a few odds and sodds to do to the car till then lol,let me know when you can mate thanks tho:thumb:

Will do bud:)
23-09-09, 03:16 PM
spanishfly

o last night I went to Lee's garage to use the press and pressed in my new bearings.
So today I decided it was time to fit them.
I started by replacing the sperical bearings in the top mounts, I also gave them a light sand to try remove the carbon marks and make them a bit shinier.
Removed the grease from the hubs

That fitted, I put the hubs on.
I then fitted new bleed nipples and crossover pipes to the calipers, that completed the rebuild.
http://img14.imageshack.us/img14/5862/dscn4336d.jpg http://img14.imageshack.us/img14/dsc...jpg/1/w640.png

Then it was time to put my wilwoods on. I also made up new brakelines, I decided to keep the front lines one piece so there is no join.
http://img6.imageshack.us/img6/4011/dscn4338n.jpg http://img6.imageshack.us/img6/dscn4338n.jpg/1/w640.png
Going to use these discs then get some Bells and rotors when there finished, I also have fitted some Ferodo DS2500 pads.

So after doing both sides, it was time to put the wheels on...
http://img17.imageshack.us/img17/7991/dscn4339v.jpg http://img17.imageshack.us/img17/dsc...jpg/1/w640.png

Look great... but whats them new marks?
http://img21.imageshack.us/img21/3807/dscn4340p.jpg http://img21.imageshack.us/img21/dsc...jpg/1/w640.png

Oh f**k, so I now need a small spacer or new wheels... gonna get a spacer for now and move the wheel weights, then in a few months get the wheels I wanted. Well, not the ones I wanted as Lee has them, so other ones lmao

Will get some paint on hammerite to touch them up...
http://img21.imageshack.us/img21/4633/dscn4341u.jpg http://img21.imageshack.us/img21/dsc...jpg/1/w640.png
http://img260.imageshack.us/img260/460/dscn4343.jpg http://img260.imageshack.us/img260/d...jpg/1/w640.png

I then got upset, and decided to fit the window wiper arm... but remembered I had left the blade at home, so I left in a huff.
http://img14.imageshack.us/img14/8397/dscn4344x.jpg http://img14.imageshack.us/img14/dsc...jpg/1/w640.png

My life sucks...
23-09-09, 06:11 PM
scott.parker

lol Never mind mate could of been allot worse eh??
23-09-09, 06:27 PM
MARTIN KELSON

Looking good matey.

What wiper arm you using.
Just fitted an Uno motor as i have removed firewall on mine and mate wired it in at weekend and he says my Peugeot wiper arm can slip on the spline so just wandered what yours was as i may need to source something else to try.

Cheers

Martin
23-09-09, 06:37 PM
scott.parker

I used AX set up on mine, but it did start to slip on the spline as it's worn, so i drilled it and tapped a small screw into it.

Scott
23-09-09, 06:38 PM
sparkie1401

what size brake discs are they? info please

cars looking a lot better
24-09-09, 08:52 AM
tony k

looking good mate,not long now ay,shame about the brakes rubbing on the calpiers(nice colour),cant you just take a layer off the inside of the wheel,but as you said your getting different ones so,why did i put that lol,have a good time in germany hope it all goes well
24-09-09, 09:00 AM
spanishfly

Quote:

Originally Posted by MARTIN KELSON

Looking good matey.

What wiper arm you using.
Just fitted an Uno motor as i have removed firewall on mine and mate wired it in at weekend and he says my Peugeot wiper arm can slip on the spline so just wandered what yours was as i may need to source something else to try.

Cheers

Martin

Cheers mate, it's a pug 306 REAR wiper arm, I like the metal version of the earlier ones, however they also do a plastic smooth one on the later cars. I got the AX motor, believe the uno is the same spilinage though:thumb:
24-09-09, 09:01 AM
spanishfly

Quote:

Originally Posted by sparkie1401

what size brake discs are they? info please

cars looking a lot better

280mm I believe, it's not the discs that's the problem, it's the caliper widths.:(

Cheers:)
24-09-09, 09:02 AM
spanishfly

Quote:

Originally Posted by tony k

looking good mate,not long now ay,shame about the brakes rubbing on the calpiers(nice colour),cant you just take a layer off the inside of the wheel,but as you said your getting different ones so,why did i put that lol,have a good time in germany hope it all goes well

Cheers dude, and see ya when I get back:)
24-09-09, 09:03 AM
spanishfly

Thought I would put a little guide I made for wheel studs up on here, it'll save people between £30 and £40...

For the studs themselves you have a choice:
The length is the amount remaining AFTER it's been screwed in the hub.

38mm exposed
48mm exposed
68mm exposed

Nuts
open end nut
closed end nut

I went for the 48mm exposed stud and open end nut. This is because i'm running a 5mm spacer.

To work out what you need:
Measure the wheel thickness from the back of the wheel to the start of the taper. Ex. 15mm
The wheel nut is 22mm long (open)
So 22+13=35... so a 38mm stud will do , and leave 3mm spare...You could use a closed nut on this setup.

If for example you have the same but with a 3mm spacer, so:
22+13+3=38mm I would advise going the next stud up to leave plenty of thread.

It works out to around £20-30 for most combos :beer:

Hope this helps people, mods you wanna copy this to tech or something?
24-09-09, 09:04 AM
spanishfly

Quote:

Originally Posted by scott.parker

lol Never mind mate could of been allot worse eh??

Yeah I suppose, the car could have caught alight:roll: lol
24-09-09, 10:28 AM
AlexW

Stick the stud guide in articals. :)

Car looks good :)
24-09-09, 01:16 PM
spanishfly

Will do and cheers:)
24-09-09, 04:40 PM
scott.parker

Quote:

Originally Posted by spanishfly

Yeah I suppose, the car could have caught alight:roll: lol

I was thinking along the lines of, you put it together and then drove it like it! lol
06-10-09, 07:01 PM
spanishfly

An update with PICS!!!!

Today I started more work on the head, then got pissed off with it as I need to get a block to head dowel.
So I went and bought a sand blaster, glad I did too! Wicked job! I bought some aluminium grit abrasive in 80-120 grit.
I then took it to the throttle bodies! I warn people use googles when doing this!
Manifold before
http://img202.imageshack.us/img202/5937/dscn4383.jpg
http://img202.imageshack.us/img202/4569/dscn4384.jpg

Starting to look better
http://img7.imageshack.us/img7/7905/dscn4385f.jpg
http://img23.imageshack.us/img23/554/dscn4386.jpg

After
http://img7.imageshack.us/img7/9470/dscn4387i.jpg
http://img7.imageshack.us/img7/6739/dscn4388d.jpg
Tbs before and after...
http://img185.imageshack.us/img185/7186/dscn4389w.jpg
After
http://img340.imageshack.us/img340/6910/dscn4390.jpg
http://img7.imageshack.us/img7/7862/dscn4391t.jpg
http://img7.imageshack.us/img7/25/dscn4392p.jpg

Need to buy some new m5 allen head bolts from screwfix tomorrow!:)

I also found out what the problem is with one of my hubs, so thats sorted. Now I just need to press in one new one and i'm done! Have sent my dampers away to gaz, so should hear what they need in the next few days!
06-10-09, 07:03 PM
spanishfly

So I decided today to have a clean up of the bodies, and remove all the sand remains etc. I soaked them overnight, then used carb cleaner and an air line. There is no remains of sand:)
I bought some new bolts from screwfix, allen head m5 jobs.

I've fitted the LET yellows and trumpets as a temp measure. I want to go back to carbon fibre trumpets when funds permit and every thing else has been done.

Linkage on, cleaned and parts renewed that needed it.
http://img23.imageshack.us/img23/7339/dscn4393c.jpg

Trumpets I got of Gills (cheers) New fuel rail.
http://img42.imageshack.us/img42/8080/dscn4394po.jpg
http://img40.imageshack.us/img40/5622/dscn4395o.jpg

Lucky for me at events I take the filter off, and to run the nitrous at full horsepower I ran shorter lines. This meant my airfilter was in the car rather than in the engine!
http://img14.imageshack.us/img14/5633/dscn4396f.jpg

Looking like new-ish. Really happy with the outcome!
http://img3.imageshack.us/img3/4010/dscn4397.jpg
06-10-09, 07:28 PM
Plug

good progress mate :thumb:

at least your not letting the fire stop you
06-10-09, 08:02 PM
spanishfly

Can't let it beat me, taken longer than expected but have spent alot of cash upgrading everything!
06-10-09, 08:31 PM
Benn

Shes comming on very well dude.
07-10-09, 11:03 AM
Mazz

the sand-blaster has done a really good job cleaning up those parts, looks like new now - nice to see it going to live again..
07-10-09, 11:59 AM
MattBrown

How much was the blaster?

And be careful not to leave any grit/sand/bead/shot in the work!

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