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May 31, 2013 19:03:37 GMT
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More done today. One engine in the back of the trusty 405, its been in here before, about 5 years ago!  Set the height roughly on the crane, reverse the car up to it, pop a bolt through the D-shackle  Take up the tension with a ratchet, drive the car forwards!  Shift it into the garage out of the way, pop the gearbox on.  Lower the car on the jack, swing+shove the engine into the bay, jack the car up enough to get the LH mounting bracket on the chassis leg.  Take the car back up with the jack, fit the LH rubber mounting, wind the crane down till the RH arm is sitting over the mounting and taking the weight of the engine, shift the crane out of the way and pop the car back on the axle stands. Dropped the slam panel on out of the way.  Got the RH driveshaft in and secure, main long gear rod from the base of the stick in (its different on the RS engine to clear the cat+downpipe) fitted the gear rods, starter motor in place, PAS pump and alternator bolted on, for some reason the AUX belt sems too short, but I haven't tried the one from the black car, might be that the RFS crank pulley is larger, forgot to check this. |
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May 31, 2013 19:05:06 GMT
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Seeing as I need to get it rolling fairly soon, thought I'd get some suspension back on it. Quite pleased with how these look after 2 years, springs are only cheapo's not the top dollar Eibach's AST use on their competition stuff, but the bodies are pretty much as they were bar one bit where they must have been scratched. (Yes they are VERY dirty...)  Got my Wishbones off too, one side is all bolted up, having lunch then cracking on with the other side shortly.  Found that the n/s f brake pipe was also a little crusty, so did that whilst fiddling with the suspension on that corner, also got the o/s built up.  Re-taped a few bits on the loom and got it fitted and clipped in to anything available, only the ECU and anything on the inlet to go.  |
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May 31, 2013 19:07:17 GMT
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Car is now at the back of the house with the old shell gone, wasn't a great deal left on it, subframe struts wishbones 2x tailgates passenger door, 15 tin roof sheets a dozen brake discs a few clutches, the old dash + heater box, came to 580 kilos. The ZX non aircon only used a single speed single fan, but last time I was over at a decent scrappy near Cheltenham there was a TD ZX in there, also single fan but two speed so I got the loom off it, I couldn't take the fan cowling as it had forklift damage :lol :doh but its the same as a 306 twinfan housing which I already have.  Swapped the fan over and fitted the wiring, just need the box and a relay, and a clip for the low speed resistor.  Got the radiator and the cowling in, headlamp/slam panel on.  Bolted the air box on, slowly filling that bay up with clutter!  Stroke of genius, needed to sort a few flares that the £10 heapos**te flaring tool had made a mess of, take one Sykes vice mounted Flaring tool, and a large pair of stilsons.  No more jobs to do with the inlet off, so Bolted that on to get it out of the way in the workshop  then got p**sed off with catching my overalls knees/thighs on the pointy wing ends, so fitted the bumper and lights.  |
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May 31, 2013 19:08:36 GMT
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Beam stripdown day, I knew this needed doing at some point and already had bearings in stock, picked a pair of shafts up from Neat Autos Quite nicely finished, no branding at all on them.  felt pretty light which I don't remember them being so previously, maybe all the ones I've had before have been the smaller bore ones? I know the Febi spec is large bore, and these came out at a similar price but my local motorfactor never got back to me after I asked them to order a pair, so sod them, they might even be on the shelf for all I know :lmao  Take one beam, weighs a fair bit as is there! Fat torsion bars too, not the original 21's   Got to use part of my recent tool kit purchase.  Still don't know what half of these are meant to be used for!  But this one was ruddy obvious Set it so I didn't have to faff remembering to measure when I re-assemble.  Pulled the dampers and torsion bars brake calipers etc off, then pulled the trailing arms out.  Left this pile of dust from one side!  So yeah, it was dead but not seized! |
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May 31, 2013 19:10:28 GMT
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Avert your eyes, bright shiny thing! :lol:  Got this from Rich Walker some time ago (Lynx Power engineering 500 bhp 306 gti6 supercharger dude, the guy that developed the low boost 260 bhp and high boost 400 bhp Rotrex Supercharged conversions) Already powdercoated and unused since  |
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May 31, 2013 19:11:49 GMT
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Has been some time since I last touched this! Progress finally, got the trailing arm shafts swapped at Area52 back at the end of January.  Built the beam up, can't remember now what I set the damper bolt distance to, other than it the same both sides :wacko: but then browsing my pictures I see I had the great idea to take a pic ! yep, 300mm, but its 23mm bars so no its not a 50mm drop    Front beam mounts are o.e peugeot, rear ones have done little mileage as they were replaced by the previous owner. Dropped the fuel tank off fitted the front to rear brake lines, made up two from the compensators to the beam flexi's and bled up the brakes with an Eezibleed. Sorted the two snapped seatbelt bolts by removing the captive nuts and using harness nut plates as they're the same thread. As soon as a little welding is sorted on the outer sills at the rear the fuel tank can go back on then tidy the bodywork, fit the inlet an save up for an MOT. Dropped a donor inlet and my Jenveys with Sandy Brown too... |
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May 31, 2013 19:14:09 GMT
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I think this will do the job.    Playing around with my 50mm lens, got this one on a half second exposure.  Big thanks to Sandy Colin and Dave. |
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May 31, 2013 19:21:48 GMT
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And now we're up to date pretty much, the workshop has had a lot of stuff cleared and shuffled about so it nearly has a 1700x4100 hole ready to push the ZX into so I can cut it open a bit and weld some fresh metal in. awesome stuff!!! those wheels look the dogs danglies! Thanks, unfortunately they didn't clear the standard 283mm brake calipers as they have a relatively low offset on the discs, I guess the Escort has far more offset and also smaller brake discs, so I sold them on to Bruce who In turn changed his mind and sold them to a guy up north who now has them on a 205, the daft sod bolted them straight up with normal flat faced pug bolts  I will probably run with these that I just bought last week and currently have on my 205.  Speedline Chrono's 6.5x15, wrapped in 8mm deep Michelin PE2's, were originally on Nick Charles's two time Castle Combe saloons championship winning 106 gti. |
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I done stuff! as I need to get it in the garage to jack it up properly and do the welding, and that is up a fair slope I thought I;d see about making it drive, so stuck the radiator in, spent an hour hunting fruitlessly for the bottom hose wire clip, bolted the inlet manifold on. Emptied 15 litres of fuel from the fuel tank that's been sat in the back garden a few months! bolted the tank on, then got the exhaust hung and clamped up. tank on (only 3 from 4 fixings, 4th is in o/s sill right by the rust and has a snapped bolt) -  Exhaust on, not a bad job apart from faffing with the downpipe to manifold, only the rear box has hangers, though does have three, so fit the centre loosely to the rear and hang the rear up, offer the centre up to the cat and pull together and clamp up, I'm using genuine peugeot/citroen single piece clamps.  wire brushed the tailpipe :lol: yeah, the box looks crusty, and has a little condensation inside, but doesn't rattle...  |
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love the bodies ! so you have welded flanges onto the ends of original chopped manifold? top work !
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Last Edit: Jun 2, 2013 10:30:17 GMT by welshpug
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Bunged a battery on, Radio still works  Filled the engine with water, left the bleed points open so it doesn't build pressure as I haven't got hold of a clip for the top hose yet. Fitted a lambda sensor, removed the coils and plugs, spun over and got 2 bar oil pressure on the dash. Plugs back in and cranked it, but wouldn't fire, couldn't hear the fuel pump going, primed the pump with a power probe and swapped the fuel pump relay, it fired up and swung straight up to 4k rpm and a great load of hissing! Obviously quite an air leak, resonator intact, inlet bolted down securely on a PhillipM PTFE gasket, so the only thing left was the idle valve and sure enough it was stuck, I had a spare thankfully  There's an ABS sensor unplugged on the drivers side, and no aux belt as I haven't got any PAS fluid yet. A good day, the engine hasn't run in 18 months, very happy with how it sounds |
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Today, I bought PAS fluid and an AUX belt, dug out some track rod ends form the shed, fitted the radiator hose clip and radiator securing clips, swapped a few wheels about so I could get the summer tyres on the 205. Clipped the Clutch cable on, adjusted it vaguely, bolted the drivers seat in, bolted the drivers door mirror on. Then I only bloody drove it up and down the back lane still air in the brakes somewhere good thing the handbrake works  |
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Last Edit: Jun 5, 2013 20:51:40 GMT by welshpug
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traveller! |
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eh?! what? have you broken the gti6 forum Phill? Tea Power, it is the future  New AUX belt, I didn't realise there was two options, depending on which alternator was used, presumably they have different offset or pulley size, a longer belt for the higher power units, I did swap the alternator as it was noisy but didn't think anything of it, its only 9mm longer! (actual spec is meant to be 1076, but the factors list a 1078, guess more vehicles use that size and this will take that up ion the adjuster fine)  £1.20 of clip, off the shelf, quite surprised they had one as they (peugeot/citroen) haven't been using a 16v XU for some time and they are stainless so don't need replacing unless lost!...  |
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Last Edit: Jun 5, 2013 22:12:06 GMT by welshpug
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Probably why they still have them, nobody has needed one |
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juggs
Part of things
Posts: 151
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Ace cars these i used to have one & loved every minuite of owning it.
Well apart from when some idiot put all the windows through on it, awsome handling so underrated!
It would of ran rings around my mk2 golf gti yet no one remembers them!
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Currently cut down the fleet, Pulsar gti-r, sierra v6, E36 328i.. currently looking for crude oil...
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juggs
Part of things
Posts: 151
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Also is it just me but are the front seats the most comfy things out their!?
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Currently cut down the fleet, Pulsar gti-r, sierra v6, E36 328i.. currently looking for crude oil...
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yeah, they're very very close to the 405 MI16 seats, also a slightly bucketed velour seat |
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Tidied the tools and nuts and bolts in the Workshop last night. Moved the ZX  Swept out.  Squeezed in, found it was still a bit long, took the bumper off.  Toight!   peekaboo.  |
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