Posts Tagged ‘Parts’

First Haul Gone

Posted: 21st April 2013 by asteriskr in Rallye 16v
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Parts

With this lot having been collected today there is no going back. All brakes and suspension now are now sold. I have a day off on Tuesday to drop of some bits and put down a deposit on what’s coming next all being well.

Thursday night I was quite busy and didn’t have much time, but decided I had just enough to finish up the EPAS work. Oh, how wrong could I be. I needed to press fit the inner bearing race onto the machine top hat. This was simple enough, just a case of getting the parts lined up and into the vice.

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Once that was done it was just a case of fitting them onto the column. However whereas the top hat spacer had previously slid on and off the column with only a little assistance it was now tight getting it on… So out with the torch to heat it up and expand it. Sure enough, it slipped on fine… until I got about half way to getting it into position then realised that it was back to front. Oh and then I also realised that it had just transfered it’s heati into the column and cooled and was now stuck fast.

It was not coming off. Drifts wouldn’t touch it. Trying to heat it up again wasn’t working because both the top hat and the column shaft were both expanding. At this point the language became quite colourful as I worked out how to get it off again. I tried wrapping exhaust wrap around the column shaft and all sorts of other things. Then I ran out of time.

So after sleeping on it, I decided the only thing to do was to make a press. As I don’t have one I had to improvise. To start with the vice had to come off the bench and be mounted to a structural vertical steel I beam. This meant I could retain the top hat and then use a trolley jack and the application of heat to it to pop the column back out.

It might have looked odd, but it worked to my relief and after a bit of fine tuning with the Dremel I finally managed to get it all together late last night. What a mission – just needs painting now.

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Yesterday I took PNK’y for a spin down to Northampton, dropping a gearbox off for Spaget and then heading over to see Bic at Streamline Carbon. There are some great driving roads in Northamptonshire 😀

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The team had made me a full carbon tailgate which tips the scales at just under 5kg but is structurally stiffer than the original panel. Merv gave me a hand to get it fitted.

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It’s internally reinforced for the aerocatch mountings and the pillars for the mounting a of my AC-Sport kit car spoiler. The exterior is in primer as it’s going to be painted up and the inside surface is raw carbon. I’ve not decided what to do with that. Maybe just leave it as it is.

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They’ve also made me a instrument binnacle and I have been working with them to develop a motorsport matte finish. No glossy lacquer here.

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It was good to get some driving in and to spend some time with people who are so enthusiastic about cars and making quality product. Keep an eye on the Streamline Carbon website for some more behind the scenes features…

Progress

Posted: 19th June 2011 by asteriskr in Rallye 16v, Welding
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A few months ago I picked up some 3mm steel brackets that were surplus from a refurbishment of our office space. I think that they’re used to mount door closure mechanisms or something similar. Anyway it turns out that they were nearly perfect to make good the repairs to the gearbox mount top plate. Chopped 7mm off each bracket, v-grooved the faces to be joined and welded them up whilst they were clamped down to some thick steel plate to prevent them distorting.

Repair Piece

Once they were welded up, I ground down the welds and then looked to save some weight out of the repair piece. Two 38mm holes later and a tiny bit of grinding gave a good fit. Primed the part up and now just need to v-groove the faces and sort out some further holes for plug welding before welding it on as repair pieces.

Repair Piece

In between primer drying and other work, degreased the engine, dried it off before prepping it with POR15 Metal Ready. Once that had been left to work its magic, it was rinsed off and then left to dry.

Engine Prepped for paint

Engine Prepped for paint

Last thing tonight I gave the block it the first coat of POR15 Engine Enamel. I’ll finish it off with a top coat tomorrow.

Update

Posted: 26th November 2010 by asteriskr in Rallye 16v
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Okay, not much action happening but plenty of other things. I am convinced that I passed my driving test before January 1997, but wasn’t on the UK mainland when I took the test (I was offshore on Guernsey) and can’t remember the exact date. My Guernsey driving licence had to be traded in with the DVLA when I came back to the UK, but only shows the date it was issued by DVLA Swansea.

I have had to write to the Guernsey vehicle licencing folk and to ask them to look up the exact date I passed and then I will need to try and get the DVLA to amend my licence to include category C1 (lorries between 3.5 and 7.5 tons), D1 (passenger vehicles for nine to sixteen people) and vehicle plus trailer combinations. The relevance/importance of this comes into play if I want to tow the car on a trailer behind the van.

Carbon Trumpets

Also I have sent some of the carbon throttle body trumpets off for repair. Two of the four were slightly damaged around the lip, but Bic is fairly sure that they can be put right, so I’m leaving it to him and Merv to sort them out. I have spent the last few nights polishing and prepping a pile of parts to be sent off to Colour Anodising up the road in Radcliffe. This includes the inlet manifold which has taken many, many hours. Anodising doesn’t hide any surface imperfections like paint, so you want a good finish before the process is undertaken. Fingers crossed on these bits. The anodising will add some protection to the surface of the aluminium and stop them from oxidising.

Tools

Finally a few bits have started arriving for the next big push on the body work. I needed some brushes for getting into nooks and crannies so I will give these a go. The magnets are for holding panels prior to tack welding.

Update

Posted: 12th August 2010 by asteriskr in Rallye 16v
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Right been a while without any updates due to holidays and other things. Tyres are being fitted to the Ultraleggeras on saturday morning. Some bits have arrived to including Anodised P clips for the coolant hoses.

Rallye

Brake master cylinder blanking plug with crush washer from Speedflow. M10 x 1mm stainless steel niceness. I need this to blank off the redundant rear hose port on the master cylinder. Fitted finger tight at random for these photos. Finally I ordered some replacements for the Goodridge hoses as they were the wrong fitment for the Hi Specs. Now have everything needed to fit the brakes except DOT fluid.

Rallye

Rallye

Rallye