Posts Tagged ‘refurbishment’

8v Update

Posted: 28th January 2012 by asteriskr in Rallye 8v
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Been doing some work on this car recently. I need to take some more photos, but one of the jobs was a refurb on the cam cover.


Went for a gloss finish in POR15. Added on a new oil filler cap, oil dip stick (as the old one did not plug into the top of the tube) and fitted a new cam cover rubber gasket as the old one was degraded and split.


It was previously getting a bit of oil onto the exhaust manifold cover so this should fix that.

Well the dash on the car was a bit of a state and it needed to come out so I could screw the passenger side airbag section back onto the rest of the dash as it was loose. So while it was out I took it over to Raj at Autoflock and he did the business.


After I put the car back together it just wouldn’t start up. This led to a lot of head scratching, at first I thought the battery had suffered in the cold, but them some testing of the ignition system (no spark being produced) indicated that the ignition circuit was disabled. I traced the fault back to the induction coil around the ignition keyhole. The outer clip must have been caught and this broke the very fine wire. Soldered it back together and plugged it back in and the car started first time.


It’s looking a bit nicer under the bonnet now too.


Rear Beam Refurbished

Posted: 25th March 2011 by asteriskr in Rallye 16v
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I organised a group buy with IM Axle to get the rear beam refurbished. Here it is having just come back with the 23mm torsion bars and polybushes fitted. I also mounted up the AST adjustable rear shocks for the photos.

Rear Beam Sub Frame

N/S Trailing Arm

AST Adjustable Rear Shock

Gearbox Boxed Off

Posted: 19th November 2010 by asteriskr in Painting, Rallye 16v
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Yesterday before creating a dust storm in the garage I sanded the POR15 Chassis Coat Black topcoat of the gearbox mounting bracket down and repainted it as I wasn’t happy with the finish. Covered it up with a big tuppaware plastic box and left it to dry. I’m satisfied with the outcome – not bad for a brush painted job eh? Artist quality sable brushes for the win!

Gearbox Mounting Bracket

All fitted now and the gearbox is sealed up in a big cardboard box until fitting time.

A Little Progress

Posted: 8th November 2010 by asteriskr in Rallye 16v
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This is the standard speed sensor and mounting bolt on the gearbox.

Gearbox Speed Sensor

I didn’t like the rusty bolt so I’ve upgraded it to a titanium one

Gearbox Speed Sensor Mounting Bolts

It’s a M7 bolt with a 1.00 thread pitch with a length of 16mm. It’s also a cap head rather than a normal bolt head like some of the earlier cars. It’s a rare size so finding one tooks some tracking down, but in the end I sourced one though Singapore.

Gearbox Speed Sensor

Fitted… some other trick bits are in the post to fix up my latest purchase to my exacting standards

Gearbox Done

Posted: 19th October 2010 by asteriskr in Rallye 16v
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Gearbox finished tonight and reassembled with all new seals on the driveshafts and input shaft as well as the 5th gear gasket. At the weekend I may flat down some of the black coated sections and apply a new top coat. There are also a couple of spots I missed with the enamel, but in all it is 100 times better than what I started with!

Before & During:

Dirty Gearbox Gearbox being Cleaned

Gearbox Refurbished