Handbrake Reinforcement: Trying to repair the mess on the parts of the tunnel I mentioned last time just left me chasing holes in the affected sections. So despite getting it looking pretty good, it was full of thin metal sections and pin holes. The underside told the true story - things were not good. Only... Continue Reading →
So fitted the new catalyst, adjusted the headlights and having re-bled the rear brakes and ensured the compensator valve was free and moving, I thought that I had sorted the problem with the brakes, so dropped the car back in for the MOT retest on Monday. I found that I had slightly over filled the... Continue Reading →
Tackled the spare wheel cage today. I had some mild steel tubing, so made up an extra section - tacked in place: Neither the cage or spare wheel move about now. Welded up the additional section, cleaned the whole frame and gave it two coats of POR15 so should be able to get it fitted... Continue Reading →
A few updates from the last few days... Friday: Thanks to a fellow 106 Rallye Register member who is breaking a car, I now have a pair of doors, a washer pump (of unknown working property) and some other bits and pieces. Hopefully get a big push on this over the weekend to finish it.... Continue Reading →
Tightened up the handbrake cable so it is now on at the second click. Took the quickshift off. The bearing was really tight so I decided to loosen it up. Soaked it in this: Then used an appropriate sized socked and an extension bar and worked it in circles for 5 minutes. Applied some heat... Continue Reading →
Finished the brakes off tonight. Used a Gunson easy bleed system to push the fluid through the lines and it worked a treat. Used Dinitrol cavity wax inside the gusset repair sections, plugged them back up and painted the outsides with Gravitex. Will get some pictures of that posted up - shown here with the... Continue Reading →
Had a very frustrating few days. Finished painting and rebuilt the brakes: Went to remove the old discs and only one of the torx bits came out. Two sheared at the threads. One sheared at the torx head! Bastard things. I had applied heat to them as well and tried impact driving them. So in... Continue Reading →
Yesterday with the chassis rail and gusset repair section for the near side ready, welded the repair section on and then prepped it for paint. Prepped Fitted Also seam sealed the O/S section that had previously been POR'd. Not pretty, but no one is going to see it once it's covered in Gravitex and painted.... Continue Reading →
Yesterday ground down the repairs on the chassis rail leg and put it into primer (laid down a second coat tonight). Then cracked on with repairing the chassis rail gusset, making up a repair template out of cardboard - the gaffer tape is a structural element 😉 It's a lot easier making corrections in cardboard... Continue Reading →
Right progress from the last few days. N/S chassis rail section in primer. Fabricated up a repair section for the chassis rail. Utter, utter bastard complex shape to get right, but made it spot on in the end. Removed the passenger seat, lifted the carpet and moved the fuel line out of the way and... Continue Reading →
Finally went through the paperwork for the car today and discovered that in 2007 it had an MOT advisory on the chassis rail gusset on the near side. Kind of wish one of the previous owners had tackled it before it came as bad as it is now. Crushed metal, underseal and regular exposure to... Continue Reading →
Finished the offside repair tonight by welding in the gusset repair section. Tricky section to fabricate, but luckily I had carefully removed the original damaged gusset so could use that as a guide. Then ground down the welds. For reference swaging the holes is important for getting the plugs to fit in correctly... Over the... Continue Reading →
Rallye Project 