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November 2003
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Been working away last week and the beginning of this, and with a busy weekend in between I haven't got much
done. At the weekend I fitted the knee roll and started to fit the edge trim. I also got the internal panels out to try them for size. Fitting them will mean removing the seat squab though so I left that job for later.
The main task, though, was to make the modifications to the rear brake cylinders. I tried to just cut the centres
out, but there isn't enough room, so I cut the dust covers off completely in the end. And lo, after 24hrs the pedal is still solid! That was the last great mechanical malady resolved.
And it's a good job too. The SVA appointment arrived in the post on Tuesday - 20th November at Norwich. I've
booked an MOT on 13th so it looks like I'm going to be busy this weekend. The only blot on that horizon is the threat of going abroad again - we'll just have to wait and see. More piccies next time - promise! |
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I was off work towards the end of lastb week with this **** bug that seems to
be going round, so I didn't get much done until Sunday.
First job was to complete the interior. I had bought the cockpit panels alreday
trimmed which saved some time, but trimming the underside of the scuttle was a bit like one armed paper hanging. You have to make a template first, cut the vinyl oversize and then fix/trim. The cockpit panels are flat and the cockpit bows out, so screws are needed to hold it in place against the top rail - I used black number plate screw covers to neaten it up. Finally, trim the side rails and cut the old 2CV floor rubber to size. The cockpit looks a lot more inviting now.
Then it was onto SVA items. The steering adjusters need to be covered up,
edges around the car need to be trimmed and the air filters need to be fitted. I checked the bonnet strap buckles and they seemed to be OK, however I made up a couple of hoods for them. Phil has kindly lent me his spare wheel cover - my spare wheel should pass OK, but no point in risking it as it would be very difficult to resolve on the day.
The only remaining items are mirrors, a couple of nut covers, and the front
suspension end plate. This last one is casuing me to scratch my head. Apparently it is a fail item and needs to be covered, but I'm struggling to see quite how to do it without the "as a car manufacturer such as Ford" rule coming into play. |
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On the last lap now. Firstly, many thanks to Lolo who e-mailed me today and
mentioned the reflectors. The reflectors - aaarghhhhh. I had totally forgotten about fitting them, although I had already purchased them.
Anyway, on Monday I aligned the headlights against the garage door using rulers etc.
I am under no illusions that they will be right, but at least I have shown willing. I also had another go at the edge trim , but the main event was the suspension end plate covers. I spent several hours fiddling with different designs until I hit upon using a folded back sheet of ali located by two of the bolts that hold the end plate on, and which also folds down between the spat and body to cover a sharp nut edge. The design means that the dreaded 100mm sphere can't touch anything with a sharp edge. If anyone else out there wants the template, drop me a line.
Tonight I completed the other side, which obviously took far less time and was a far
better finish. The next job was mirrors. The plan was to fit a 2cv jobbie on the drivers side which has a longer arm to get past my (broad and manly :-)) shoulder, and something more attractive on the passenger side. Unfortunately, on the passenger side I can't get the field of vision without the bodywork being in the way, so I'll need to get another 2CV jobbie for that side. In the meantime, the drivers side is done for the MOT which doesn't check the field of vision.
Last job (I hope). The dreaded 100mm sphere will fit between the cowling, exhaust
balance pipe and cylinders and can touch the nasty sharp carburettor parts. I've been pondering how to resolve this, and in the end went for the blatant approach by forming an extended loop in 8mm rod (which I happened to have to hand) and rivetting it to the existing SVA bars for the carb sides. It also has the advantage of keeping the HT leads away from the hot balance pipe.
Thats it. the MOT is tomorrow, wish me luck. I'll post an update tomorrow evening to
let you now how I fared |
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The car failed the MOT. The drive round there was great, and everything was fine until the emissions test,
where it failed with both CO levels and Hydrocarbons too high (and by high I mean off the scale), which indicates a very rich mixture. We had a fiddle with the idle mixture screws, but couldn't get it right, so there is something fundamental needed in the carb area, probably needle settings or float position. Problem is, I'm not sure when I will get chance to work on it between now and the SVA. Hmmmmmmm....................................... |
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Sorry that its been a long gap since the last update. I haven't passed the SVA, in fact I didn't go at all.
After the MOT, I spoke to Dave who came around on Saturday armed with vacuum gauges and a very natty
laser temperature gauge. Using these it was pretty clear that the engine wasn't happy, but after half an hours teakery we had the engine running so well you could balance a coin on it. Not only that, the exhaust fumes had disappeared. I was confident that we had fixed the problem and so finished the edge trim and all of the pre- SVA work. I also decided that discretion was the better part of valour and booked a car trailer to get it to and from the test.
On Monday and Tuesday I was abroad, and on my return Dave said he had a proper gas analyser if I wanted to
borrow it, and of course I said yes. On Wednesday evening I picked up the trailer and I drove to the petrol station in the village to fill up with petrol for the test. On the way back I noticed that the fuel gauge wasn't reading (not too much of a problem) and the speedo wasn't either (bad news!).
Back in the garage I decied to do a final emissions check, and it was way over again. At this point the balck
cloud descended and I decided not to go to the test. I rang up early the next morning and postponed it. I also rang Phil who confirmed that cars have passed emmissions with the 32mm carbs.
I had Thursday booked off work, so I took advantage of it. I called Motobins and spoke to Steve, who knows
all about putting these engines in cars. He thought either the jets/needles were shot (or possibly US spec as the engine came from the US), or the fuel pressure was too high. So I drove up to Spalding to get the needles and jets and fitted them - no real change. It doesn't help that with all of the fiddling the engine is all over the place again - I need to borrow the vacuum gauges again.
I was out on Friday and Saturday so couldn't make any more progress, but today I fitted an old filter king
pressure regulator that I happen to have, and on one side the CO2 levels are a lot lower. problem is that there is a balance pipe in so unless I can get them both down, neither will be right. I think that the side that is now out is because the float valve is shot, but I can't get the float off to change it. I also rang out the speedo, the pulses from the hall effect generator are there, so it must be a problem with the speedo.
All of this has been so demoralising - part of me wants to lock up the garge and walk away, but I know that is
the wrong attitude so I will keep going. |