SteveV8s V8 (Big project in a tiny garage)

[Steve V8]

Thanks @Mightymetro , most of the originals were coroded, thread damaged or seized into their bushes and had to be cut, so all replaced with suitable substitutes, apart from the front top link and rear lower link studs, not OEM, and definitely not stainless.

[Mightymetro]

Just ordered new bolts for mine, have decided to stick with zinc coated rather than stainless as I managed to undo nearly everything that’s been in 20 years.  Wish I had the inclination to clean the chassis like you have , great job.  If I go that far I know she will become a garage queen and I’ve got to justify this expense somehow by using her when she’s finished

 

looking forward to more updates 👍🏻

[Steve V8]

11 hours ago, Mightymetro said:

looking forward to more updates 👍🏻

Updates may be few and far between, mission creep has become near mission stop, after an expensive legal battle with the stepmother from hell has left me broke but now the owner a derelict bungalow with a huge but damp garage. 

There has been a little progress over the summer but not enough to shout about so here it is.

Engine bay and quarterlight panels back from hydrodipping.

Happy birthday to me...Quaife TBD and GTO shaft and gear kit, should i by chance get bored over those cold winter months. 

[Steve V8]

Now for that nice but dull beige 90's interior...time for some 70's electric blue bling.

Of course that opens up more cans of worms, broken nylon bushings on the selector master unit, done...

But the nightmare will be the jammed heater valve, I can see the cable disappear above and behind the pedal box, I can just about feel the valve with my fat fingers but I ain't looking forward to trying to get it out, SUGGESTIONS...

 

[Chillidoggy]

"SUGGESTIONS..."

See page 53 of my refurb thread for some info. My valve was leaking, they're NLA and I got fed searching for a replacement so I replaced it with an electric solenoid valve. I seem to recall unscrewing the hose clips up inside the car, and pulling the valve downwards to remove it. I fitted new heater pipes at the time possibly from underneath the car, but the memory is vague. I do remember it's a pig of a job, though.

[drdoom]

For a simpler heater valve arrangement I've chosen a valve native to a Honda Prelude, circa '88 or so. It's reinforced plastic, turns the line 90 degrees without the complexities inherent in the Brit bit and operates with light cable force. Can't imagine why it was desirable for OEM to have the compensating apparatus in something so dead simple in function as a heater flow valve. Too cold -  open valve a touch, too hot - close it a smidge. 

Well at least you've got a large garage now and that's a good thing. I'm pounding away at interior repairs/prep and whatever else needs doing on the S2 while the Missus is being held at bay parking outside. Winter emerges in force around New Year's hereabouts and then I'll be squeezed into 1/2 the garage space for 2-3 months. As to derelict bungalows, mine is perhaps somewhat less so which would be a good thing at my age. Horrors of renovation still loom here and there but they can bloody well wait until . . . . ? 

[Steve V8]

14 hours ago, Chillidoggy said:

I do remember it's a pig of a job, though

Thanks Ian for those words of encouragement, I took a look at your refurb thread, apparently yours was already dangling, all i found was a few pictures of @Sparky on his back fiddling with his hose.

5 hours ago, drdoom said:

For a simpler heater valve arrangement

Thanks Steve, trouble is, I have to work out how to get the thing out first. 52 year old 16 stone carpet fitters aren't that flexible, the steering wheel had to come off just to allow enough neck bend to traverse into the Lotus position, it's going to be one of those that needs a day set aside without interruption. 

And lots of plasters...

[Steve V8]

The plasterers have run out of plaster, I've run out of money, so stuff the bungalow.

I thought I might sell it and buy an Evora, but with 20,000 bungalows about to become vacant I doubt it would fetch much.

So time to self isolate in the tiny garage and have a go at fitting this GTO racing gearbox kit.

First a steam clean, 

Then a good read of the manual followed by spanner time. Being split in halves makes this box relatively easy to work on, so here she is, like a Damien Hirst  work of art.

Nice and clean, no undue of wear on the synchro rings, forks or gears themselves, very fine metalic deposits on the magnet, so far so good. Now where's that Quaife...

[eeyoreish]

That chimney stack in the background looks heavy to lift onto the roof. Did you consider building it up there?

[Steve V8]

Oh dear, first mock up reveals a problem, new primary shaft rear bearing housing locating flange 2mm, original 1.6mm, locating groove 1.75mm. It'll have go back...quick message to Lee at GTO reveals a machining error. My trusted local engineering guy would have sorted that for me in the blink of an eye if he hadn't departed suddenly last year. But alas, original on it's way back, replacement on its way Monday.

[Steve V8]

I never said I was fast, but it's getting there.

The one piece primary shaft upgrade is a little more involved than I'd anticipated, notice that first gear is now straight cut which means the secondary shaft also needed attention. The new shaft was too long to fit under my press, so I had some more practice on the kitchen appliances. 

It's saved me £1500 by doing this myself, it really isn't rocket science, all thats required are a few basic gear pullers and a press. I did damage one of the diff bearings on removal, so have ordered some new ones, but apart from that pleased with the progress.

 

 

[jonwat]

Aren't you going to loose all the pre packed grease from that bearing when you turn the oven on?

[Giniw]

Well I suspect the oven temperature is kept low enough until it's time to replace the bearing by this rhubarb tart! 🤩 (like 50°C for instance?)

Edited June 18, 2020 by Giniw

[Chillidoggy]

I’m still in the shit for baking the charge-cooler in the oven. No way would I get away with putting a gearbox shaft in the freezer.

[mike_sekinger]

Same here..... Gill got back home and caught me red-handed.  I was in the dog-house for weeks.

[Steve V8]

5 hours ago, jonwat said:

Aren't you going to loose all the pre packed grease from that bearing when you turn the oven on?

It's an internal primary shaft bearing and will be bathed and swimming in transaxle oil before final assembly.  

More chance of gaining some grease in my oven😂

[snowrx]

Head off to the thrift store and get the biggest counter top toaster oven you can find for your shop. Great for bearings, powder coating, welding pre-heat, curing paint and marital harmony.

[drdoom]

.....  or picnic size gas barbecue 

[Steve V8]

Very little progress has occurred on the big project, but little is better than none. (She said)

Some may have noticed my absence over the past 2 years, in October 20 I suddenly lost the use of my left triceps, no pain just couldn't lift my arm, not good news for a carpet fitter, but the eventual diagnosis of nerve damage could have been worse. 

Anyway, after 18 months things have begun to improve, we're back at it with the Esprit carpets, and I've now sorted the impossible to reach heater valve (broken cable), fitted one of our Wessex wool carpet sets and got the interior refitted. 

 

[Giniw]

Glad you are gaining mobility, it must be quite something to lose one's arm usage all of a sudden!

Also, very, very nice interior!

[Steve V8]

I seem to have developed new urge to get on with it at last. Enjoying the time in the tiny garage again, lots more shiny for you to love or hate.

[Steve V8]

Transaxle complete with GTO one piece shaft and Quaife limited slip diff now back in position temporarily, one small issue with the new tie rod ball joints not fitting, but easily sorted later on.

[Barrykearley]

That’s gonna be one hell of a car. When’s the tesla motor and batteries arriving ??

[Steve V8]

Had a bit of a tidy up today, look what I found lurking in the corner...

[mike_sekinger]

You`re going to have a lot of fun with that one 🙂