#271 (permalink)  
Old 04-17-2017, 05:55 PM
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If I may, the imitation wood plastic can be re-colored.
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  #272 (permalink)  
Old 04-17-2017, 07:34 PM
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Quote:
Originally Posted by frodoz737 View Post
If I may, the imitation wood plastic can be re-colored.
Yes if I ever need it that is the plan, the second set was purely purchased as a spare whilst I can get hold of them.
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  #273 (permalink)  
Old 07-10-2017, 06:56 PM
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Well I unpacked the dash from the crate and it came through in one piece, which is good news. So the plan was to collect the car, take it for the MOT as it had expired then start to try and fit the dash.

So off I went to collect the Nova from its storage garage about 1 hours drive away. After turning the key for 20 seconds to get fuel into the carbs she fired up, so all sounded good and I was happy. I drove back home as I had booked an MOT for the afternoon. She ran a little hotter than normal on the motorway so I suspected she needed topping up with coolant as Iím pretty sure I have a small leak in the front radiator from when I dropped a tool on it! The journey was uneventful and I topped her up with coolant once home and bled the front radiator for good measure.

Next stop was for the MOT, the temperature was lower on the way there so that was good news. I flashed a car to let them out then the left pop-up light kept going up and down and wouldnít stop! After lots of turning the lights off and on it finally stopped in the down position as required. I obviously need to adjust the bump stop, another job on the list. Once at the MOT station I sat nervously while he tested the lights crossing my fingers it would stay down once he switched them off, and thankfully it did so that saved an embarrassing moment.




However it wasnít all good news, the exhaust back box on one side had two small holes and was blowing so that was a fail. It was 20 years since I made it so I canít complain too much. It also failed on the handbrake, which is a bugger as that wouldnít be so easy to fix.

So once home I started taking the exhaust off, which is a real pain as the nuts on the manifold are difficult to get to and you can only do ľ turn each time with the spanner. Two studs came out with the nuts, no big deal as they were rusted badly. One nut however would budge and due to the angle of the spanner it started to round of the brass nut. After lots of cursing, WD40, hitting with a hammer and general frustration it finally came off and the exhaust was removed. So tomorrow I will try out my new welder to patch it up. A neighbour suggested I use stainless hex cap bolts rather than studs and brass nuts given that the access to the nuts was limited. He said that the rover V8 crowd do that as they have similar access issues. I was worried about the metal compatibility, but he reckons stainless on the alloy heads is fine.

Next I started to investigate the back brakes. The pads looked pretty worn with not that much material left so my first step is to replace those hoping it helps the handbrake. The problem is I canít remember exactly what they are from!!! Iím fairly sure it was a Lancia Delta, need to figure out the year and where to buy them for an eighties car.
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  #274 (permalink)  
Old 07-11-2017, 02:25 PM
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Default Another frustrating day!

I welded up the exhaust as best I could to block where I thought the holes were. Then I tested fitted the stainless hex cap bolts I was going to use instead of studs. One of the bolts locked up solid, then as trying to remove it the bloody thing shearedÖ.argh...!
.
Four broken drill bits later I had managed to drill it out and re-tap the hole. Stainless is a bugger to drill, so much harder than mild steel. A few more trials and tribulations later the exhaust was finally fitted. So I started it up and bugger, it was still blowing in one spot near the original hole and then I find another spot also. Totally fed up, I spent the whole day messing about and Iím no further forward than yesterday and still have an exhaust to fix. Itís on its last legs so I need to see if I can get a new custom one made. I donít fancy doing it myself this time as itís far too time consuming. Still havenít touched the dash and wonít get some brake pads until tomorrow, which may or may not be the right ones.

Not having an MOT is a bugger, as I canít even drive it to a garage to get and exhaust made.
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Old 07-12-2017, 04:25 PM
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Well today was marginally better in terms of progress. I eventually sorted the exhaust, I resorted to a bit more welding followed by exhaust putty and bandage for good measure. I called around a few of the custom exhaust specialists. To build a new stainless steel replacement from scratch prices ranged from 500 to 1,400 pounds! So I need to think about what I plan to do as given its age (23 years) it will only deteriorate further.

The brake pads turned up, so I set about fitting them. Then the joys of rear calliperís with built in handbrake. You have to turn the piston and push at the same time to wind it back to get the new pads in. The bugger wouldnít turn!....arghÖÖwhy is every job fighting me on this trip 
I went a bought a tool to wind the piston back only to find it didnít fit my calipers. So I ended up taking them off the car and putting them in a vice to wind them back. Then refit, bleed and find one piston isnít moving. A bit of cursing and thumping bits with a hammer, then I attached the handbrake to see I that would start to make it move, luckily it did. Iím still not happy with the handbrake, but I wonít know until itís on the MOT testers rollers to know if itís good enough.

Partway through the day when morale was at an all time low I figured I needed a distraction whilst I pondered solutions, so I thought I would offer up the dash and see if it fittedÖÖ.


ÖÖÖ






And it did!  with 2cm to spare before the screen. Its only placed on top in these photos and not bolted in, but the canopy closes ok. My knees also can press the pedals with no interference on the knees. Those 3 cm I moved the centre section left made all the difference. Another bonus is I donít think I need to change my steering column bracketry. Once the car I MOTíd I will fit it properly and wire up the gauges. One section under the front binnacle does seem to have moved whilst stick in that crate for months. I suspect the packing was too tight, so the fit of the OEM insert is not as good as it was at the bottom. I will fiddle with this once fitted.









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  #276 (permalink)  
Old 07-12-2017, 04:29 PM
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Sorry guys not sure why the images didn't resize. If you right click and open them in a new tab you see them in imgur at the right resolution
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  #277 (permalink)  
Old 07-14-2017, 12:10 PM
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Got the gauges all wired up, mostly everything seems to work except the temperature gauge. The fuel gauge registers but I have no way of finding out if the range is correct and I don't fancy trying to take the sender out to test it as its pretty inaccessible. I'll come back to that another time.

I have no idea why the temperature gauge doesn't work, I assume it works on resistance with a negative feed from the sender. If I apply a negative feed to the gauge wire the needle shoots up instantly to the max (hot), but with the sender wire it doesn't even move. The sender wire is also negative as I checked so maybe the resistance range is wrong?

Using an OEM cluster has saved me about 500 pounds as that is what a new set of gauges would have cost.
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Old 07-15-2017, 03:59 PM
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A long day, but not much to show for it. Where I had drilled the hole for the dash mount on the driverís side fouled the mounting bracket for the limit switch in the down position that was inside the void area. Unfortunately this meant having to take the side off to get access to figure the best solution. Once the side was off lots of pondering, then I tried drilling another hole in the dash further forward, but to no avail it still didnít clear the bracket. So with no other options left I set about remaking the limit switch bracket to it mounted to the hydraulic ram recess rather than the side of the body.


[


Whilst the side was off I also finished adding a ground wire to the canopy switches so the LED portion lights up when pressed. The reverse the whole process and put everything back.


Believe it or not that took the whole day!

I still need to resolve the water temperature gauge that is not working, but at least the rest is.
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  #279 (permalink)  
Old 07-16-2017, 03:20 AM
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to admins, can you delete my photos in post 275 so I can re-post resized ones as its messing up the formatting of all subsequent posts
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Old 07-16-2017, 05:25 AM
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