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Author: Subject: Johns Roadster
jps

posted on 15/2/18 at 12:33 PM Reply With Quote
Johns Roadster

I've actually been chipping away at this build for a long time, and very sporadically updating my blog but am now going to try to get it complete before the proposed IVA emissions changes come in. Given I will actually be working quite a lot on it and hence will actually have regular updates - i thought it worth posting a build diary on here. (I do have a build thread on http://www.roadster-builders.co.uk/ but I think there's no-one using that now and likewise the Haynes forum is rather quiet)

I've used LCB extensively for info, both by endless searching but also posting plenty of questions (thankyou to all of you for the replies) so thought I'd postup onto here.

Here's some major steps picked out just to set the scene of where i've come from, and got to, with the project:

July 2012 - I bought a 'part done' project from a chap up in Norfolk. Not sure how long he'd had it, but he'd decided to sell up. I was told the chassis and wishbones/uprights were from Talon Motor Fabricationbut sadly had no paperwork to confirm. But the welding and measurements looked good. Although it rolled about there was still some fabrication to do.

You can see pics from collection here: A good start


A week later I went out to a little garage tucked away just off the A1 near Wyboston in Bedfordshire and picked up a 1.6 Ford Sierra aiming for a) as much stuff from one donor as possible and b) an age related reg plate.

Pics of the sale here: A willing donor

I then mostly got my workspace setup and pottered about wondering what the hell to do.

January 2013 I collected a full set of GRP bodywork from Equinox in Kent, bought mainly because it was a good price at the time. See: Bodywork collection

Then I faffed around quite a lot more, doing quite a bit of 'prototyping' - i.e. knocking things up that I knew I would not use - just to practice all the cutting and measuring and things. Probably worth it for practice but probably a bit of a waste of time too.

September 2013 I borrowed a MIG set and got help to get most of the chassis fabricating done (I thought!): 1st 'final' fabricating'

May-June 2014 I finally bought a MIG myself and then did more fabricating (but now I know not final!) before painting: 2nd 'final' fabricating

July/August 2014 The chassis got a coat of paint: Painting the chassis

October 2016 I shifted my project from my in-laws to my own house. A house I didn't own when I started the project and which, when I moved into it, a year into the project, had no garage and was half the size. A family home for me, my wife and my two small boys, who were not born when I made that trip to Norfolk in July 2012(see where the time went??!!).

October 2017I rivetted and bonded the internal panelling: Transmission tunnel side and bulkhead and then a few weeks later the floor panel. This really represented a big step. I think (hope?) I will never turn the chassis over again now!

February 2018 I'm currently working hard on getting the GRP bodywork fully prepared for fitting. I am nearly there, but have identified some MORE fabricating I need to do - to relocate the diagonal roll bar stays - but am really focussed now on getting this step complete. Wanting absolutely perfect panel gaps and alignment is not conducive to speed with this job, but it's something I won't compromise on. Fibreglass cutting ongoing


Of course, in and amongst these 'big steps' there has been lots of graft which takes time but doesn't give visible progress. But i've also gone at things very cautiously and probably made myself more work in doing so. I have also done plenty of random small jobs, and LOTS of putting things into the car and then back out again to position things, to make sure clearances are OK, etc, etc. I am hoping siome of this will pay off now as I put a big effort in to pushing on.

[Edited on 15/2/18 by jps]

[Edited on 15/2/18 by jps]

[Edited on 15/2/18 by jps]

[Edited on 15/2/18 by jps]

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jps

posted on 29/3/18 at 02:54 PM Reply With Quote
Well, all the snow and some seasonal 'flu hasn't helped progress loads but I have got a few things done. Most satisfying is actually completing something (so many of the jobs keep going on and on!!), i've made a seat subframe from scratch and, today, got the drivers seat mounted. Just need to get the column and pedals in to fine tune the position but I only need to drill a pair of 8mm holes to change the mounting position!

There are a few photos on my blog

Other work has been ongoing but progress is all a bit random (I have to group together all the 'noisy' tasks for each Sunday morning because I am doing most work on the car starting at 4am before I go to work...) I'll post up the other things as i actually get jobs completed - I expect there's only so many "I cut another bit of fibreglass" updates people can tolerate when all they want to see is a picture of something actually looking done!!!

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jps

posted on 15/5/18 at 08:54 PM Reply With Quote
Another (minor) milestone passed, i've stripped, cleaned up and painted my engine and gearbox . Tomorrow morning i'm getting an order finalised with Burton Power and once the gaskets arrive i'll be able to do the, rather more important, mechanical stuff!

[Edited on 15/5/18 by jps]

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jps

posted on 24/8/18 at 02:58 PM Reply With Quote
I've found myself running out of space in the garage. This is partly because I have the wishbones, driveshafts, hubs, etc all laid out on a pallet on the floor. So, given the engine is nicely painted up and I have still been agonising over whether I have the 'E-max' engine or not (which determines if I can happily buy a 2.0ltr cambelt or not), I decided to finish off refurbing the back end running gear.

A few photos on my blog here...

LCB was, as always, great for advice on how to get the old bearing races out of the hub carriers (40 mins @ 200deg in a fan oven worked wonders), whether or not Hammerite was any good (I saw enough comments on here saying 'yes' to be convinced) and how to correct the hamfisted scoring I put into the hub carriers when I punched out the old races with a screwdriver... It was also on here that I saw a tip-off to get an electric impact driver from Lidl which has worked OK so far, and found someone with a better set of keywords to use to find the 'banana' washers I need for my CV joints. Hopefully i'll get the back end bolted up next week....

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jps

posted on 16/12/18 at 07:48 PM Reply With Quote
A bit late in the write-up, I did finish off my rear hubs and get the diff & driveshafts all bolted up, in early Sept - and then get the whole car onto 4 wheels for the first time since 2012! It has cheered me up immensely about the whole job now it looks a bit more like a car!

A few pictures on my blog here

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jps

posted on 16/12/18 at 09:08 PM Reply With Quote
Some slightly more recent work, i've done a few bits to get the engine and gearbox into a slightly better state than it was when it came from my donor and then fitted it into the chassis, so I can start positioning things more confident that they won't foul stuff...

A few pics

on my 'blog here

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jps

posted on 3/3/19 at 02:49 PM Reply With Quote
Another step closer, my calipers are now all refurbed and ready for a final fit.

A few pictures on my blog here

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James

posted on 3/3/19 at 10:33 PM Reply With Quote
quote:
Originally posted by jps
but am now going to try to get it complete before the proposed IVA emissions changes come in.



Glad to see you're cracking on apace.

I've been away for a while and hadn't heard this- sounds like bad news!

In brief, what are they changing?





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"The fight is won or lost far away from witnesses, behind the lines, in the gym and out there on the road, long before I dance under those lights." - Muhammad Ali

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jps

posted on 4/3/19 at 09:40 AM Reply With Quote
quote:
Originally posted by James
quote:
Originally posted by jps
but am now going to try to get it complete before the proposed IVA emissions changes come in.



Glad to see you're cracking on apace.

I've been away for a while and hadn't heard this- sounds like bad news!

In brief, what are they changing?


Short answer is "nothing". There were proposed changes which would have basically meant that older engines (like the Pinto i'm using) would have been judged against much more modern standards at IVA. Thankfully there was so much feedback to the consultation which opposed this that the proposal was dropped.

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James

posted on 4/3/19 at 11:35 AM Reply With Quote
Good- thanks for that!





------------------------------------------------------------------------------------------------------------

"The fight is won or lost far away from witnesses, behind the lines, in the gym and out there on the road, long before I dance under those lights." - Muhammad Ali

View User's Profile View All Posts By User U2U Member   James 's Aim
jps

posted on 8/3/19 at 06:14 PM Reply With Quote
Today i've put the repainted timing sprockets back on and (possibly!) refitted the timing belt. Some pictures on my blog here

Some sprockets had got moved about a bit since i'd taken the timing belt off - and (see here: https://www.locostbuilders.co.uk/viewthread.php?tid=212359) I am fairly sure that the old belt it was not set up exactly correctly when I removed it anyway.

So - as I have a completely standard engine - putting my trust in the TDC mark on the crank pulley and the advice about the keyways lining up vertically - I turned Number 1 piston to TDC and turned the cam sprocket to the TDC marker with both the inlet and exhaust valves closed. Then I made sure that the distributor arm was pointing at the Number 1 cylinder contact.

I *think* this is correct, my understanding being when number 1 piston is at the top of it's compression stroke both valves will be closed and the spark will be sparking (and the rest of the cylinders will synchronise accordingly)- but very happy to be corrected now if i've got this wrong!

[Edited on 8/3/19 by jps]

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jps

posted on 5/6/19 at 09:33 PM Reply With Quote
The end of March saw me using up what was left on the years annual leave, and making a bit more progress with the car...

Clutch pedal/cable (hopefully!) done: Clutch part 1 and Clutch part 2

Coilovers specced, ordered, and partly fitted (with all the necessary final cuts to the bodywork identified and marked out!): Shocks

Front bulkhead cut to fit and (despite the lack of photo evidence) fully drilled, deburred and cleco'd in place: Bulkhead

I've also been grappling with the seat position/harnesses and the final lengths of tubing for the rear roll hoop. Pics, etc to follow!

[Edited on 5/6/19 by jps]

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Elmof1

posted on 12/6/19 at 12:49 PM Reply With Quote
Build is progressing well. good work
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Abe

posted on 12/6/19 at 09:19 PM Reply With Quote
Good blog Enjoyed looking through that, keep up the good work mate.
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