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GENERAL => Your cars => Topic started by: 5-Mission on 18:09, Mon 12 October 2009

Title: My 5... gradually going back together :-)
Post by: 5-Mission on 18:09, Mon 12 October 2009
I also have an R9 GTX doner car which some of you may know about - took the engine out of that today. I drained the oil and water ages ago though and I've heard it's not good for an engine to sit for long periods like it, will hopefully be ok.
Gonna officailly make this my project thread now, so probably won't be any updates for ages! lol
After finally managing to create some space 'next door' and ordering an auto darkening welding helmet I should finally be able to get the chassis sorted on the 5 and get some bits back on it. Trouble is I think it probably needs an inner and outer o/s sill - a job I'm NOT looking forward to! :roll:

Don't know whether to break to 9 up or offer it for collection on here - what do you think?

Will get some pics up of the progress soon! :D
Title: Re: My 5... gradually going back together :-)
Post by: 5-Mission on 21:02, Tue 01 December 2009
Finally got a panel welded into the chassis today! Still got masses of work to do though, fuel and brake lines need changing, front chassis rails need cutting out and new panels fabricating, metal bracket that secures the fuel filler is all rotted away, needs cutting and and one fabricated, engine needs stripping and refurbing etc etc...
(http://img37.imageshack.us/img37/2683/dsc01612n.jpg)

Panel in place on the other side ready for welding
(http://img686.imageshack.us/img686/2165/dsc01619.jpg)

There should be a bumper mounting bracket here! This front one is actually worse than the backs which usually go
(http://img51.imageshack.us/img51/3203/dsc01611.jpg)

The old rotten one and one I knocked up
(http://img189.imageshack.us/img189/3614/dsc01610f.jpg)

An old pic of it in it's heyday..
(http://img36.imageshack.us/img36/2959/dsc01615jz.th.jpg) (http://img36.imageshack.us/i/dsc01615jz.jpg/)
(http://img257.imageshack.us/img257/5532/dsc01616g.jpg)

Before it went into the 'shop
(http://img412.imageshack.us/img412/8033/dsc01618o.jpg)

and how it looks at the moment..
(http://img340.imageshack.us/img340/3883/dsc01613ym.jpg)

this has turned out to be a seriously long process, hopefully it'll see the road again sometime next year. :?  :|
Title: Re: My 5... gradually going back together :-)
Post by: andy_wpo on 12:11, Sun 06 December 2009
Don't you have bigger pics?It looks intresting
Title: Re: My 5... gradually going back together :-)
Post by: bazr5gtt on 20:25, Sun 06 December 2009
hey 5 mission how tricks,see your getting on with yer project very nice,5 looks well mint in the photos have you any that are a bit clearer,keep me posted bud
Title: Re: My 5... gradually going back together :-)
Post by: 5-Mission on 22:41, Sun 06 December 2009
Yeah, I'm not sure what happened when I uploaded them. I uploaded some pics on Baz's thread once I'm sure with the same hosting site (imageshack) and for some reason you could click and enlarge them and it just automatically ended up like that.
The black and white pics are lo-res pics of black and white photos out of an old album hence the crap quality. I'll try and edit some bigger pics up here!
Regarding the restoration, loads of people say gasless migs are sh*te, but I've been phoning round recently and speaking to some mobile welders and one said he uses nothing but gasless and finds it absolutely brilliant (his words!)
I do wanna do the job myself, but I'm not a welder and the areas I'm concentrating on at the moment are right in between the rear axle mounting points, so need doing professionally in my opinion to maintain structural strength when (and if) it's back on the road anytime!  :?  :roll:
Title: Re: My 5... gradually going back together :-)
Post by: Ash-Lee on 23:39, Sun 06 December 2009
I've got one of those MIG welders that works with or without gas.

It does weld better with gas IMO, but if you choose to weld without gas then the quality of the wire you choose will make all the difference.

I use electric for smaller cosmetic parts and gas for anything substantial.
Title: Re: My 5... gradually going back together :-)
Post by: 5-Mission on 22:18, Tue 30 March 2010
I was tacking my bumper mounts in place today to check bumper alignment after temporarily refitting the wings and I noticed the n/s one fits like shit. Basically the shape of the upper swage line ion the wing is different to the door. The door came from a D-reg 5 as mine was too rippled.
Bearing in mind my car is a 5-door, that door is of Phase 1 age, so does anyone know if the shape of the doors and panels was a bit flatter on older 5's?
I think the 2 profiles must always have been a bit out, I'd just forgotten- it's been apart that long :oops: also it's a pattern wing so that might have something to do with it?
I'm still in 2 minds whether or not to reshell the car as it would save stacks of restoration and rebuilding work (lazy :P ) but would work out more expensive due to painting again?! :?
Title: Re: My 5... gradually going back together :-)
Post by: Steve! on 22:26, Tue 30 March 2010
Why... is it special paint?
Title: Re: My 5... gradually going back together :-)
Post by: 5-Mission on 22:30, Tue 30 March 2010
Quote from: "Steve!"
Why... is it special paint?
No, it's normal paint but I'd be swapping all the doors and kit, wings and tailgate etc over if I reshelled it after getting the shell painted to match
Title: Re: My 5... gradually going back together :-)
Post by: 5-Mission on 20:09, Sat 29 January 2011
Well, I decided to stick with what I had and not go down the reshelling route! I actually finished all the welding and bodywork months ago but have hardly really done anything to it since :|  :oops:
My engine is mostly back together, just need to get hold of a clutch centering tool and refit the gearbox to it. I jetwashed it recently which brought it up pretty well although I ended wearing half the water myself! Turns out the 2nd hand GTT rear discs I bought appear to be slightly warped which can never be a good thing. I bought a bargain set of Williams Clio discs a few weeks back - took a chance on them as they looked the same as GTT discs. Turned out they are identical but the bearings are fitted slightly further forward from the front of the disc.
This means the disc sits slightly further back so they go solid and won't move when you tighten the centre nut.
I don't know what the part of the axle is called that sits on the stub axle the disc mounts on - the little round removeable part wheich the disc slides against. These must be narrower on the Williams I'm guessing! I might try some hardened steel washers to bring the discs forward a couple of mil. Don't know if it's the right move or not?
A thread chaser for a Lambda sensor mount sorted the caliper mounting holes finally, I'd like to sort the 2 bolts I knackered trying to fit originally but I aint paying 11-odd quid for one piffling M12x1.25 die nut on ebay!
So, not much progress really.. but still a step closer to the car seeing the deck again at last.
Anyway here's a couple of bad pics from my crap camera phone.

engine back together minus gearbox
(http://i817.photobucket.com/albums/zz98/5-mission/DSC02752.jpg)

A brand spanking new caliper actually in place at last with new pads in
(http://i817.photobucket.com/albums/zz98/5-mission/DSC02757.jpg)

Axle's been on back on for ages, all electrolysised and painted
(http://i817.photobucket.com/albums/zz98/5-mission/DSC02760.jpg)

nicely warped GTT disc - fits perfectly
(http://i817.photobucket.com/albums/zz98/5-mission/DSC02759.jpg)

Williams disc in perfect nick with new bearings in - won't fit my axle for shit!!! :lol:  :x  :x
(http://i817.photobucket.com/albums/zz98/5-mission/DSC02758.jpg)
Title: Re: My 5... gradually going back together :-)
Post by: nadgtt1982 on 11:28, Sun 30 January 2011
Getting there matey, just keep giving yourself targets and it will be done before to long, like i said in pm if you need a hand just give us a shout.
Title: Re: My 5... gradually going back together :-)
Post by: 5-Mission on 21:59, Sun 06 February 2011
Rear discs, calipers, compensator, brake & fuel lines, new handbrake cables and fuel tank all back on. :)
Turns out my turbo discs weren't as warped as I first thought there's barely any movement against the pads when spinning. I've stuck the williams discs on ebay now as I can't use them which is a shame as they're in spanking nick!
Spent the weekend making up pipes and plumbing them in and getting the fuel tank back on - trying to stretch the flexi breather pipes big enough to fit where they go on the tank when they hardly want to reach as it is what a fun job that was! :roll:

Quick question: when you buy brand new calipers do you need to lube/grease them yourself or is this done when they're assembled in the factory? Is this what the grease nipples are for?? sorry for asking stupid questions, never fitted rear calipers to a car before :lol:  :oops:
Title: Re: My 5... gradually going back together :-)
Post by: nadgtt1982 on 11:32, Mon 07 February 2011
Quote from: "5-Mission"
Quick question: when you buy brand new calipers do you need to lube/grease them yourself or is this done when they're assembled in the factory? Is this what the grease nipples are for?? sorry for asking stupid questions, never fitted rear calipers to a car before :lol:  :oops:

Surely your talking about your bleed nipples Peter? ive never heard about pumping grease down one of them  :lol:, looks like your finally cracking on now though well done matey.
Title: Re: My 5... gradually going back together :-)
Post by: linni on 12:54, Mon 07 February 2011
the pistons should be pre lubricated from factory mate bit of copper ease on caliper bolts and pad carriers never goes a miss though.tighten up quick bleed and jobs a good en ! :D
Title: Re: My 5... gradually going back together :-)
Post by: 5-Mission on 16:06, Mon 07 February 2011
Quote from: "nadgtt1982"
Surely your talking about your bleed nipples Peter? ive never heard about pumping grease down one of them  :lol:, looks like your finally cracking on now though well done matey.
:lol: thanks, I ask because they came with four small tubes of assembly grease and I didn't know what I was supposed to do with them?!  :?
Title: Re: My 5... gradually going back together :-)
Post by: 5-Mission on 16:08, Mon 07 February 2011
Quote from: "linni"
the pistons should be pre lubricated from factory mate bit of copper ease on caliper bolts and pad carriers never goes a miss though.tighten up quick bleed and jobs a good en ! :D
Yeah, I should probably buy a pot of the old copper grease.. the original bolts were wound up with threadlock from the factory though?! :?:
Title: Re: My 5... gradually going back together :-)
Post by: Ash-Lee on 20:00, Mon 07 February 2011
I know the front calipers have sliding pins which should be lubricated.

Not sure about the rears, i think there fixed?
Title: Re: My 5... gradually going back together :-)
Post by: 5-Mission on 18:27, Tue 08 February 2011
Quote from: "Ash-Lee"
I know the front calipers have sliding pins which should be lubricated.

Not sure about the rears, i think there fixed?
yeah they are fixed. I made sure the fronts were well lubed when I was changing the pads. Still have no clue what that assembly grease is for though as they turned up already assembled? :? Don't know if it's what they use in the factory and they threw some in with the calipers by mistake?
Title: Re: My 5... gradually going back together :-)
Post by: Gav on 09:03, Wed 23 March 2011
keep it up looks nice
Title: Re: My 5... gradually going back together :-)
Post by: 5-Mission on 23:26, Fri 27 May 2011
well ,I got myself an engine hoist albeit without an extending boom but have managed to get the engine back in a while ago now. The trouble starts here I reckon! As I took the engines out of both cars over 18months ago now I was scratching my head to remember where everything went back, although it's 95% done now.
Does anyone know if the thick cable that comes directly from the battery +lead goes onto the starter solenoid? There's already a cable attached there. So far got no electrics or clicking relays or anything on turning the key but I'm getting some bits off a breaking 5 tomorrow so should give me some clues!

I'll get some pics up over the weekend. :)
Title: Re: My 5... gradually going back together :-)
Post by: 5-Mission on 22:20, Sat 28 May 2011
Set myself back now due to stupidity! Found out today that when I took the engine out not only did I break the end of the speedo cable but I also broke the white plastic bit the inner cable locates into in the gearbox!
So I've fitted the gearbox and refitted the engine and box and now it looks like it's all gonna be coming back out again as the white bit in question looks like it's only accessible with a stripdown! :P  :oops: I had the old blown up 'box on the bench earlier but the input shaft and mainshaft drivegear looks like it's a puller job to get them off and then loads of disassembling to get at the white bit and I can't be arsed with all that. Don't know if anyone has any experience of stripping gearboxes on these cars?
I can't get any pics up either as I've forgotten my photobucket password and they reckon they've sent the reset email but it never turns up!
Title: Re: My 5... gradually going back together :-)
Post by: 5-Mission on 21:20, Sat 09 July 2011
For anyone thinking of putting a JB5 gearbox on an F2N that usually takes a JB3 - don't bother they don't fit!
The initial differences I spotted were the threaded stud and hollow dowels were located differently on the JB5 so quickly changed them around to match the JB3, put the rubber and clutch release fork and bearing in and tried to fit it but had about an inch gap between box and block and it wouldn't go any further. I don't know how I never spotted it before but the bellhousing is shallower by about 12mm, and looking at the C1J earlier the clutch cover and clutch itself are smaller and probably don't stick out of the end of the engine as much.

So now I have to find another JB3 box, that'll be 4 gearboxes knocking about in the garage.
I was hoping to get the car off the axle stands and back on the floor by august as well lol :x  :roll:
Title: Re: My 5... gradually going back together :-)
Post by: 5-Mission on 16:14, Thu 04 October 2012
Got him running the other day! :D Turned out my fuel pump wasn't drawing any fuel, so quickly changed that over as I had a spare, then I had no spark so changed the coil over for another one I had, turned out to just be the immobiliser on the alarm, so after some frantic button pushing and  knackered eardrums later i turned that off (not used to for nearly 12yrs! Now I need to drain the oil as it's leaking from the sump gasket (I'd used liquid gasket, that stuff that sets), as soon as the engine started warming up it started dripping, so will buy a proper sump gasket and fit that.
Something's burning off on my engine as well, there was smoke coming from the back of the block as got hot, no idea what it was and didn't really smell of much either?

Just need to sort the leaks and get him running nicely, brake fluid in + bleed, get the kit finished and on etc. The window tints are now illegal on the front windows which is a downer and have been advised all doors need to be openable from the outside which is an even bigger downer :?  :(

Can't get any pics up as i don't have a USB lead for my phone, will try and source one and get some up.