405: Major Works

[ekjdm14]

Ooooh Mate.... Sorry, whenever I see Madame Guillotine she brings to mind "Carry on Don't Lose Your Head"

Which is especially ironic given the 405's current issues... Perhaps it is a Guillotine after all, to negate the potential struggle with those head bolts!

[Pug_XUD_KeenAmateur]

Hi Guys, aware things have been quiet the past few days. Still alive & well and making progress, but things have been mega-busy

Daughter's Ford has been cleaned, an online Owners Manual sourced and a replacement Wheeltrim ordered; no preventative maintenance yet, but I don't intend leaving it long

The bits of wood have been of some use straightening the 206's Boot Floor, having Routed them with a Router I was given some time ago but had never used.

I've also created some wooden Wedges and cut down a Brick Bolster to use as a Drift . .... but the real key bit of kit in sorting it out has been a couple of sturdy bits of Angle Iron; its not yet finished but I'm delighted with the results so far

The 405 misbehaved on a regular run, with the temp reaching 105c; and I was fearful of being completely transport-less, but running it without the cap on the Header Tank has provided further respite. Its 'Sun Holiday' time again and as such its booked on a Cross-Channel Ferry for late May

Back soon.... ish

[Pug_XUD_KeenAmateur]

a couple of bits of good news

1: just purchased Low Ash oil for the Focus, Euro's have a 60% off sale so Mobil's Super £49 a gallon 3000 5W-30 works out very reasonable. It'll also be used on the Polo... but the 206 has a record of an oil change 2k ago, so no need there.

2: the 206 is sorted for now (I've replaced the Fog Light since the pics were taken) and so is ready to be pressed into action when the 405 comes off the road for its much delayed work

[ekjdm14]

Now that looks a helluva lot better than what it did , that boot floor's never going to win any beauty contests & nor is Daniel's cars inner rear quarter but the shell's at least close to the shape it started out as & should serve well whilst the 405 gets some love. Just have to hope the 206 bug doesn't bite you as hard as it has me, else we'll have some competition! (the more time you spend driving that thing, and knowing it has virtually free tax as well as great economy and decent power, they really do grow on you!)

[Pug_XUD_KeenAmateur]

Thanks ekjdm, well said I'd say; reckon there's a good chance of that 'competition' you mention . Done maybe 200miles in it so far and often finding myself taking a longer than necessary route for wherever I need to be.

It'll be a sad day when the 405 is fixed and its gotta go, but tempered with happiness that the old girl 'll be back to normal. She's in for MOT next week. I considered just letting it run out (late Feb expiry) , but its worth £45 to ensure I know if there's anything 'extra to expectation' to deal with.

If anyone fancies the 206, I'm thinking of a bartering 'start' of around £500; but it'll be ready when its ready, probably March/April. History includes Cam Belt and Back Axle.

[Pug_XUD_KeenAmateur]

She runs !

At last some progress with the 405.

After overcoming inadequate Earths, weeping Injectors pipework, badly set Timing and the fact that this is the first time I've started an engine outside of a vehicle.

[mickthemaverick]

Well done, but I have to say I don't think you'll win any awards for Health and Safety!!
Onward and upward!!

[ekjdm14]

Health and Safety!!

What's that?





quite a thrill when a "loose" engine fires up and starts dancing on the chain/blocks... Though I daresay it was less "lively" with the gearbox attached, first fire of Black's replacement lump it tried to do a backflip and then when the wire came off the stop it tried to headbutt me All good clean fun. (but in seriousness, do stay safe. )

[Pug_XUD_KeenAmateur]

no probably fair comment with regard to some seriously 'iffy' / absent H&S.

I did at least ensure that I wasn't in contact with the metal framework of the Crane while it was cranking.

Can't say I've yet experienced firing up an engine without its Gearbox, how'd you work that with regard to the Starter Motor?

Meanwhile in other news
The Micra is now sold

Daughter's C-Max has had an oil change with top quality Low Ash Oil, and its Injectors tightened, but I want to see what size the Copper Washers are on the Oil Feed Pipe before I replace the Banjo's each end, hopefully I'll find a suitable vehicle in a Scrapper.

The 405 has failed its MOT on Suspension & Steering, that's next job. I've decided I want it to have a fresh one before I whip the lump out. Surprisingly, emissions were just fine.

[ekjdm14]

Can't say I've yet experienced firing up an engine without its Gearbox, how'd you work that with regard to the Starter Motor?

Starter mounts on the block, I'd already fitted the flex plate/flywheel (don't recall having to do any funny business with the bolts either so I think it must have been threaded independently to the bellhousing bolts.)

Come to think of it, that's likely another reason it was so lively (like an angry fish on a hook!) would have been the lightness of the flex plate compared to a manual flywheel (most of the mass is in the torque convertor so the flex plate is super light).

[Pug_XUD_KeenAmateur]

Aha, that'd work then.

The 206 has a rattly noise at Tickover, after its warmed up; which sounds a lot like an Aux Belt Idler to me. Certainly hope its not a Cam Belt idler as I'm far too busy to think about spannering on it. Am I gonna have to remove the Aux Belt to check it out, or is it likely to be visible if I look in the right place? The car has AC, so its a serpentine set up

Meanwhile... check out my 'improved' Steering Rack Gaiter fitting Cone, tested on the spare rack; will report shortly on whether it makes the job any easier with the rack in situ.

[Pug_XUD_KeenAmateur]

Little bit of an update....

... I really needed an MOT Fail like a hole in the head. This year it was
Wishbone Bushes
a Ball Joint
Steering Rack Gaiters, both sides
and a CV Boot

As well as imbalanced Back Brakes, which were easily rectified.

That's all been taken care of for the princely sum of £35's worth of parts the old girl's got a fresh new MOT and her spare set of Struts & Wishbones on til I can find some time & energy to sort the old ones

...but that's the last time I attempt to replace a Rack Gaiter in Situ. It would've been considerably easier to have had it out.

...but I've got really good at getting recalcitrant Ball Joints out (Angle Grinder) and I was able to complete the works just before the weather turned really nasty; so now engine works can recommence, hopefully !

Meanwhile the 206 now runs lumpy when cold, feels like its not burning its diesel properly. I'd think GP's, but it starts immediately without any cranking and I've not noticed any unburnt diesel smoke. Its fine when its up to temp....

...unlike my 405 which I know has very iffy Glowies, starts reluctantly and is not a pretty sight on a cold start, but its getting very little use, so it'll 'keep'.

I'd be sad if the 206 died and it'd be a waste of all the hours I put in at the back end of it, but I'm sick to death of things getting in the way' of sorting the 405 and really getting quite anxious about it; so hopefully that'll 'keep' too.

Next!! Header Tank Bracketry

[Stickyfinger]

Health and Safety!!

What's that?





quite a thrill when a "loose" engine fires up and starts dancing on the chain/blocks... Though I daresay it was less "lively" with the gearbox attached, first fire of Black's replacement lump it tried to do a backflip and then when the wire came off the stop it tried to headbutt me All good clean fun. (but in seriousness, do stay safe. )

Naa, dat-ill-be bree allreet

[Pug_XUD_KeenAmateur]

well fingers crossed this is successful....

Header Tank is physically fitted and appropriate plumbing is in place with many thanks to Chris who, many moons ago, supplied helpful Diagrams

As yet its un-tested...

[mickthemaverick]

As yet its un-tested...

Does this mean its tin hats at the ready time