Sent back the tacho to ETB for inspection, they said they found nothing but were going to reduce/increase the resistance (?). This is now back with me, fitted and working. Also finished off fitting the dash tonight. Got some quotes for insurance, Adrian flux came in at £182+200xs with 3000 miles and CIC came in at £171+100XS, others were more expensive. Once I have an SVA date then I can get this sorted.
Filled the back of the windscreen and painted it (still not perfect but OK), resprayed the driver side pod cover and fitted the ECU bracket, tidied up all of the engine bay wires. Gave the car a good clean and drove it up the road. Filled in the SVA forms and sent them off.
Well, finally got the injection inlet manifold sorted. Took the plunge and purchased a low level system from Trust Electricals (YKC) which sealed OK onto the head but again had manufacture issues with the injection Bar. A second manifold should be here on Tuesday (8/6/04) to finally put that to bed, four inlet manifolds later. In the process I have had to have a new alternator bracket made up and an idle valve connector also made up at work to fit the new manifold. Other jobs completed during the first half of the year include fitting the inner front arches, fitting blanking plates to the gearbox to keep the stones out and making up various brackets including one to keep the ecu in place. List to do is - fill the back of the screen frame, make up some panels for under the dash, fit the dash, sort out the tacho (still), paint up the under bonnet, make up a heat shield for the exhaust (not essential), finish off the carpets and tunnel cover. Finally get the car MOT'd, insured, SVA'd and registered. I have two days off next week to crack the back of it.
Still can't get the Tacho running even after trying various resistors and wiring combinations so drew up the oscilloscope output and sent to Fishers to see if they can get any joy out of ETB. Refitted the various brackets and fitted the carpets on the cockpit upper sides.
Spent a short afternoon in the garage and got a few jobs done - cut a bit more off the front of the side pods so that the wheels do not foul on full lock, filled the back of the screen surround with fiberglass bridging compound, sanded the doors a bit more where they have been filled, and gave a number of brackets a first coat of paint. Drove the car up and down the read a couple of times, goes well !!! So next job is to filler and paint the windscreen surround, finish off painting the rest of the brackets and order some more carpet/vinyl from Mark. Almost there!
Another productive day. Finished off a couple of locators for the bonnet to make the shut lines neater, these entailed bonding two ally blocks to the inner side of the bonnet and drilling them out, into these two spikes locate that are screwed into the top of the pods. These seem to work but need a little fine tuning. Next on the agenda was more filling for the doors and then after a couple of hours lots of sanding, again there is more to do on these and so will continue this next week end. Next came fitting the passenger seat, easy. The big job for the day was fitting the windscreen. This went surprisingly well and even the fitting of the rubber went in well, the dash top can be put in with a bit of persuasion so all looks good. Finally fitted the water jets for the screen wash, again an easy job entailing just drilling two holes and putting the through (there were off a Lada !). Final job of the day was to give it a polish and see what needs sorting out on the body work.
Taken a day off work to try and make some headway into the list of odd jobs than need finishing off. So to start I cleaned up the windscreen and surround and painted this with primer, not that satisfied but it will do. Next I painted the underside of the bonnet with black hammerite, looks a lot better, also tidied up the wiring with tie wraps and insulating tape and then painted the steering column that had a few scrapes on it. I then started on the interior, put some holes in the dash to fix the top to the front, painted the seat floors with hammerite again these had got a bit scratched and then cleaned down all of the surfaces. Next I put in the boot carpet and then cut the holes for gearstick and the handbrake in the tunnel top cover, I then fitted the drives side carpet, seat and seat belts, finally I fitted the passenger side carpets. The only trouble I had today was the tunnel cover has a hole for the handbrake in the side and I have put it inside the tunnel and I messed up the screen mastick so have had to order some more, this will be here on Monday. A generally productive day. List of things to do are finish off filling the doors and painting the inners, fit the windscreen and fill the back of the frame/paint it, fit the passenger seat and seatbelts, finish off the carpet under the dash, then paint up all of the odd brackets I have made over the time, enlarge the cutouts to stop the wheels rubbing on the side pods, then there is the minor body work blemishes to sort out and we are there. I have Monday off and so should get the back broken of these also.
Dave King from Kaelec came round this morning to try and sort out the main electrical fault on the lights/wiper circuit. After two hours or tracing the electrical circuit in the dash loom, the fault was rectified. The only remaining electrical issue is the Tacho which can wait until after SVA. Over last week I also started to fill in the edges of the doors ready for spraying, I resprayed the light cowls and also the dash top, all black gloss. So hopefully it is full steam ahead from now.
Competed a few more small jobs this week, made an ally top for the foot well, resprayed the "elise" light covers, sprayed the dash top and organised an auto electrician to come out an look at my final electrical problem. Hopefully by next Monday we will be on the downhill stretch. Last Thursday met up with a number of Sylva owners at the Liphook meeting, saw three sylus, and three fury and met a guy who works at the same place as me who owns a nice 1700 Xflow fury. A good evening was had by all.
Brain wave - more like lobotomy, the earth wire did not do the trick so I will have to get a sparkey in to look at it, Stuart Parley knows a man that can. I've always not been happy with the running of the engine and so I decided to do something radical about it. I went down to the scrappers and bought a Zetec inlet system complete for a 1.6 Escort (ally inlet with separate injector bar). I then cleaned this up and put in on the engine without gaskets etc. and guess what, it did not run any better therefore my belief that there are loads of inlet leaks was proved right. I then took off the low level system, stripped it down, cleaned it up, filed clean the mating surface between the inlet and the head and put it back together with Ford gaskets. The engine now runs much smoother. Ran it for about 25 minutes, the thermostat tripped in the second longer circuit and the fan on the rad came on at about 97 degs as expected. Looks good. I think I am going to get the inlet/head face machined at work just to be sure I have a good mate between the two. I also tightened up the pedals and made a cover for the access hole. Next job is to sort out the electrics and it's down hill all the way from here (hopefully).
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October 2010
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