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Holey water pipes batman! 16 April 2010

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I gave up on getting a later exhaust bracket as no one wanted to sell me one. Instead I just bent my original bracket back how it was and refitted it. I removed the freeze plug that was not fitted properly. It cracked very easily and so must have been rotten with rust. The replacement went home so easily that I decided to do the other three as well, they were all quite crusty as well so I was glad that I decided to remove them. Now I have one new fitted freeze plug and three empty holes waiting to have theirs fitted. I am going to try and flush out some of the crud that fell off the freeze plugs as they were removed before I fit the new ones though.

It looks like the Motorola alternator I bought 2nd hand late last year will actually fit OK with just a shorter bolt, no need for a spacer. At least that’s what the measurements I took tonight suggest. So now I have a plan to move forward with which is a big relief. Apart from actually fitting it I also need to source the correct voltage regulator. There are differing opinions about whether or not a Bosch regulator will work with a Motorola alternator but I think I’d like to have it correct.

Unfortunately while cleaning up the water pipe that goes from the head to the oil cooler, I found that it had a rust hole in it. As these are NLA new I asked Brookhouse Volvo to get me a good used one. Apparently they went through 5 pipes before they found me a good one.

Drip stopped 13 December 2009

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24th October 2009

Well the gear box drip seems to have stopped. Maybe I just didn’t clean up properly after changing the seal. I certainly hope so. Last weekend I bought some parts from a guy living not too far from me. A NOS hand brake cable, a pair of original arm rests and an alternator. Of the arm rests, the passenger side is not split while the driver side is barely split at all. I’ll have to see if I can do anything to prevent it getting any worse. I have decided to refit the oil cooler so I bought a new O ring to seal it to the block, it may need a coat of paint though. I also sourced a plug to fit on the remote regulator for the alternator but I could only find that from Dave Barton who is in the US. I could have just used three separate spade connectors as most people do but I felt like doing it properly. The main charging feed cable is threaded around the front of the car and awaiting fitting of the alternator. It looks like the rebuilt alternator I bought a couple of years ago is a Motorola unit and should have come with a spacer to get the pulleys to line up correctly. I am going to space it out with some washers until I sort something better out. The alternator I bought last weekend came with a cranked adjusting bracket which is the part I most wanted, the alternator itself is a bit dubious having sat unused for quite a few years and is another Motorola unit so no help in the correct fitting stakes.

Today I spent most of the time fitting the rear half of the Simonz exhaust I bought a while ago. The rearmost rubber hanger was tough to get on. The body bracket seems to be too large a diameter for the hole in the rubber. I had to use a ‘G’ clamp to force it on. There are reports of this part failing prematurely, but stronger alternatives are easily available so it is not a big deal. I spent a while considering how to fit another bracket from the fitting kit. however it turns out that it is for very early cars and is not applicable to mine. I did however find that there is a bracket attached to the gearbox that has been bent out of the way which I will have to straighten. It is clamped in place by the gearbox support bracket so will be a bit of a pain if I have to remove it to straighten it as it will mean supporting the gearbox while the support is removed and that is going to make access difficult.

I need to sort the oil cooler out next as that must go on before I can refit the manifold. I also need to decide if I am going to fix that freeze plug before I refit the manifold. I need to fit the manifold before I can finish the exhaust and I need to finish the exhaust before I fit the alternator as it impedes access to the manifold to down pipe nuts. I’m also going to fit two new hand brake cables. One of the current ones has a completely perished rubber seal and although that could be replaced, I’ll be happier with a new cable.

Spiral binding 12 December 2009

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21st February 2009

I bought the blanking plate for the head to seal off the feed to the oil cooler, but I need to get some gasket material to use with it and it also needs painting. I also bought an inlet ring and a freeze plug. I removed the rear brake backing plates that I had put in place so that I could get at the rear bearings. After a bit of an effort I managed to get the axle half shafts free, using the brake drums as a slide hammer. There was not enough space to use a real slide hammer. I put fresh grease into the rear bearings, the stuff in there was old and probably diluted with gear oil as it was quite runny. I’ll have to keep an eye on it and see if the inner grease seal needs to be replaced. I started to peel off the insulation tape that is wrapped around the wiring loom so that I can re-wire for the alternator. The braided covering underneath is in quite poor condition. I ordered some new cable and terminals to cope with the higher charging current that the alternator will supply as well as some spiral binding.

One screw missing 12 December 2009

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14th February 2009

I put the starter motor back in its place a couple of weeks ago but I have not tightened the bolts up yet.┬áThe prop shaft went in the same time as the axle and I tightened the big nut holding the centre bearing in place before I replaced the starter. I have not fitted the new nuts and bolts at each end of the prop shaft yet. Today I drained the coolant from the engine and removed the oil cooler. When I bought the car it had one screw missing from the valve cover and when I removed the oil cooler, there was a screw lodged behind it which I think must have been the original valve cover screw. On removal of the feed pipe I found the remains of an ‘O’ ring that had disintegrated and fallen into the oil cooler. I think I managed to get all the parts of it out. I have a replacement shorter oil filter spigot and the simpler bottom radiator hose without the extra connection from the oil cooler but I don’t have a good way to remove the longer spigot that is used with the oil cooler. Also I cannot find the blanking plate I need to seal off where the feed pipe attaches to the head so I may just refit the oil cooler for the present once I have given it a good flush. I found the alternator and voltage regulator I intend to use amongst my boxes of spares that I have bought,┬ámany ‘just in case’ but some, such as the alternator and regulator, were actually bought with a plan in mind.

Grit in my eye 12 December 2009

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31st December 2008

Progress has been slow as usual but it has been happening. The rear axle is back under the car and the trailing arms and torque rods are connected. While doing this I decided to redo the paint on the panhard rod mount on the body. I only managed to get one coat of hammerite on it before I got some grit in my eye. By the time that was sorted out it was too late to put a second coat on immediately and I have to wait six weeks for the first coat to cure properly. With the cold weather I am probably going to give it a bit longer as well. I had given up on getting an alternator bracket from Scandcar so I bought an IPD version from eBay, whereupon Scandcar got back in touch and sent another bracket which has now arrived. So I now have two alternator brackets to choose from. The IPD version is the nicer of the two so I’ll probably go with that one.

V5 arrives 14 November 2009

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18th November 2005

CVI have just sent me an email with the total price and informing me that the parcel will leave them on Monday. I’m glad I’m not in a tearing hurry for this stuff although the sooner I get it the better. I went to the scrap yard this morning hoping to find a B20 engined car that I could get the alternator from but no luck. I also received the V5 back from DVLA today with my name on it, so the car is definitely mine to keep now – yippee!