davkav's Mk2 Oak Green 8v

Discussion in 'Members Gallery' started by davkav, Feb 6, 2018.

  1. Ronan Halpenny New Member

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    What's next Dave?
     
  2. davkav

    davkav Paid Member Paid Member

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    What's next you say, I think the plan is sit down and cry some. I need to make a list, I've gone out to the garage a few times now to try and get some work done. Only to be overcome with the mountain of work that I have made for myself.

    Someone seems to have started a trend on here, so I thought I would follow suit and make a LIST!

    Part A:
    • Treat surface rust under driver side A-pillar
    • Fit replacement driver side wing
    • Seam seal wing to chassis
    • Spray wheel arch/inside of wing with waxoil
    • Remove subframe, steering rack, wishbones
    • Check steering rack for play/leaks etc - refurb/paint
    • Gather parts to be sent for powder coating (Subframe, front cross member, bumper bar etc.)
    • Treat any rust in the engine bay and general tidy up
    • Electroplate nuts and bolts
    • Refit subframe, steering rack, wishbones once powder coated/painted
    • Tidy up the brakes line I fitted a few months ago, I'll need a pipe bender and straightener to make the nice and neat
    • Fit refurbished engine bay looms

    Part B:
    • Recondition engine
    • Electroplate nuts and bolts
    • Powdercoat/paint brackets/housings
    • Fit new gearbox input shaft (current one is leaking)
    • Paint engine and gearbox
    • Get the intake manifold media blasted as it has been painted metallic silver by PO
    • Rebuild driver side driveshaft (passenger was done last year)
    • Refit engine and gearbox
    • Button up the front end

    I've started tipping away at it again, starting at the top of my list.

    Cleaned up the surface rust under the driver side A-pillar
    IMG_20210125_220205.jpg

    I scraped back the original seam sealer by about a 1cm as I wanted to ensure the new seam sealer created a proper em seal ;) You can also see where I have scraped off the sealer around the seam between chasis leg and cabin. When I was removing the old wing I used a stanley blade to cut through the sealer. What I didn't know was that there was a seam there and I had cut the sealer right on the seam. So to ensure the seal was not compromised at the seam, I cut back about 1 cm from there and scraped some out the seam also.
    IMG_20210125_220213.jpg


    Cleaned back the sealant on the wing also to ensure the new sealant will be able to do its job.
    IMG_20210125_222415.jpg

    IMG_20210125_223510.jpg

    Sealant applied to bellow the A-pillar
    IMG_20210201_213139.jpg
    And the replacement wing fitted with new sealant
    IMG_20210201_215228.jpg

    IMG_20210201_215230.jpg

    As you can see I am no good at body work [:v:] Comments/advice greatly appreciated.

    Next on the list is to waxoil over the seam sealer and bolts for added protection.

    I'm not overly worried though. The main objective was to get rid of the wing with the stupid looking vents cut into it. When the car is 100% mechanically sound, someday I would like to strip it all down and send it to a pro for bodywork and a respray.
    When Part A and Part B are done, the next chapter will be to refurbish the fuel system but that will be next winter. I think then, everything bar the body work will have been addressed on the car.
     
    Last edited: Feb 2, 2021
    NateS2 likes this.
  3. Tristan Forum Junkie

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    Want a lend of my pipe straightener and bender?
     
  4. davkav

    davkav Paid Member Paid Member

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    That would be awesome.
     
  5. cupracraig

    cupracraig Paid Member Paid Member

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    upload_2021-2-2_14-21-23.png
     

    Attached Files:

  6. davkav

    davkav Paid Member Paid Member

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    Haha, I promise it's all about Getting Things Done now. Regular list updates will follow!
     
  7. Savagesam

    Savagesam Moderator Staff Member Moderator

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    Oh good. I enjoy this one!
     
  8. cupracraig

    cupracraig Paid Member Paid Member

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    i feel like a few of us might be doing this in the not so distant future.

    What you have done looks good Dave, you have inspired me
     
  9. Savagesam

    Savagesam Moderator Staff Member Moderator

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    If you want some practise, you can come and do mine first [:D]
     
  10. Tristan Forum Junkie

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    You're doing a GTD swap?
     
  11. davkav

    davkav Paid Member Paid Member

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    Thanks lads. The fuel system definitely needs an overhaul. When I first bought the car the swirl pot needed to be cleaned of debris as it sounded like a box of smarties when shook. So I am sure the fuel tank will need cleaning. I'd like to replace any flexible hoses too for peace of mind.
     
  12. davkav

    davkav Paid Member Paid Member

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    Wash your mouth out!
     
    Skool, Tristan and costel1969 like this.
  13. davkav

    davkav Paid Member Paid Member

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    More progress updates! Looking back at the photo's, it feels like I haven't gotten much done but my back says otherwise... :lol:

    Next on my list was to get the subframe dropped out so that I can get all of the connected parts cleaned up and refurbished.

    Subframe dropped
    IMG_20210218_230916.jpg

    Made a pile of stuff to get media blasted and powder coated. Aluminum parts are getting vapor blasted.
    IMG_20210220_144435.jpg

    Stripped down the front bumper to get blasted and coated too
    IMG_20210221_185746.jpg

    I basically went around the whole front of the car to see what needed to be media blasted and coated, and came up the following long list....
    • Front cross member bars
    • Front bumper bracket
    • Subframe
    • Power steering reservoir bracket
    • Coolant reservoir bracket
    • Bonnet
    • Headlight mounting brackets
    • Power steering line bracket
    • Anti-roll bar
    • Wishbones
    • Caliper carriers
    • Cylinder head cover
    • Clutch cable support bracket
    • Gearbox support bracket
    • Gearbox lower flywheel cover
    • ECU bracket
    • Fog light brackets
    • Front engine mount bracket
    • Power steering belt adjustment bracket
    • Alternator adjustment bracket

    Anything that is steel and should be black!:lol:

    I then moved on to stripping down the steering rack for a freshen up. My steering felt a bit light so I was fully expecting play in the rack but there was none. I'll have to investigate the steering rack itself.

    IMG_20210221_203039.jpg

    IMG_20210221_204804.jpg

    I was debating stripping the rack down completely, but from what I have read online it's a whole world of pain, and quite a number of seals that need to be replaced. It seems in good working order so leave well alone.

    I had added new tie rods and tie rods ends to my list of things to buy, but discovered this lovely box of parts that I must have purchased in the past. Nice one! One less thing to buy..

    IMG_20210221_210103.jpg

    Next up is to clean and paint the steering rack.
    Grind back any rust in the engine bay and paint.
    Tidy up my brake lines.
     
    Last edited: Feb 22, 2021
    NateS2 and costel1969 like this.
  14. Tristan Forum Junkie

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    You say it felt light, the steering, Dave.? As in, too light? Sticky release valve?
     
  15. NateS2

    NateS2 Paid Member Paid Member

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    Your subframe looks immaculate compared to mine, I don't think there's any paint left on it :lol: Will look satisfying with it all cleaned up and coated though
     
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  16. davkav

    davkav Paid Member Paid Member

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    Maybe it's the way they are and I'm just comparing them to more modern machines.
    But to me it always felt a little light and as if there was playing in the steering wheel to road wheels.

    What is this release valve you speak of? I'm off now to research how hydraulic steering racks work.
     
  17. davkav

    davkav Paid Member Paid Member

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    Yeah I'm looking forward to getting them back now. You can't beat working fresh parts.
     
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  18. Tristan Forum Junkie

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    Every hydraulic pump has a pressure relief valve. Sometimes it's a piston, sonetimes it's a ball on seat. The odd time they get sticky.
     
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  19. davkav

    davkav Paid Member Paid Member

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    Ah, use your head!
    I was stripping down the pump before clean up last night and the relief valve popped out, so I know exactly what you are talking about now. I'll give it a good look over tomorrow.:thumbup:
    And now that you say it, the pump was a little whiney.

    Edit: here's some really good information and diagrams on how the power steering pump and racks work
    Link
     
    Last edited: Feb 22, 2021
  20. Tristan Forum Junkie

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    If the pump was whining, bin it. Mine went from whining, to fc.uked in one trackday.
     
    costel1969 and davkav like this.

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