our first car project (bye bye 56K)

[bihus]

So, any news on the progress?

 

[bone]

no, not realy

the car is located in the house where my friends sister lives during school. but she needs to redo some tests, and is studying right now, and we aren't allowed to go over and make noise

i can tell you that the device we took from the blue one and put on the gray one fixed the problems with the engine, so that's good news, only 50? instead of 1500? for a new exhaust. but on high revs it still dares to miss a beat, and we think the fuell-filter may need replacement since the car has been standing for more than 6 months.

to counter the "not-working-on-car", we placed a new clutch on the banshee, cool to see as well, 7 disc wet clutch, when i get them off my phone, i'll post them as well

and next weekend i will be at pukkelpop, so there won't be any progress as well

 

[bone]

time for an update on our work

so yesterday i got a phonecall from my friend "can you jump in the jeep and come tow me home?" that's for the gray renault, since the blue one is still in pieces

hmm, not that good. He was racing big time, suddenly, no power at all, switched off the engine, and it woudn't start no more. a closer inspection showed the timing belt had skipped a teeth

DOHC

so a new one needs to be installed, and therefor, a part of the engine needs to be stripped. we first took off the plastic covering the spark plugs

i wasn't able to take a clear pic of it, but there was fucking 3cm of oil surrounding the spark plugs

it clearly came from the top gasket, so valvecover has to go

cams rule (and still look OK)

so now this bolt has to come off (pulley for accessory belt)

but that's connected to the crank, so that's not that easy. i looked on the internet how to block it, and they say everywhere: "block your flywheel with a screwdriver"

flywheel? we don't have the intention of taking the engine out of the car, we'll have to find another way.

 

[Svempa]

Maybe there should be like a Project Forum on Finalgear. You could show us your Super Seven Replica that you're building or your car that your modyfing and update it every now and then.

 

[bone]

WTF?

since when am i building a super seven replica? :lol:, and there aren't that many here working on their car themselve, would be a pretty passive section i think

anyways, here's the proceed

so we were replacing a timing belt, but we have kinda difficulties commiting to 1 job only
when he bought the car, these were in the trunk

so might as well install them.
first get out the original setup, but of course those screws are tight as hell --> abuse them with a torch

gone

quite a lot shorter

looks better than the ugly black springs

that's done, continue with the belt
accessory pulley is gone (tnx to a bouloneuse, impossible to do without)

remove the old belt, align up all the marks (on the crank as well) and slide over the new one (beware of the directionarrows)

after tensioning it, it was time to start the car...and it gave nothing

but before panicking, always take your multimeter . turned out battery was dead , it gave 12v, but when trying to start, it fell back to 6, which is way to little

find another car, take out the battery and hook it upt

ever seen such a easy hood? it stands vertically, all the access to the engine you need

with its battery connected as well, it fell back to only 8v , which is still short of 12v

then put the battery of the xantia back, connect it with the renault and try to start this with the xantia running, still nothing.

we were starting to phreak out by this time, but as a final messurement, we towed it around the block where i live, halfway...VROOOOAAAM... it started i think it woudn't start right away due to all the oil that was surrounding the spark plugs. some must have dripped in when we took these out (and the spark pluggs realy realy realy need replacement)

the gasket that was leaking oil in the first place still looked ok, but the screw holding the valvecover, could be undone with a simple screwdriver. they were fare from tight enough, we tightened them and hope it won't be spilling any oil no more.

oh yeah, and pic of the new suspension

that doesn't look good, it looks ever worse caus the car is standing half on the sidewalk, but still, i think he'll might to go get some 4cm lowered springs for in the rear , after all, he did save 700?, that's what it would cost to have the timing belt replaced by an official dealer

EDIT: i have some pics of a banshee 7-plate wet clutch, you might be interested to see this as well

 

[fbc]

Thanks for the update bone - keep it up

So how's the super seven coming along?

 

[freakster_991]

nice....wow....work in progress is like a weekly tv show...

 

[bihus]

Thanks for the update bone - keep it up

Hear, Hear.

So how's the super seven coming along?

 

[sydney_walker]

beautiful, i always love to tinker around with car engines although i'm not really good at it

keep up the good work guys
have fun with the rust

 

[bone]

we replaced the spark plugs, and they were nasty

i also took one from the spark side of the plug, but it didn't show up well, i'll try and reshoot it

 

[watto]

Looking good bone... just saw thw side on pic and yes, it would be a good idea to get lower springs for the rear...

look foward to more of your pics mate

 

[iboss429]

nice work bone keep the pics coming

 

[bone]

Looking good bone... just saw thw side on pic and yes, it would be a good idea to get lower springs for the rear...

look foward to more of your pics mate

turns out it doesn't have springs in the back

it works with torsion bars. not completely sure, but i think it's a spring in the chassis in which you slide your wheel-mount, and the rotation of this part, makes the torsion bar swing and act as a spring

you can see the horizontal mount which slides in the torsion bar, and all you need vertically, is a shock absorber

so you can change your ride height without getting new springs (and that's why there were only 2 in the trunk)

 

[bihus]

Looking good bone... just saw thw side on pic and yes, it would be a good idea to get lower springs for the rear...

look foward to more of your pics mate

turns out it doesn't have springs in the back

it works with torsion bars. not completely sure, but i think it's a spring in the chassis in which you slide your wheel-mount, and the rotation of this part, makes the torsion bar swing and act as a spring

you can see the horizontal mount which slides in the torsion bar, and all you need vertically, is a shock absorber

so you can change your ride height without getting new springs (and that's why there were only 2 in the trunk)

It's gonna be cheaper than planned.

 

[bone]

cheaper, yes, easier, no. i've been reading on the net and it turns out she's a real bitch to lower. first it'll be stuck completely, very hard to undo, and second you can't see the effect of the changes while you do them. you have to make changes, and lower the car back on the ground to see if the result pleases you, if it doesn't you have to lift it agian, ... this for both sides

anyways, the timing belt skipped a teeth because it wasn't tight enough

see the srew in the green circle?

that's the one which needs to screwed in to tighten the belt. problem is that it's srewed in fully tight, and that the head is worn out, you have no grip anymore with any sort of screwdriver. so that has to go

it took us 3 days :shock:, but she's out
we bored once through the threat to take off the pressure

and once through the middle to have any grip

and then you insert a special screw with threat in the opposite direction in the middle hole, and keep tighten it, untill it's so tight, that the screw gives, what a great feeling that was

new screw in, put belt back in, and tighten it. to tighten you belt you need a special device called a "belt tightener" like this

for this engine, value has to be between 22 and 25, so this is fine

 

[jayjaya29]

Sweet, stripped screws are a B1tch. Deal with them all the time while working on my friends boat. Corroded and Stripper screws makes for a lot of cursing.

 

[bone]

the gray renault started making weird noises this morning, so we decided to go continue on the blue one before the gray one gives it's life

lot's of work, few pics, but the dash is gone

look at the wires (although i was expecting worse), they were strangled in the dash and the heating, and were a bitch to get from in between

find the steering shaft?

my friend already has the piece that needs to get in the car, so now we have to figure out how to get the rusted one out, find someone to weld the new one in, and then hope we've received the manuel that was ordered on internet to put the car back together (although i don't think we'll be needing it much, it's pretty straight forward)

 

[bone]

by reading mancs update it striked me i forgot to write an update as well. i already had to go look for the topic on the end of page 2. good thing we're not working for a client, or he would be pissed :lol:

first a little bit about the gray one. the timing belt had slipped a teeth, and we replaced it, and by miracle everything worked fine, no valves broken or sth at all (going by the sound and performance). but then after having driving a few 100km, the engine started making a realy distinct ticking sound, like the valverockers had play. to bad, we're not gonna take the engine apart as long as the blue one isn't fixed, so just keep driving...until a certain moment...engine dead (on the middle of a roundabout :? ) and wouldn't start no more. towed it home, took a quick look at it, but couldn't find anything. we did a pressure check, but all cylinders gave values between 10 & 11 bar

we put everything together again, and tried to start, now it did, but the sound that came from it sure wasn't healty, it sounded like ther were parts in the engine just shaking around, but it does run, so we think one of the bearing of the crank will be broken.
so basically it's dead untill the blue on is fixed.

on the blue one there's been also some progress, last update the dash just had come out. some more taking apart has been done, such as the windscreen whiper mechanism, and the heater.
now everything is basically stripped, and teardown can start
first cut out roughly what has to go (jessy james style )

start drilling out first spotwelds

and after a little bit of smashing and tearing, first piece gives way

after the sides have been done, it's time for the center spotwelds to go, and for the metal to be taken apart

now the piece is only connected on the inside with some spotwelds, but those are for next time

and for the rebuild to go smooth, my friend bought this

and this is the piece that has to go in

(it's a lot bigger than it appears on the pic!)

 

[bone]

IT'S OUT

and underneath...everthing is still clean metal, no rust yet

drilled out spotweld are cool

we were always with a few to work on the car, and there was always someone who couldn't do anything on the problemarea, so we also sanded off the sides, caus there was a minimal of superficial rust, nothing bad, but if it's open you better clean it.
afterwards a few layers of zinkcoating is applied. (zinkcoating is the same as ordinary coating, prevents rusting, but you can still weld through it)

and finally a layer of the same stuff they put on the underside of a car, so it's good for the next 10 years

 

[bone]

again enough pics to write an update

so the panel was out, but where it was welded together, its now clean metal, which already had superficial rust when we got back a week later. so we sprayed a special something on it, which eats away rust.
it has no color, but where its rust, it eats it away, and becomes black, and leaves a protecting coating on the metal

shortly after applying

later it looks like this

after this was done we could start sliding the panel in. as you can imagine that didn't go very smoothly. in 1 place it had to be above another piece of metal, 5cm next to it, it had to be under the piece of metal, and at the corners we also had to cut some out to make it slide in. took us quite a while before it was settled

we first threated it with zinc-spray. a type of primer on which you still can weld

corners were a bit tricky

but it looks good in its final place

of course it still had to be welded in place.

the guy welding is studying (well more working) to be a body repair dude, he welded the panel in. he didn't had a welding machine though, but he found one for 50?

looks a bit old, but makes OK welds

monster garage style

where the windshield has to come, there are also welds over the whole width over the car, but they need some threathing or the window would crack again
before they look like this

afterwards like this, you can't even see where the weld exactly was

unfortunatly we ran out of gas before they were all finished, there are still 10 or so spots that needs to be welded. that kinda sucks, but besides that, its coming along nicely