May 2011

Once the luggage containers were removed I can see another couple of build errors. On the rear brake line there was at least one P clip that did not have the rivet through both holes allowing the pipe to be lifted out of the P clip. This appears to have be an error when fitting as the P clip hole did not look like it had come adrift from the rivet, although none of the rivets for the brake line had a washer between the rivet and P clip. Looking at the plastic P clips supplied by the factory I decide that since I have removed most of them I will replace them with galvanised steel P clips that have a rubber insert to protect the lines.
 

Another problem found was the thick red live feed cable from the battery to the rear of the car was tie wrapped to the aluminium heater pipe instead of being P clipped to the chassis rail below with the brake line. This will also get P clipped correctly with appropriate steel P clips.
 
The heater and radiator bleed hoses were removed and although the black rubber looks in good condition, the appearance does not compare to the shiny blue Samco hoses. I look around but Samco only seem to make lengths of hose up to one metre, further searching I find a company called Viper Performance they can make any length of hose and so I order two 3 metre lengths of 16mm internal diameter heater hoses and one 4 metre length of 8mm internal diameter radiator bleed valve hose. I am hoping these will have a longer useful life than the standard rubber ones, particularly the radiator bleed hose as once the luggage containers and side pods are fully fitted access to this hose will not be possible.

  
Previously I have commented on the poor state of the petrol tanks, or more precisely that they appear to have been painted by just pouring the paint over them. I know most of the tank surfaces will not be seen, but I was keen on having the visible areas shiny. I set about stripping the paint off of them using a combination of cellulose thinners and paint stripper.Although a slow messy job, all the paint eventually is removed and they do now look impressive. I will paint the sides and bottom to protect then and leave the visible areas in the engine bay as shiny aluminium. 

Another job I tackle is the  labelling of the wiring loom. This is straight forward and gives me the opportunity to inspect it. A couple of connectors have different colour wires to the manual but I believe this is just factory changes of wire colours. There have been no modifications made, but some of the crimps do not look secure, so I decide to remove each connector from its receptacle, I crimp the cable support and run some solder into the joint. 

 
I have been reading other blogs etc and at the moment have decided to use Mk4 Escort/Orion indicator and washer stalks. I purchased a new set from Ebay along with a cheap second hand set  complete with connectors from the local car breakers. I can use the old ones to mess around with mounting and cowling fabrication etc. then when ready install the new ones.

 Its coming up to my birthday and as a response to the wifes requests on what I want, I have decided that parts for the car are in order. They have to be something tangible so that she can say I got those for his birthday. I end up ordering front and rear lights and the mirrors.  I also order the windscreen wiper kit, the battery and fitting kit, G50 gearchange linkage, the body grill set and a few other odds and ends.

My daughter and her boyfriend also reminded me that they still owe me last years birthday and Xmas presents and we have pencilled in a pair of seats. If they are still up for it I will add them to my next order.