S1 Rebuild(s)

[Dave Adams]

some pics of the rebuild process,

the top trailing arm bracket is broke......

the diff is sloping back a little (looking up) so that will need sorting.......

As you can see there isn't a lot of bracing in an S1 chassis, that will be sorted.

[Brian (up north) Morris]

it will dave be confident   :-)

[Dave Adams]

an unexpected day working on the car today......it has two gallons of fuel in the tank (well 10L so just over 2 gals....) and no leaks! but i forgot i needed a fuel cap. so down the local motor factors and i got one for £14 the fuel lines are now fully fitted and the fuse box has a set of fuses. I also moved the gear box mount and raised it by about 25mm, it gives me a lot more ground clearance and it also helps the ignition coils clear the bulk head.

I also finalised the heater hose connections....by moving both of them and undoing all my previous work....bummer.

tomorrow if i get time it will get some electricity and a hot wire and i will find out if it runs......

[Brian (up north) Morris]

good luck dave

[Jim (across the pond) Adamek]

Good luck tomorrow Dave

[Dave Adams]

Problems.....
tried to start the car yesterday the pats immobiliser seems to be working ok but the car cranked for a second or so then the starter just clicked as if a flat battery......however the starter when hot wired cranks the engine OK. ...the car will also fire up but it sounds like it's on 2 or 3 cyls..... (new spark plugs ordered) but with in a second or so of stopping cranking it goes off. Exactly like when a balast resistor is faulty.
It seems to have fuel pressure but nothing in the return line. Before I get into wiring what do I need to check?

[Brian (up north) Morris]

id check for a spark at every plug. coil. fuel filters.fuel pump. their should be fuel returning dave. id check you have enough fuel in the tank also. sometimes its the odvious staring you in the face. goodluck. :-)

[Dave Adams]

Sorted....turns out the idle valve must take its air from the inlet manifold in front of the throttle body.....once I ducted it with a small pipe it started. ...the ecu needs to see a signal from the MAF sensor to keep the injectors firing...

[Steve Kerswell]

Good result Dave, must be chuffed.

[Dave Adams]

Yup.....really happy..

[Dave Adams]

I have also been building myself a 4-1 exhaust manifold.....it will have 41mm primaries and a 50mm tail. This combination should give an improved torque response , rather than going for maximum HP....

to modify my inlet manifold i cut a small hole in the pipe and got a short piece of copper water pipe and soldered a compression olive onto it then cut little slots into the end,by bending them over into a star like pattern it forms a base to the pipe...i then pushed the pipe through the hole......the olive and the star jammed into the hole and to make sure it stays and is air tight i glued it with epoxy.

[Dave Adams]

today i finished my exhaust.....and tested it....its very quiet i may need to fit a stereo!

the collector on the header pipes was a pain to get fitted......but i think i did ok.

all i need to do now is make a securing bracket to take the weight of the silencer.....some thing made out of soft rubber to allow for some engine movement as there really isnt much room for a flexi pipe.

[Dave Adams]

yes that is a spark plug sticking out of the exhaust......the thread from a pinto spark plug is the same size as the Lambda sensor and i fitted it to the boss so it wouldn’t distort when i welded it in.....