Ian's S4s refurb

[Sparky]

Any ladders involved?

[Chillidoggy]

Only in your stockings last time we met.

[Chillidoggy]

And what a complete pain of a job it is getting the tanks out, and that's with the engine out. It would have been easier to cut a tank-shaped hole in the side of the car. Nevertheless, they are out, and not before time too. The driver's side one is perfect, having not long been replaced, but as for the passenger side one - oh, dear! A disaster waiting to happen, the bottom of the tank is completely rusted away.

[Sparky]

Really, really excited.

[Chillidoggy]

Calm down. Getting excited is not good for a man in your condition.

[Sparky]

Surely it can't get any smaller...

[Chillidoggy]

Tie a knot round it?

[red vtec]

Can I ask what was the rating on the lift? As I have to remove my engine and box.

Thanks

[Chillidoggy]

It's 2.7 tonnes.

[Chillidoggy]

Anyone know where I can get some of the hose clips used around the engine bay in various sizes?

 

I'm on about the white nylon ones that are rivetted to the GRP, and wrap around the pipes, but are open-ended so you can easily release the pipe.

[Vanya]

The usual place stocks them (SJS), but I haven't had luck finding anywhere selling large quantities of them separately...

[eeyoreish]

Ian, just noticed there's a brand new charge cooler name plate been listed on eBay today.

99p start price

[davevr6car]

Its not the same plate as installed on the S4S

[Chillidoggy]

No worries, the engine compartment currently looks like the result of a drone strike, so a new chargecooler plate is not too high on the priorities list at the moment!

[molemot]

The kitcar fraternity is a good source of silly little plastic bits....you could try these guys....

 

http://www.carbuildersolutions.com/uk/brake-pipe-clips

[Chillidoggy]

I've used CBS on many occasions, but they don't stock those clips, so I have sourced them from SJ.

 

I will try to post some more photos at the weekend, but generally the job has slowed due to having to go back to work, and also that I laothe cold weather, thus tend to hibernate in the winter. Apart from the turbo shenanigans, I'm in cleaning mode at the moment, attempting to remove 20 year's worth of accumulated shite off of everything. There are some parts that require refurbing, a bit of GRP work, rivnuts, insulation, and heat shielding. Also, I hope soon to put a few things up for sale, the driver's side fuel tank (passenger side one needs a new bottom), the air-con pump, possibly a flywheel and release bearing, but to be confirmed later.

[Chillidoggy]

It's been a while since I posted any update, but I've been busy mainly with cleaning stuff up so I can see what goes where, and ordering parts.

 

But one of the things I found will be familiar to quite a few Esprit owners, from what I hear, and that is a broken engine mount bolt. This is what it initially looked like, after some previous individual had bodges it up good and proper. It seemed like there was an obstruction in the original hole, and he's tried to drill either side of it, probably with the engine still in situ. As it happened, it wa a broken tap ion the hole, which proved to be a real problem to remove. I eventually managed to remove it by using some tungsten-carbide die-grinding bits, and drills. I drilled down the sides, and finally managed to hook out the offending article.

This is the result -

Next up was to fill the hole with Devcon aluminium, and using an old, cut off engine mounit as a template, I first drilled the hole to 8.5mm in the old mount, then bolted it up to the block, and drilled the block itself with the same drill bit.

It looked like this when finished -

Then I tapped through the old mount (a good guide), into the block with an M10 tap, and did the same for the other holes. I then wound in some M10 studs, using Loctite -

I relieved the areas on the new mount to accommodate the larger M10 nuts, and drilled clearance holes for the larger studs -

And mocked it up with the new support strap I fabricated earlier -

I have some new self-locking nuts on order to complete the job, and will do the other side of the engine in due course.

[Chillidoggy]

An update -

The engine bay was pretty much full of 20 year's worth of accumulated thick greasy gunge, so I shoved the car outside, and got in there with a scraper, Gunk, and a hose.

Before

After

I know it doesn't look much different, but I can see all the individual pipework now!

The original cams heatshield was in a pretty rough state, so after some researching, and a bit of blagging, I managed to get myself some Firefly millboard and covered it in reflective insulation. I'm not sure how long this is going to last, because to be honest, the millboard is a bit like hardboard, but time will tell. It looks better than the old one, if nothing else.

I carried on with putting bits back on the engine, recon waterpump, alternator, and a brand new air-con pump. It looks a lot cleaner than it did when I pulled it out from the car.

[Sparky]

Sex on a stick.  Back in at the weekend?

[Chillidoggy]

Yes, I will definitely be in at the weekend, but the engine definitely won't. As for sex on a stick, some may consider it a tempting offer, but I'm afraid I'll have to pass on this occasion, if that's OK with you.

[Chillidoggy]

After some advice from Leon at Alunox, a good deal of checking, and some harsh language, I finally managed to fit the new exhaust manifold. It does look nice, but I wouldn't want to do one with the engine in!

And the new fuel tanks from Axminster Specialist Panels have arrived. The quality of the workmanship is extraordinary, and I would be happy to put them on display in my lounge. It's such a shame no-one will get to see them.

[Bibs]

Nice touch with the optional legs on the tanks

[ramjet]

You have the upgraded gearshift I noticed. I thought from pictures in my manual that I did, but I don't. What I do have though is the shaft extending out the right side of the box. I could remove my current shift mechanism and fit the newer one. I noticed that your car doesn't have the extension on the left side.

Is it a big improvement over the shift that wraps around the back of the box?

[Loose Cannon]

Wow what a shame those tanks are hidden!

[ramjet]

I meant to say they are really nice as well!