Chassis

Heater Fan Fix

For a number of years now the heater has caused problems with the fans moving out on the shaft and scraping against the side of the outer casing. The tick tick scraping noise can be heard even with the exhaust on the louder setting.

It’s finally time to fix it properly.

Step 1, spend a few hours swearing at hard to get to bolts to get the outer casing off and the wiring disconnected.

Here’s the culprit – right next to where it’s supposed to be stuck to.

It moves out here and scrapes on the case.

Decided to use a few different methods, first drill a 2.4mm hole down the end of the shaft.

Tap the hole using set of M3 taps.

Test fit (this is a super long bolt, use a much shorter one)

Added a number of washers

This will stop the fan from moving off the end of the shaft.

Then to add a bit more security roughed up the motor shaft and the inside of the fan, then used some epoxy to keep the fan on, and the washer on and the bolt in place.

Reassembled the whole lot:

Put a fresh connector on for the earth (had to cut that to get fan off the car, with the scuttle panel in place it’s hard to get to some of the wiring).

Re-arranged the wires, new connector for the earth and zip tied everything back up.

Heater snapped back together, bolts put in and the 6 metal clips back on. Used tape to seal the front panel and connected up the window de-misters.

Re-installed the headunit

And now it’s back to looking like nothing happened.

On the plus side I can use the heater again without it being super irritating!

Maintenance

2019 MOT – handbrake failure and fix

So the MOT tester is a beast of a man and ripped both handbrake cables clean off the mounts! Better it failed here than in an emergancy though.

The orginal handbrake adjusters are bolts with the head of a bolt chopped, the end drilled with the lathe and a recess to capture the shorted handbrake cable with a spot of weld.

As the handbrake cables were now shorter than before the bolts were too short. These were extended by chopping the machines part off the old bolt and welded on to a new bolt making it longer. The recess needed drilling out again to remove old handbrake cable.

If this fails again it will need new handbrake cables.

The torn ends zipped tie down to make them easier to clean up for welding

Cables welded back on

Finally mounted back into the handbrake handle and adjusted. Hand brake retested with better results than the rear brakes!

The car was also failed on emission first time round as the machine was set wrong. HC limit for an 88 engine is 1200, it comes in around 650 – which as been the same for a numbr of years now. They incorrectly wanted to see less than 18 – keep an eye for that one, page 12 of this document is useful if you need paperwork: https://assets.publishing.service.gov.uk/government/uploads/system/uploads/attachment_data/file/676700/in-service-exhaust-emission-standards-for-road-vehicles-19th-edition.pdf

Maintenance

Easy access

Working on the Sportster is great – such easy access to everything!

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Maintenance

MOT time

It was MOT time this week. I changed the driver side ball joints as they had a warning last year, the lower one had noticeable slop.

I didn’t check the handbrake, or the driver side ball joints this year – guess what it failed on… hindsight a wonderful thing.

The rubber on the lower driver side ball joint was perished so failed on that. I replace the whole ball joint as I had spare ones.

The passenger side handbrake had no brake effect, on checking the cable seems to have stretched a bit and there was not enough thread to tighten it up properly, so put a space it and did them up.

Passed just fine with those two little fixes – could have avoided them if I’d spent a bit more time check the car over before the test.

Maintenance

MOT pass

Yesterday the Sportster passed it’s MOT. Testers were ready and waiting as they heard it coming!

Advisory on near side lower balls joint so I’ll be replacing that. He said there’s only a tiny amount of play but they’re relatively cheep parts which are easy to whip out with the airgun!

Maintenance

MOT Pass

MOT Pass – bar a slightly dodgy light on the rear number plate everything is fine

Might get some LED’s for the number plate lights and solder them in. The plastic ones I have are of very poor quality

Maintenance

MOT Time is just around the corner

Got my MOT reminder this week, time to stick the Sportster up on the ramps and see how its doing this year

Have noticed a few rust spots that need sorting on the chassis underneath the doors – this is a bit of a water trap. Rest of the chassis usually needs a tiny bit of surface rust cleaning up and painting.

Only other problems in times past has been the handbrake cables – the attachment to the level broken on one side last year, and the previous side the year before. Both are now welded so hopefully that will be fine this year

Only other issue that needs looking at is a sticky idle control valve, that’ll hopefully just need a blast with carb cleaners

Maintenance

Engine issues

My M20B28 started making loud high pitch noise. The pitch changed with RPM and seem to reduce under load. I thought it might be a loose belt or a shot bearing. Noise was located near the back of the engine.

After a an hour or so of poking around today it turned out the intake manifold gasket was leaking on cylinder 6.

I’m pretty sure it must have been a materials failure as I’ve not put that many miles on since the rebuild. Need to order new gaskets, going to do all of them to be sure. Some non-setting gasket sealer has shut it up as a temporary solution 🙂

Maintenance

1st Aniversary of SVA pass

I can’t believe its been a year and 2300 miles already!

It’s been little turbulent in that time:

  • Shortly after SVA pass we lost a wing stay (oops)
  • During December a complete disaster with the lower wishbone.
  • While off the road we completely rebuild the engine enlarging the capacity to 2.8ltrs.
  • In March we finally got the new and improved parts to put the car back on the road, decided to get light weight Carbon fibre wings to avoid issues with the (albeit stronger wing stays).
  • From then on it was a pretty uneventful summer with regards to mechanical issues.
  • We visited a number of kit car and other cars shows which was great to finally have the car there rather than just looking at everyone else’s!
  • Recently it pass its first MOT with one issue to sort out (handbrake cable loose), no problems with emissions on the rebuilt engine which was great.

The car is fun to drive now that it’s had most of its teething issues sorted out (still one or two such as the clutch and pedal box assembly need strengthening)

To come in 2009 a paint job (I know I keep saying it but I mean it this time)

Maintenance

MOT

It’s been a year since the MOT it passed today! No problems at all with emissions on the rebuilt engine.

Only one small problem, the hand brake cable had slipped out of one of these things:

The solution was to mill a hole in one side through to the centre bore that the cable sits in. We then welded the handbrake cable into the bolt – its not going anywhere now!  Pictures to follow at some point.