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HaHa what cross member.....

The radiator brackets I'd cleaned up on Sunday were ready to fit back to the freshly recored rad so set about that tonight so it's ready for fitting tomorrow.
The brackets at the front here get a hard life with all the spray with sitting behind the grille, all the rust cleaned off and sprayed with hammerite so hopefully they'll last a few years to come, the brackets are for the oil cooler to bolt to.


The engine side of the rad finally got reunited with the fan housing that I had blasted and powder coated with the other bits a year or two ago. Fan got a little clean up, fresh coat of heat proof paint for the heat shield.



The bottom brackets are also ready for fitting along with the intercooler shroud that again needed a good clean and paint. Inlet connector for the turbo got a lick of paint for good measure.

Propshaft got its' new rubber boot for the front where it attaches, the rear end is solid mounted to the rear diff.



Should be able to get a goof few bits back on it tomorrow afternoon....

Will you cut the bolts down or are they that length for a reason?

Sud 145 wrote:Will you cut the bolts down or are they that length for a reason?

They are just there to hold the joint to the new metal cap on the drive boot mate, the ones holding it to the transfer box are like the Sud gearbox ones, pretty much identical in fact!

Despite all the freshly revived parts ready to fit I had to ignore them and set about fitting up all the front suspension to make sure I have all the bits sorted.

Thought I'd fallen at the first hurdle with the D bushes for the front anti-roll bar, looked nothing like what they needed to be, spent an age kicking myself as the parts have been waiting to be fitted for months...should have checked before now
A check on Powerflex website though revealed that I had actually got the correct OE bushes, same shape etc as the ones to hand.

Just meant that they were super tricky to get fitted and clamped up, greasing everything up for longevity meant it all was too slippy to get in place!

Eventually though it all went together.
Powder coated parts which should hopefully last a good few years, rest cleaned and painted.
New ball joints and track rod ends, all should be good for a few years.

Slow progress continued today, had a couple of visitors too so that delayed things.
Spent ages trying to figure out what pipes went where, most were obvious but it's like Medusas' hairdo down there!
Eventually I got everything lined up save fopr one pipe, I'll have to consult the pix for that one..

So with that all about sorted I went to fit the radiator.....only to notice i'd fitted the fan shroud to the wrong side of the rad!

Oil cooler on along with the rad, now the right wy around, intercooler shoud waiting to be bolted to the 'cooler...once I've sorted the top mount for it, now I've found the mount!

Getting tight on space now, will only get worse once the heater box goes in with the bulkhead panel...

Slow progress....

Managed to get the integrale over the pit yesterday, I needed to fit the fuel tank before I can start the car of course but that means the propshaft needs to go on as it runs through the tank, sort of.
Was talking to Ade about this last Sunday at Donnington, it's not as bad as it sounds!
The rear section of prop that goes through the tank doesn't rotate, it's more like a torque tube.
So no danger of it rubbing through the plastic fuel tank!
As it is solidly mounted to the diff flange and bolted to the floor this also handily creates a kind of tramp bar to prevent the rear diff twisting under power.

It's been ages coming and seemingly endless more little jobs to do but it is close to starting up now....

That last pic of the fuel tank just looks so wrong.

Looking good Kev
Every bit fitted makes the finish that but closer.

Rsfruitbat

Sud 145 wrote:That last pic of the fuel tank just looks so wrong.

Yep I am with you on that. The meeting when someone suggested it must have been interesting, or perhaps they just simply agreed being good engineers.

Well, the last couple of visits have been frustrating to say the least.

I'd intended to stretch the full wiring loom out to check stuff out whilst it was out of the car but never got around to it, guess it being sat in a box for a year or two wasn't long enough!

Upshot was that there's a load of wires, added to non original wires, that I really don't know where they should go to..



Once the car was plumbed in for all fluids a start up attempt was made but although the car cranked over nicely there was no spark and no activity from the fuel pump....great..

Got the fuel pump going this last Wednesday afternoon having found the missing wiring but no matter what I tried the spark was missing. Decided that a large relay that was in amongst the loom near the coil must be the issue, the fact that I couldn't find the relay to be more accurate! A good search was called. Nothing found...

So last night I set about scanning the workshop manual to see where all the wires related to ignition went, from the coil and ignition amplifier block to the distributor and inside the car to the ECU. Made myself a little wiring diagram on an A4 sheet so I could easily trace each wire.

On testing all the wires for continuity all seemed well until I tried the wires running to the ECU, one wire from the ignition amplifier to the ECU had to connection at all, must be a break somewhere in the loom. Rather than peel all the loom apart I ran a makeshift wire inside the car and joined it all up.
Still no spark! Damn, this is getting annoying, what the hell is going on.
Then I noticed, it might help if I plugged the ECU back in!
Try again, at long last a spark!

Next to check fuel was getting to the injectors, cracked off the pipe at the fuel rail and no fuel, damn again!

Stupidly I'd fitted the fuel pipes at the pump the wrong way around, a quick swap and run the pump and hey presto, fuel...…...loads of it squirting out of the new filter at the connection
Swapped out the copper sealing washers and that stopped it.
Then noticed the fuel pump was covered in fuel inside the car, a split in the O ring! Can I please catch a break Luckily I'd got a spare pump with an old connector still on it so swapped out the O ring and all well again.

Finally connected everything back up again engine wise and cranked it ion hope....it fired up straight away and settled to a lovely idle!!

At last, a running engine.


Had some funny readings on the gauges though, fuel tank insisting it was nearly full despite me putting just 3 gallons in, water temp climbing fast, no voltage reading....
Water thing was a worry but everything looked well engine wise so knew it wasn't drastic.


Turns out the whole dash gauges assembly has only one earth wire for all the gauges and warning lights, which of course wasn't earthing so all the gauges were getting mixed signals with the power to it trying to get out any way it could.
A new earth wire made up and all gauges working properly.


A big step, but a lengthy one to take, but a big step at last.


I can now start to think about getting the rest of the wiring sorted then get the wings, bonnet and lights on


Did get it to move forwards and back under its' own power again, although I've still to finalise all the brake pipes so no rides around the yard just yet, but it's getting closer

There you go Kev - I said it would be MOT'd on the 18th March ages ago.

Hey, big pat on the back mate.
Massive progress there. Even if it was a challenge, you got it sorted.
Top work. I really envy your drive to get things done.

Yes, still a way to go before the MoT gets done mate, although that's already sorted.
The guy I bought the pair of HF turbos' off last year came by a week or two back for a couple of bits I had that were no use to me, did a deal for him to MoT the car for free as he works at the garage very close to the unit, he did Rob's Imp last year. Hoping it will be this year...

Drive to finish things gets seriously tested mate, times when I've wanted to walk away have been and tested my resolve but I need to get this one over the finish line.

I hope your keeping this one Kev !

Great work.

Not be long now.....

Sounds a peach Kev.
It is so good seeing that engine bay all full again of stuff.
Power on my friend.

Yes, a keeper this one guys, know I always say that but pretty much top of my wish list for years, well the obtainable list anyway, still would do anything for an 037

Things are starting to fill up engine bay wise that's true, still more stuff needs to go in though!

Can actually start to think about fitting the wings, lights and bumpers etc another loft trip planned then

Great news it's running . Well done kev

Well, that is the end of a busy week.
With a ton of little jobs to do, and some big jobs, I took the opportunity to have a week off work to get the car moved on a bit if I'm ever to get it done in time for it to actually be used this Summer!

Still a lot of wires to sort out under the bonnet then fit the false bulkhead in there somewhere between the heater box and the manifold, tight but it had to go in.
There are some bits and pieces I need to relocate so they'll need wires extending, memory isn't sharp enough to know if they used to sit in better places but space is ridiculously tight.

Needed to run the car up to temperature to check the rad fan etc so the rear exhaust section needed fitting ideally, which wasn't quite straightforward as the middle section didn't fit that well. Not helped by the hanger brackets that need the captive studs on the boot floor to actually be there, something I'd overlooked to replace when they snapped off a few years ago, all that welding and such tiny details missed cause no end of grief! Another hour or two spent rectifying what would have taken minutes

Made sure the exhaust was in the right place by fitting the rear bumper, which again meant finding all the parts to mount it!

Pleased to say that the car ran up to temp just fine, fan in and out OK, but the water header tank was leaking from the level sensor! Old one had been gunked up with sealant which I hoped with a fresh clean seal would have been alright but it wasn't, at least new ones are available but another £70 or so spent..

Now it will run OK and with no leaks then the front end could go on - bonnet, front wings, headlight units, grille etc all made the car look much more complete. A bead of sealant went along the wing rail to stop water running under the wing itself, which I've painted today so the underbonnet is nearly there, save for the few little alterations to wiring. I do still need to fit the front wiper linkage which looks a real tight fit...

All the wiring inside the car has nbow been checked and placed, so stuff like the central locking and electric windows work OK. Still got the front glass and regulators to fit, a job for next time.

All the lights are in and working save for the side repeaters, only had one useable so again more money spent on new ones, £50 or so doesn't buy a lot on these integrales!

All the brakes are now built up and bled through, new handbrake cable fitted which has a hard life having to dodge the propshaft and exhaust.

Actually plopped the carpet in tonight and placed the seats in the car, almost ready for them to be bolted down but some trim parts need to go in first.

I'm sure there's loads of other jobs I've done to it this week but most of the time has been spent finding parts nd getting them ready for fitting!
Pleased with the weeks work, car appears to have moved on quite a bit but still a few jobs to go, not least to make a headlining for the sunroof and lining itself. Looking forward to that job

Starting to look the part now..

Wheels that Shrew refurbished for me over a year ago finally on, at first without tyres on I liked the colour, now I wonder if it's a little too dark without the diamond cut lip. I'll see how I feel but may end up spraying the lip and little spokes silver.

Great work! It's going to be a lovely car!

Looking good kev

Fantastic stuff mate, that tunnel is nearly through.
Looking great, and without seeing it in the flesh, I think the wheel colour is fine.

Good effort. You have come a long way with that project. I could not have have done half of it.

And as to the cost to get a firm to do it, you have saved a small fortune.

Cheers for the praise guys, very nice to know I'm not wasting my time, which I know I'm not really as it's a labour of love but nice to know it's appreciated

Funny work schedule this week so my day off was today rather than Wednesday, but I also get the pleasure of a full day at work tomorrow so swings and roundabouts for getting work done..

Planned on getting all 4 doors built up today.
I'd put the rear windows in some time back but not the fronts as they are electric. Tested them before they went in, greased and oiled the mechanism and all well until I fitted the passenger front one and it made an awful grinding noise half way down, guess the gearing inside the regulator is damaged somewhere so I'll have to source another one, of course I have a spare drivers side one...

With the doors all built up I took the car outside to spray the tetroseal treatment into the doors. I use a schutz gun to apply it which gives great, easy coverage but you do get a bit of fog off it so best done outside.

Next the plastic door liner which is there to protect the door card from any rain that gets in past the outer weather seal.
It's really important when fitting these plastic sheets that the bottom edge of anywhere that has an open section of door that you tuck the bottom piece of plastic inside the door, that way if any water hits the plastic whilst inside the door it runs down the plastic back into the door and out the bottom drains, rather than going down between the door and plastic which can get on the door card.


Rear door all built up, I really like the 80's design of the door cards, which match the seats too.

Tidied up a few other jobs whilst in the mood, the central check system now tells me when each door is open, once I'd found the wiring for it! Just got an issue with the brake fluid warning light which needs sorting then that little unit is done.
Still got a few jobs to do on the dash binnacle itself, fit the speedo cable etc.
One job I'd not been looking forward to was to reconnect the heater controls which are actually well over engineered with little control rods and plastic universal joints! Meant laying in the footwell looking up under the dash but at least it's another job done.


Might go up Sunday morning for a few hours to keep things ticking along as I won't get a day off next week, time is marching on so got to keep at it..


Couldn't resist parking the 145 besides it when outside for comparison, the Delta was supposed to be a big car!!

That looks very nice.......apart from the front fogs

Veesix75 wrote:That looks very nice.......apart from the front fogs

decision still pending on them mate

Love the fogs and the two cars