Danny's K Series Conversion Project

[Danny]

Well yesterday all I had to do was put the panels back on and generally potter about and get the buggy ready for its mot.

Well I decided to run up the buggy and realised there was an airlock and even with the vacuum bleeder I was struggling and that damp little bleed valve kept disappearing.

So I got frustrated and went to the pub...

The following day I jacked the rear up and systematically bead the system and after 2 hours it was running as it should....

I then did a test run and as ever my brakes are vague but with new disc and pads I an not surprised....

I need to check the wheel alignment and what not but have the mot tomorrow so won't do that till I have a ticket

Also need to find the settings I used to do the camber and stuff

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[Danny]

Quite a productive day in the garage....

Mot done and passed

Clutch bled

Wheel alignment checked and tweeked

Panels refitted

I think I am ready


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[Danny]

At the mot station

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[Danny]

Well after wales I now have a job list to do ready for next year (i need to get these done before october really

I think I am going to change my clutch as the pedal is high and I think another wales trip would kill it totally so going to fit a new one of those and an uprated one to take my driving ***cough** style

I have a missfire or something that is causing the buggy to feel under powered and hesitate so going to change the dizzy and gubbins and hope that solves that, failing that it will be fuel or air

Myself and Phaeton also realised that the fronts of our buggies are low and I mean really low... in fact we are running on our bump stops so I need to look at that and get something sorted for that...

The rear quarter panels need a re think and a slight re design... I am still not happy with how it looks...

I also want to fir a spare wheel carrier and I think that is what the back of my buggy needs so I will be coming up with a design for that

Also my exhaust does not sit quite right and the cat rattles on the subframe so that needs a look

I need some seats to hold me in place as there is sooo much grip that I am literally hanging on in the corners and that is tiring as hell

Other than that I cant think of anything else that needs doing and I am quite happy with how it goes and handles...

 

[Danny]

This is the clutch I am going for http://www.ebay.co.uk/itm/ROVER-MGF-1-8 ... Ciid%253A1

and also fitting a new slave cylinder and arm

 

[Danny]

Right so I have decided to go for a standard clutch and bought a few uprated gear selector parts as well

My next mammoth task is to look at the front suspension and look for a coilover system spax do one for a mini for the rear

https://www.minisport.com/spag896-as164 ... -each.html £131 each so thats £262 for the pair and I still need the springs as well :-\

and the springs I think are right are these (cant find spax ones) https://www.minisport.com/spag896-as164 ... -each.html

or I can get a pair from here with the springs for £200 all in http://www.minispares-online.co.uk/rear ... ssic-mini/

But the ones above have been offset... dont think that is any good :-\

 

[owelly]

I'm altering the brackets on the upper suspension arm to take standard coilovers rather than the Mini type. I have plenty of coilovers to try with a big pile of different springs.

And it's probably too late to recommend CG Motorport in Leeds for clutch parts?!

 

[Danny]

I'm altering the brackets on the upper suspension arm to take standard coilovers rather than the Mini type. I have plenty of coilovers to try with a big pile of different springs.

And it's probably too late to recommend CG Motorport in Leeds for clutch parts?!

Yeah I ahve gone with a standard LUK clutch... the buggy is light and does very few miles now so I think that will be ok... I hope!!

The 100lb springs use to be ok so I am hoping that will be the same for the coil overs

 

[Danny]

Well I got 3 months notice to get out of my garage.... yup... the landlady was not too impressed that I screwed her over on some land/property/freehold purchase and decided to evict me On a side note though I now can remove her electric from my old garage as teh cable goes across my land Evil Laugh

The deal is nearly done, I have keys and what not and should get all the legal stuff sorted in the next month or so as it is complicated purchase and there are lots of complicated land registry stuff and access rights to people... bla bla bla

However I do have 3 months to get my buggy ready for stoneleigh so next week I start to get the buggy ready and the job is to do the clutch as I smoked it in wales :-(

but to do the clutch I need to drop the engine from the chassis and then need to look at rejoining connectors and stuff So anybody got any suggestions on electrical connectors that will take some big cables and little ones as well

 

[Danny]

I bit the bullet and made a start on the clutch.... quite a big job now I have started but whatever...

Getting the engine out was not too hard I only damaged one ally tube... I will see if I can repair it or I will just buy a new bit

I got to a point I needed a hand so tomorrow I should have the clutch out and fitted... then I will make some repairs to the chassis paintwork before she goes back together...

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[Danny]

I bit the bullet and made a start on the clutch.... quite a big job now I have started but whatever...

Getting the engine out was not too hard I only damaged one ally tube... I will see if I can repair it or I will just buy a new bit

I got to a point I needed a hand so tomorrow I should have the clutch out and fitted... then I will make some repairs to the chassis paintwork before she goes back together...

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I have been busy putting the buggy back together and making a few adjustments and tweaks along the way

My exhaust has only been held up by the cat resting on the lower suspension arms so I got the welder out and made a new bracket which works well but needs a slight tweak

Fitting the new Mike satire clutch arm was a Ballache as it was machined wrong and I had to get the grinder out to get it out then they sent me a new one ;-)

The clutch was almost down to the metal so glad I got it out but the main cause was the clutch arm was rotten and sticking which made the release a lot slower but the new one has a grease nipple on it which is much better

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[Danny]

I bit the bullet and made a start on the clutch.... quite a big job now I have started but whatever...

Getting the engine out was not too hard I only damaged one ally tube... I will see if I can repair it or I will just buy a new bit

I got to a point I needed a hand so tomorrow I should have the clutch out and fitted... then I will make some repairs to the chassis paintwork before she goes back together...

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Also been quite distracted with a land purchase that has been sapping time... very complicated but the good thing is that they have allowed me to start clearing it as it was over grown

Watch this space to see what I do with it

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[Danny]

Well. ..

The buggy runs

Not tried getting it in any gears but it runs I have an air lock somewhere in it as it won't cool down but I will sort that when I get an hour or so more time

The spare wheel carrier is made and painted as well so just need to get a tyre for it and that is another job off my list.

I also rerouted some wiring and tidied up a few bits along the way that was bugging me

The next job is to sort the rear side panels out... going to chop the tips off and see how that looks

But the job that is going to be the costly or the biggest headache is the front suspension....

My top arms sit about 10mm off the bump stops... any pothole that is deeper than a match box sends my buggy dancing...

I have toyed with going the full adjustable coil over option bit that is quite a big cost...

Phaeton has suggested using spacers to move the spring up the shocker... so I might knock up some of them and see how that works out...

Or do I just go coil over route....

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[Danny]

Decided to start the buggy suspension. ..

Ordered the adjustable coil overs and made a template for the bracket on the laser.

Spent about an hour cutting some 50mm angle iron to shape

I also dot punched for the holes as well

I am going to tig the angle iron together then bolt it as a complete unit to the buggy... this way I can modify it as I see fit without doing too much to the main chassis of the buggy....

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[Danny]

Got quite far today....

Beginning to wonder if I have welded it up a bit too narrow..

Will find out tomorrow

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[Danny]

Bit more progress yesterday...

Temporary bolted with small bolts for now

Had to modify the bracket a bit further to get clearance but so far soo good.

It takes ages grinding the old suspension brackets away....

Got some paint on the bare meta before I left last night.

Also need some spring compressors as well as I think that will make it easier to do

Anybody got any suggestions on how to set these up when they are fitted?

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[Danny]

Did a bit yesterday all seems to be going well....

The suspension seems to sit right and now the top arms are off the bump stops

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[Danny]

I have been tinkering further today....

Spent far too much time trying to find somewhere to mount the horn as I had chopped the original place off....

Then just started bolting it all back together...

All went back fine and then thought I would cut a hole in the chequerplatebso I can tweek the settings of the shocks without stripping all that off.

I am not totally sure how to set things up but I know I need more clearness between the top arm and the bump stop so need to tighten the springs up a bit more..

On Friday I am going to put the rest back together and drive the buggy round the yard to see if the clutch repair worked and generally make sure all is good



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[Danny]

Got to the garage today and it was bloody cold so I turned the heater on and went out to buy an axe....

Come back and started to put things back together and decided to weld the wires back on to the low temp alarm switch that failed in Wales earlier this year.

I decided to crank the springs up a few more notches and I am not sure if it is right or not... I quite like scraping on speed bumps.... hmmmm

Started the buggy up and warmed her up.... the fans kicked in and welll. .. that's all they did.... they made no impression on the cooling system.... can't seem to get this thing to circulate it's water.... there is an air lock somewhere....

But I thought seeing as the seats were in I could see if my clutch repair worked.... at last I have a clutch peddle

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[Danny]

Got the the garage today... gets lonely in the garage on your own all day... quite nice sometimes... but today I was dying for some company. .. lol

Anyway....

I ran the buggy up and I think I got the airlock out now as it circulates as it should

I then also decided to tackle the rear side quarter panels that I painted black earlier this year...

I cut the top off one and bent it slightly and got the gap ok between the top panel....

Not sure if it's going to stay but does look better..

When I got to the other side I realised theat that the top panel is 25mm too narrow on this side... always puzzled me and it clicked today...

Not sure if I am going to the garage tomorrow or out on the bike but I think I need some human interaction... lol

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