Melvin the Mev Mevster

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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Sun Nov 08, 2020 6:35 pm

Just a bit of a progress report, fuel pipes finished in the engine bay, ordered & received a new braided clutch pipe, seemed easier than trying to modify what was there, only thing is the banjo bolt is a bit long, had to use 4 washers 1 under the head to keep the fluid in the right place but 3 under the panjo otherwise the bolt bottoms out, I could grind 2mm off the bolt but this way works, then I think I'll stick with it.

Then tried to fit the steering column but found the brackets were too far from the bulkhead (one has to be modified anyway), but because of the way I am doing it I'm using a MK1 steering rack with a MK2 column, but as usual it's not that easy. You can't swap over the last part of the column as they are different diameters, you can't swap over the racks because they are completely different mountings & the diameter of the UJ connector is different, not only that they are a different length

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So I managed to get some of the distance back by extending the slot where the bolt goes through

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So I think I'm close enough, just waiting for the son to bring me some steel to extend the brackets, then the rest of the time was taken up by making a tray to go under the fuel tank so that if it leaks it can't drop onto the exhaust, some Mev's have passed without having this, some have failed for not having it, so thought best to make one now.

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Just needs spraying up now


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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Tue Nov 10, 2020 7:52 pm

Last night I was making brackets to fit a Mazda MX5 fan & cowling to fit on a Nissan Almera radiator, all was good till I noticed that it would foul with the radiator mounting.

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Fouling the next bracket to be made

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Also a bit close to the coolant pipe

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Modified & sprayed again.

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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Wed Nov 11, 2020 6:52 pm

Fitted the bracket back to then radiator to the frame along with the main bracket, need to make up 2 further brackets for the top of the radiator but waiting for some rubber mounts to arrive before I do.

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The fitted the petrol drip tray to the subframe & then placed the tank in place, just waiting for the fuel filter to arrive before running the pipes

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I've got 3 days off next week I was hoping to get the wiring harness in & consider getting it started, but my fathers boiler has packed in so it looks like I'm fitting a new central heating system instead.

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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Wed Nov 18, 2020 7:01 pm

Took 3 days off to spend on the car but had to fit a new central heating system in my dad's bungalow, we're waiting for the delivery of the last 3 radiators so did a bit on the car.

Made up some more brackets along with some Land Rover rubbers to make the top mounts.

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It still moves a little at the bottom, I have the space to fit a couple of stays between the anti roll bar bracket & the bottom bracket, but it's close to the bonnet hinge so want to wait until I get to that point before I make them up.

Then did the hoses, there was a full set of hoses from the MX5 with the kit, so I managed to repurpose them

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Finally went to the back & mounted the fuel filter bracket along with a new filter, along with the pipes, waiting for hose clips now, hoping it's all in the right place & doesn't catch the bodywork when I come to fit it.

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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Wed Nov 18, 2020 8:24 pm

Need some foam/rubber padding to put under the tank about 30mm wide, 5mm does anyone know a source?

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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Sun Nov 22, 2020 6:28 pm

Managed to get a bit done today started with finishing the water pipes with clips, apart from the overflow tank that is done, but want to see how much space is left before committing to using the MX5 one, may need a smaller one

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Next had a look at the air intake made up a pipe to take the crank breather, for now the air filter is going behind the radiator, need to make up a bracket to mount the MAF, there is also what looks like a air temp sensor, need to find if that can be mounted after the MAF

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Clamps had come for the fuel lines so all that was finished off including the rollover vent, then after fitting the viton sheet under the brackets, fitted a couple of Rivnuts for the bodywork when I get that far.

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Then fitted new handbrake cables, just need a couple of the spring clamps to hold the cables in place

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Finally laid out the wiring, there's a hell of a lot more than I remembered & I'm missing set of 3 relays, I saw them last week, just a tip, don't get old!

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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Tue Nov 24, 2020 8:59 pm

Don't you just love it with no garage

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A wise man once told Danny whatever you do get it all working before you start to remove wires, I decided to follow my own advice, I've removed some of the insulation so I can get the wires where I want them.

Connected the battery, I've got ignition & it will spin over, some carb cleaner down the throttle body & it fired, I can hear the fuel pump running so we're getting there. just need to prove out all the lights, I wish now I had not thrown all the old ones away, I could have just plugged them in to test.

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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Fri Nov 27, 2020 8:41 pm

Today was a good day, daylight helps rather than trying to find things with with a floodlight, started by checking the fuses for the hazards, both okay, checked for 12V after the fuse which we got, checked for 12V at the switch 0V, so started to follow the wires back & found it in an unconnected connector, lad was with me & said this one looks similar, plugged them together & we now have hazards & indicators win!

Next was the reverse, same problem, there's a huge connector which I thought had all the wiring for the rear of the car, but nope, there's 2 wires in a separate connector which I hadn't seen connected them & we now have reversing light.

So with all that done I thought I'd try for a start, cranked it over & it didn't want to know, went to check the plugs to find them under water, blew them out & tried again, still not having it, sprayed brake cleaner in throttle body & it fired & tried to run. So checked the fuel pipes, yep there is a 50% of getting them right & I had got them 100% wrong. Swapped them over & tried again, it would fire, run & then die, lad said connect the air inlet hose which has the MAF fitted, did that & it now runs nicely, didn't leave it running long as no coolant.

Which brings me to the only downbeat part of the day, filled the brand new radiator only to find it's leaking, so need to find another, problem is I'm not sure exactly what it is.

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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Tue Dec 01, 2020 8:00 pm

The other day when making the brackets for the radiator I made a slight mistake I drilled & tapped unfortunately I must has managed to pierce the water chamber, not 100 % sure how, but when I filled it up water started to escape, I was hoping to bodge it until after Christmas & tried to epoxy resin up the error, unfortunately on starting there was a PSSSST & suddenly could see a stream coming out.

Bought a new one, had the option of a NIssen for £3 extra so went with that, unfortunately when it arrived the fan mounting holes where not in quite the same place, so the 2 hours of bending & bracket making the other week was wasted, but that is kit car building

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It also must have the top hose in a slightly different place as it now fouled the fan shield so a little angry grinder later

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New brackets made, quick spray & will try to get them back on tomorrow.

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Wanting to think the harness out a bit more, but need to ensure the car still starts & all lights work each time I remove wires.


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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Sun Dec 06, 2020 8:49 pm

Just an update for myself more that being interesting to others, fitted the new radiator, then the hoses, started the engine & brought it up to temperature, the good news is that the fan cut in as controlled by the ECU (so got the wiring right), the bad news is the thermostat didn't open so the engine overheated & spat the coolant out, but an easy fix.

Then I had a look at the horn, I'm trying to fit a MK1 Momo steering wheel to a MK2 column & of course they don't fit straight away. I managed to modify what they call the 'clockspring' this takes the airbag wires & horn from the wiring before the steering wheel & allows you to rotate the steering wheel, but a little angry grinder & some solder I've got it working. Found this quite interesting that the clockspring has the facility to take 6 signals plus earth to the steering wheel which means in the future buttons could be added for who knows what.

Hopefully the weather will be kinder next week & I may get some more of the wiring thinned out.

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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Wed Dec 09, 2020 7:59 pm

Got a new thermostat today so fitted that along with all the hoes, hopefully this is the last time, ran the car up to temperature radiator getting hot this time, fan kicked in & out a couple of times so figured I've sorted that now, just got to decide where I'm mounting the header tank & pipe it in, it's basically a unpressurised container so nothing fancy may use the original depending on space.

Carried on removing some more wires, think they were for the electric windows this time.

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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Thu Dec 10, 2020 8:44 pm

Managed another couple of hours today, virtually finished removing the wires, what's left now has to stay, some are too long, next thing to decide is do I shorten them or just wrap them up out of the way.

The only real bummer is now I've been running the engine I've found it has an oil leak, yep you guessed it the rear crankshaft seal, so everything has to be disconnected again, the frame lifted off the subframes to split the engine & gearbox FFS!!

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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Sat Dec 12, 2020 7:02 pm

So between 08:30 this morning till 4:00 this afternoon I went from

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To engine out to replace seal

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Then back in, I'm knackered still have starter & brakes to do again, I ran out of energy

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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Sun Dec 20, 2020 7:50 pm

Yesterday was taken up replacing the gasket in the son's LT35 flatbed whilst he was at work, it failed it's MOT on poor handbrake & the rear hub to diff leaking oil, the tester figured the oil was getting on the shoes. It has disc over drums so caliper off, hanger off, then remove the disc, strip down the brake shoes, remove 6 bolts & the pull the whole driveshaft & bearing along with the hub. I'd already bought a new bearing oil seals etc, but once stripped it was clear the bearing had been replaced, but when they'd rebuilt if they's not used a gasket. So back to the olden days, local motor factors sells gasket paper, so made my own, then built it all back up again, but this time adjusting it up this time, also found out the cable adjuster bolt had been stripped so had to add an extra bolt to stop is slipping again.


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Today I turned back to Melvin, spend a few hours putting all the stuff I'd had to remove to get the engine out, so I'm effectively back where I was 10 days ago, had one issue though on rebuild, I connected everything up (or so I thought) tried to start it went up to 4K then died, tried again exactly the same, so I wondered had I managed to get the fuel pipes the wrong way wrong, changed them over & now he wouldn't start, so swapped back & he starts up to 4K then dies. So has to be something I'd done, spend the next 20 minutes going all the way through the engine electrics making sure everything was connected, checked over all the earths as it's a known issue, still nothing starting to get frustrated & annoyed with myself, when I happened to look at the throttle body & noticed that I hadn't connected the servo take-off pipe, once connected harmony in the universe was restored & he started & purred nicely.

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Phaeton
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Re: Melvin the Mev Mevster

Postby Phaeton » Mon Dec 21, 2020 2:39 pm

Forms filled in & submitted, hopefully with the waiting list I'm hoping I'll get late Feb, early March, although I'm booked for a trackday on the 11th March so the week after that would work out perfect.


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