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Old 07-04-2011, 10:06 PM   #101
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Did you drop the tank to weld the feet in?
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Old 08-04-2011, 08:38 AM   #102
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Did you drop the tank to weld the feet in?
i did on my if your wondering.
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Old 08-04-2011, 09:43 AM   #103
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I totally forgot about the nipple pics, sorry.
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Old 08-04-2011, 01:34 PM   #104
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Did you drop the tank to weld the feet in?
I did not!!! I did cover the tank with a fire blanket when it was being welded. Just had another look today on the ramp at work and cannot see any leaks.

Also I filled the tank up last night and it didn't smell much on the way to work today. So I'm hoping its a breather problem which would be worse if the tank was empty as the returned fuel is being pumped into the empty tank. I'll drop the tank next week and have a look.

Don't worry about the nipple pics, cheers. I now have my own nipples!!!lol
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Old 08-04-2011, 02:21 PM   #105
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What's the issue with the axle?
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Old 08-04-2011, 02:39 PM   #106
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What's the issue with the axle?
A knocking noise can be heard when pulling away from standstill. If you bouce up and down on the rear of the car when stationary you can also hear it coming from inside the yellow tube on the right hand side. I opted for the upgraded bush kit from Imaxle, so maybe there is a dry spot on the bush which is causing the noise. Might try adding some more grease throught the nipples on each side. If its still noisy after Castle Combe I will phone them up... again.

Also the "Pinging" noise from the antiroll bar has reappeared with this axle.
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Old 15-04-2011, 10:41 PM   #107
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After Castle Coombe the knocking has stopped. Maybe it needed beding in. Who knows, I'm just glad I don't have to take it out again.

Car has now done 130,000mls.
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Old 16-04-2011, 07:46 AM   #108
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That is by far the best fix for a knocking rear beam i've ever seen.
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Old 17-06-2011, 09:38 PM   #109
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Some pics from Rally day at castle combe...





Still running well with a slight fuel smell!!! Still need to fit the front CF door cards.
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Old 19-06-2011, 02:51 PM   #110
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such a nice rallye, looks gorgeous in tht last picture
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Old 03-01-2012, 05:34 PM   #111
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Finally put the CF front door cards in! Only had them a year!



Need to take some "proper" pics soon.

Also bought larger front brake discs and calipers (266mm I think) not fitted yet.

Still made 139bhp on the rollers at the end of last year. Need to get atleast 140!

Really need to do a track day soon. Let me know if anyone is going.

Cheers, Ian.
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Old 03-01-2012, 05:38 PM   #112
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I think there is something being arranged by Mike in February.
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Old 03-01-2012, 05:45 PM   #113
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Feb 25th @ Oulton Park, might be a bit far for you though.
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Old 13-06-2012, 09:08 PM   #114
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Right need to start a list so that it'll motivate me to work on the Pug. Been busy with my other 2 motors, anyway...

1. Fix that fuel smell!!!
2. Need quieter exhaust! Pug sport is going!!! Looking into custom exhaust with sport CAT.
3. Still need to fit brakes and need 22-23mm Master Cylinder.
4. A bloody good clean!!!
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Old 02-07-2012, 12:34 PM   #115
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Went to Powerflow on thursday and had a "quiet" system built with a 100 cell CAT.
No exhaust tailpipe and is the same diameter system as the Pugsport. I opted for a hidden type...



Very quiet on the move and on the motorway. And more importantly hasn't lost any power.
Still a little boomy on idle but I can live wiith that!
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Old 02-07-2012, 05:39 PM   #116
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Nicely done!
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Old 02-07-2012, 08:04 PM   #117
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Nicely done!
Cheers! Just trying to make the car more enjoyable as I use it everyday!
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Old 13-09-2012, 04:28 PM   #118
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Time for an update...

Fitted the 266mm brakes from a 206 GTi...



New Pagid discs and pads. Had to grind a small part from the caliper carrier to clear the hub. Washers needed on the bolts for the caliper carrier (some people buy correct bolts). Wheel weights need to be moved to clear calipers.

Quick roadtest showed that I need a 23mm master cylinder as the brake pedal is too long and soft. So I've ordered one from Brakesint.co.uk. Should be here tomorrow.

Also pulled the fuel tank out to check for a fuel smell. Tank is ok but the two rubber hoses onto the sender were perished, so changed them...



Got a track day at Silverstone on the 24th so getting it ready for that.
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Old 13-09-2012, 05:57 PM   #119
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just read the lot looks a very clean car and what a great way to fix your beam lol. love the seats aswel very nice indeed.
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Old 13-09-2012, 07:24 PM   #120
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just read the lot looks a very clean car and what a great way to fix your beam lol. love the seats aswel very nice indeed.
Cheers!!! I can't believe I've owned it for 6 years now!!! Thats the longest I've owned any car!!! Still makes me smile and I guess thats why I still have it!!!
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Old 13-09-2012, 10:00 PM   #121
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New discs always look good when they go on
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Old 14-09-2012, 08:39 AM   #122
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Paint looks awesome!
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Old 14-09-2012, 09:16 AM   #123
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I saw this car around 2 years ago and it's very clean indeed. Nice mods too
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Old 14-09-2012, 05:06 PM   #124
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Been keeping an eye on the blog since you decided to 16v Ian.

Impressed with the work gone into it! Looks so much cleaner than mine. I havent washed mine for a long time.
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Old 29-09-2012, 07:51 AM   #125
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Thanks for the comments!

I try to keep it clean. Washed, clayed, polish then waxed. Hard work but looks good when finished.

Little issue yesterday when I snapped the right engine mount. Not sure how but the bolt snapped in the mount. So replaced left and right mounts. (gearbox mount is Powerflex).

Squeezed some grease into the beam nipples to remove slight play in the beam. Was worried for a minute that the beam was fucked again!

Track day didn't happen on the 24th in the Pug. Had to take the bosses BMW 335i in the wet. Day got cancelled due to bad rain and is rescheduled for Nov. So I'll try and take the pug out then.

Insurance is due on the 10th Oct, which will be 6 years of Rallye ownership!!! 400 TPFT not great though!
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Old 29-09-2012, 08:35 AM   #126
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That seems high. Renewed mine at 390 fully comp this year.
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Old 08-10-2012, 05:15 PM   #127
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Had the MOT done today. It passed with a few advisory's regarding corrosion around the front in two area's. So I'll attend to that over the next few weeks and still need to sort out insurance renewal which runs out in 2 days!

Milage now on 138,000m.
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Old 08-10-2012, 05:35 PM   #128
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what do you use it for Ian? I was insured with REIS and they were very good.
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Old 08-10-2012, 06:39 PM   #129
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Im with Graham Sykes theyre very good also, worth a call mate.
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Old 08-10-2012, 07:58 PM   #130
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what do you use it for Ian? I was insured with REIS and they were very good.
I use it for the daily commute and at weekends. Think thats called social and commuting. But I only do 6,000 miles a year.

I'll give them all a call tomorrow. Thanks for the info guys.
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Old 09-10-2012, 03:54 PM   #131
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Car looks amazing mate! Just read the whole blog! Soo smart but shame it has a 16v in :P The 8v engine will be put to good use don't worry
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Old 11-10-2012, 04:57 PM   #132
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Car looks amazing mate! Just read the whole blog! Soo smart but shame it has a 16v in :P The 8v engine will be put to good use don't worry
Cheers. Good luck with engine.

I've fitted the lower strut brace today. Car does feel tighter but that might just be in my head!!!

Also bought a battery box from ebay to relocate the battery in the back somewhere. So that'll go in at some point, after I figure out how to strap/bolt it down. Then might move the engine bay fuse box inside.
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Old 11-10-2012, 07:46 PM   #133
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Behind the passenger seat is a great place if it will fit.

Which insurer did you go with in the end dude?
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Old 11-10-2012, 08:31 PM   #134
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Yeah, I had a look at that but it wont fit there cos of the SD cage. Might have to go just back from there on the area above the fuel tank.

Went with Adrian Flux again! They matched last years quote of 370. Still only TPFT.
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Old 11-10-2012, 09:28 PM   #135
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how about in front of passenger's feet, ideal for weight dist.
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Old 12-10-2012, 08:31 AM   #136
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Ian, have you thought about one of the smaller race style batteries. They are good value and the one on the Escort has never needed charging (touch wood). They don't need a box and can be laid flat if required.
We've got an Odyssey 30.

Exhaust still going strong, it bangs the heat shield a bit forward of the fuel tank. nothing a session with the 'mer won't sort out.

Lovely car in the flesh this one, really is as nice as the pictures.
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Old 20-10-2012, 02:16 PM   #137
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Ian, have you thought about one of the smaller race style batteries. They are good value and the one on the Escort has never needed charging (touch wood). They don't need a box and can be laid flat if required.
We've got an Odyssey 30.

Exhaust still going strong, it bangs the heat shield a bit forward of the fuel tank. nothing a session with the 'mer won't sort out.

Lovely car in the flesh this one, really is as nice as the pictures.
Not sure about the race batteries because I use the car daily. Do you know if this type of battery would be ok for daily usage? Perhaps going for one of the larger race batteries?
Glad the exhaust is ok and thanks for the comments!

Don't think I'll put it in front of the passenger seat. Looks a little untidy imo.

Spent a few hours at work today on it, did an oil and filter change 10w40 (139,241m)

Bottom pulley was trying to spit the belt off. Bottom pulley was coming apart...



So fitted new aux belt tensioner, belt and bottom pulley.

Tidy up the brake pipes going to the Master Cylinder and replaced crankcase breather hose.



Check tracking = 0 degrees 5' toe in (which is in spec).

Seem to have an issue with the brakes pulling to the left on really hard braking. The left front tries to lock before the right but the camber of the road really affects this. Sometimes its ok. Could also be a weight distribution problem. Will report back with findings...
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Old 20-10-2012, 05:47 PM   #138
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My Odyssey 680 has been fine for daily use, and less frequent use too. Only problem I had was killing one when my alternator died as they are sensitive to low voltage.
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Old 03-11-2012, 09:26 PM   #139
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My Odyssey 680 has been fine for daily use, and less frequent use too. Only problem I had was killing one when my alternator died as they are sensitive to low voltage.
I am slightly worried that if I move the battery, that I will want to remove the airbox for some throttle bodies!!! Could prove expensive!!!
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Old 22-11-2012, 12:11 PM   #140
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Engine died on the way to work this morning. Lots of metallic noises from the engine, resulting in inlet valves meeting pistons...


IMAG0542 by iewen, on Flickr

Possible cause is the aux belt (which I replaced last month) had shredded and parts of the belt have gone into the timing belt causing it jump. Other that that the belt may of been loose and jumped a tooth.
Getting prices now for valves or possible scrap value!

Either way a crap start to the day, esp when I had Silverstone tomorrow and Bedford booked for next Sat.
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Old 22-11-2012, 12:39 PM   #141
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Bugger! Shouldn't be too hard to find someone with 16 J4 valves after a JP4 conversion, ask on moaners.

What kind of aux belt did you fit? *glances nervously at fresh contitech*
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Old 22-11-2012, 01:10 PM   #142
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Eurocarparts list some inlet valves at 4 each so probably going down that route.

It was a Conti belt but I think there is a further issue with the alignment of the bottom pulley, tensioner and alternator.
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Old 22-11-2012, 08:44 PM   #143
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christ that's cheap for valves!
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Old 22-11-2012, 09:10 PM   #144
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christ that's cheap for valves!
+VAT of course!!! and that's at trade discount.
All parts ordered and should be going back together on Sat... fingers crossed!!!
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Old 25-11-2012, 04:11 PM   #145
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Car all fixed and ready for Bedford on Sat!
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Old 25-11-2012, 05:18 PM   #146
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Blimey, great work! Did you get the head skimmed etc?
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Old 25-11-2012, 10:26 PM   #147
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Blimey, great work! Did you get the head skimmed etc?
It's easy if you are a mechanic!!! Head didn't need skimming but did lap the new valves which took a while!
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Old 25-11-2012, 10:44 PM   #148
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Old 01-12-2012, 07:42 PM   #149
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Had a very cold and frosty track day today at Bedford Autodrome. This was my first time at this circuit and first time with Javelin Track Days. Top marks to both and got 20min instruction for 20. I did spin once! But I was asking too much of the tyres as it was sooooo cold! A great track for novice drivers thanks to a lot of run off area's but also very rewarding when a series of corners are taken at speed. Perfect for the Rallye as it kept up with faster machinery in the twisties but did lack the speed on the long straight. All in all a top day and was able to drive it home too!!! Bonus!!! Anyway pics...
















I should add that there are a few issues that need sorting...

1. Slight knock from front - Fixed, driveshaft nut needed tightening!
2. Too much rear braking happening with bias valve fully closed. - Only really a problem with the Soft Yoko A048 on.
3. RHF wheel had alot more brake dust than the LHF wheel. Wasn't pulling to one side though. - Fixed, caliper sliders cleaned and greased. Seems ok now!
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Old 03-01-2013, 01:17 PM   #150
ejarvo
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Nice work mate. It's nice to see the car being used on the track!

One thing it could be, in regards to the brakes, is the rubber bushes that cover the sliders on the brakes. I have a similar problem with my brakes (266mm lucas ones i think) and i am going to either get a refurbished set or buy the kit and do it myself. The slider rubber bushes on mine have perished and let in moisture to the sliders which can cause them to stick.

Also, i had the same damn problem with the bottom pulley. Mine actually separateed and fell off while driving!!! however it has not affected the timing belt (phew!). I dont know why they made a pulley that wasn't one solid piece - it just doesn't make sense to me.
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