Ben's (an emotional quandry) 1975 SE5a

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scmarf
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Re: Ben's (an emotional quandry) 1975 SE5a

Post by scmarf » Sun Feb 05, 2017 3:04 pm

Ever wondered why you never get any water out of your engine block drain plug?
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Honda Jazz
1977 SE6a, previously 1985 1300 SS1
Worlds longest coupe restoration
Chief mechanic for offspring's fleet (SE5a, Bond Equipe, Ford Focus)

Henry Royce: "The quality remains long after the price is forgotten"

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Re: Ben's (an emotional quandry) 1975 SE5a

Post by scmarf » Sun Feb 19, 2017 8:05 pm

After some trials on Salisbury Plain with some logs and rocks, I decided the platform and roller technique was the best way to move the block out of the garage for its cooling jacket flush.
crankcase rollers sm.JPG
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Quite a lot of crud came out just by transporting the crankcase in the inverted position.
crankcase clean1 sm.JPG
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Honda Jazz
1977 SE6a, previously 1985 1300 SS1
Worlds longest coupe restoration
Chief mechanic for offspring's fleet (SE5a, Bond Equipe, Ford Focus)

Henry Royce: "The quality remains long after the price is forgotten"

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Re: Ben's (an emotional quandry) 1975 SE5a

Post by scmarf » Sun Feb 19, 2017 8:16 pm

The block was placed inverted in the Wilko greenhouse seed tray and the Wilko homebrew bottle brush was used to help clear the jacket. The old core plug was fished out with a wire coathanger. I'm sure Ferrari use very similar tools :lol:
crankcase clean3 sm.JPG
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Additional crud accumulated in the bottom of the tray ...


After a quick wipe, it was rolled down to my car and loaded up ready for delivery to the engine shop tomorrow. While it is away, I will try and get somewhere with the chassis welding and possibly the gearbox though that may be a little ambitious.
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Last edited by scmarf on Sun Mar 05, 2017 3:59 pm, edited 1 time in total.


Honda Jazz
1977 SE6a, previously 1985 1300 SS1
Worlds longest coupe restoration
Chief mechanic for offspring's fleet (SE5a, Bond Equipe, Ford Focus)

Henry Royce: "The quality remains long after the price is forgotten"

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Re: Ben's (an emotional quandry) 1975 SE5a

Post by scmarf » Mon Feb 20, 2017 5:14 pm

Engine now delivered to the engine shop. minimal wear on standard bores so as suspected, not a lot wrong with the bottom end. Oil pump drive looks fine. Camshaft and followers need replacing though. Time to do some research!


Honda Jazz
1977 SE6a, previously 1985 1300 SS1
Worlds longest coupe restoration
Chief mechanic for offspring's fleet (SE5a, Bond Equipe, Ford Focus)

Henry Royce: "The quality remains long after the price is forgotten"

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Re: Ben's (an emotional quandry) 1975 SE5a

Post by AnotherTim » Wed Feb 22, 2017 12:09 am

scmarf wrote:I'm sure Ferrari use very similar tools
It's a little known fact that Wilko started out as an apprentice to Enzo Ferrari but the two fell out over the design of some pruning handles. Wilko, an angry man with a very short fuse, walked out and set up his own company less than a week later with the sole specific purpose of beating Ferrari in the home handy tools category, which he succeeded in doing, forcing Ferrari to focus on cars in order to survive. So I very much doubt they use those tools. Wilko products are banned from all Ferrari premises.



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scmarf
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Re: Ben's (an emotional quandry) 1975 SE5a

Post by scmarf » Sun Mar 05, 2017 3:19 pm

Collected the bottom end from the engine shop last week. Work done:
* Wash cylinder block (FOC). Hone bores (30) and fit a set of core plugs (FOC).
* Polish crank (25)
* New oil pump (45.80)
* Gasket set (27.43)
* Thrust washers (14.77)
* Bearing set for standard crankcase journal bore with -0.010 crankshaft (169.38)
* Ring set (90)

All prices are plus VAT.

However, the engine has been oiled up and put to one side in order to tackle the chassis which is way easier to repair with the engine out.

Step 1:
Introduce the area to mein freund Herr Bosch. This revealed an earlier repair. A plate has been welded over a corroded area. It seemed adequate but that is not how we do things at Faulkner's Scimitar Services.
chassisweld15sm.JPG
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Step 2:
Make the area safe from sparks by sweeping up and installing a spark guard (fancy name for the back of an old electric fire that yielded a handy sheet of galvanised steel :wink: ), and keeping a half empty water extinguisher nearby (left over from a training course)
chassisweld1sm.JPG
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Honda Jazz
1977 SE6a, previously 1985 1300 SS1
Worlds longest coupe restoration
Chief mechanic for offspring's fleet (SE5a, Bond Equipe, Ford Focus)

Henry Royce: "The quality remains long after the price is forgotten"

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Re: Ben's (an emotional quandry) 1975 SE5a

Post by scmarf » Sun Mar 05, 2017 3:28 pm

Step 3 clean to assess damage on top of chassis rail.
chassisweld2sm.JPG
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Step 4 cut out infected area (As they say where I come from 'donne be fraid oit') and clean up the edge. The shiny bit on the right is for the earth.
chassisweld3sm.JPG
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Honda Jazz
1977 SE6a, previously 1985 1300 SS1
Worlds longest coupe restoration
Chief mechanic for offspring's fleet (SE5a, Bond Equipe, Ford Focus)

Henry Royce: "The quality remains long after the price is forgotten"

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Re: Ben's (an emotional quandry) 1975 SE5a

Post by scmarf » Sun Mar 05, 2017 3:38 pm

Step 5 make up cardboard template.
chassisweld4sm.JPG
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Step 6 Cut a piece of 16swg sheet (1.6mm or 0.064 inches if you are reading this after March 2019 :w ). The magnets are just to stop it falling into the chassis member during the fettling process :evil:
chassisweld5sm.JPG
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Honda Jazz
1977 SE6a, previously 1985 1300 SS1
Worlds longest coupe restoration
Chief mechanic for offspring's fleet (SE5a, Bond Equipe, Ford Focus)

Henry Royce: "The quality remains long after the price is forgotten"

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scmarf
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Re: Ben's (an emotional quandry) 1975 SE5a

Post by scmarf » Sun Mar 05, 2017 3:45 pm

Step 7 Apply anti-spatter spray and weld (Clarke 120 MIG setting A2min to tack and A3min to weld for my own reference) and clean off bead to check for porosity and full coverage.
chassisweld6sm.JPG
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Step 7 Apply paint. I opted for a 'cooking' anti rust primer. I anticipate POR15 or Frost's Chassis black on top. Not sure yet.


Honda Jazz
1977 SE6a, previously 1985 1300 SS1
Worlds longest coupe restoration
Chief mechanic for offspring's fleet (SE5a, Bond Equipe, Ford Focus)

Henry Royce: "The quality remains long after the price is forgotten"

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Re: Ben's (an emotional quandry) 1975 SE5a

Post by willholderogri » Sun Mar 05, 2017 4:13 pm

" oh yes


1962 mini, bedford CA , KR200. morris 1000, mini pickup.several escorts,ford grandad.ford cortina X2 ,astra, SE5A x 2 ,ford focus.

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Re: Ben's (an emotional quandry) 1975 SE5a

Post by scimjim » Sun Mar 05, 2017 6:07 pm

Looking good. My only concern would be the quality of the gasket set at that price? I'm very choosy about head and inlet gaskets :-)


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Re: Ben's (an emotional quandry) 1975 SE5a

Post by AJL Electronics » Sun Mar 05, 2017 6:12 pm

Is the chassis really only 1.6mm?


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Re: Ben's (an emotional quandry) 1975 SE5a

Post by scmarf » Sun Mar 05, 2017 8:07 pm

scimjim wrote:Looking good. My only concern would be the quality of the gasket set at that price? I'm very choosy about head and inlet gaskets :-)
Bottom end set only Jim. :)


Honda Jazz
1977 SE6a, previously 1985 1300 SS1
Worlds longest coupe restoration
Chief mechanic for offspring's fleet (SE5a, Bond Equipe, Ford Focus)

Henry Royce: "The quality remains long after the price is forgotten"

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Re: Ben's (an emotional quandry) 1975 SE5a

Post by scmarf » Sun Mar 05, 2017 8:22 pm

AJL Electronics wrote:Is the chassis really only 1.6mm?
Good question Andy.

I have always used 16swg for main chassis sections. Can't remember who told me it was correct but from a practical point of view, it can only really be cut by hacksaw or grinding wheel (not snips) and is just about bendable. I had a quick google a minute ago and it seems in tune with what the Triumph boys use. Land Rovers seem to talk about 3mm but I guess they have different design parameters.


Honda Jazz
1977 SE6a, previously 1985 1300 SS1
Worlds longest coupe restoration
Chief mechanic for offspring's fleet (SE5a, Bond Equipe, Ford Focus)

Henry Royce: "The quality remains long after the price is forgotten"

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Re: Ben's (an emotional quandry) 1975 SE5a

Post by philhoward » Sun Mar 05, 2017 8:38 pm

Sounds about right to me.

Some sections of the Small Sports chassis were a lot thinner even when new :shock:


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