Passenger side LCA adjuster bolt flange reshape & spot weld
had a look and this isn't needed there's a small misalignment at the bottom but the camber/tracking bolt only uses the sides to alig itself and he bottom is not used. Rear suspension reassembly & torque check
Done Drill out and install riv-nuts and remount the petrol filler neck.
Filler neck reinstalled but I've not bolted it in place around the fuel door. Acquire 2 new airtight 225/45/17 tires
Done, got some 235/45/17's looking at how the wheel sits with the spacers to clear the calipers they do come out as wide as the arches. So this has answered a question I had which was would I go for 235... I won't. Front suspension assembly and torque check.
Done, need to get my arch liners back in place and fitted correctly. Weld in bung for lamda sensor
Removed a section of the exhaust to get this done.
Level out coilovers and set car height
Done
Final install of Accusump
There aren't any nicer pictures so sharing a pic of this mockup for the centre console. It needs to be tweaked a little before the final design is done.
Replace the passenger side front indicator, fog light, and washer jet pump loom
Replace the washer jet reservoir
Got a unti but it has no hole for the rear washer jet I'll try fix mine with epoxy (NOT FINISHED)
HID wiring
I tried replacing the relay no joy then tested the connection with a multimeter and noticed the poles were reversed from the colour of the wires so I flipped around the wires in the terminal and TA DA
STILL TO START
Acquire manual gearbox mounts - I bought a set and they have arrived in Ireland just need to collect them from another FTO owner
Burn-out bushings, vapor blast and paint engine and gearbox mounts and install polybushings.
Windshield wiper wiring? This is bugging me big time, since I removed the dash the wipers won't turn off, and are running very slow and sluggish. I fear I'm going to have to remove the dash again to find a problem but don't even know where to look. I was hoping replacing the damaged loom would fix it but no.
Heres a few pics of the underside as it stands as I've not posted any in a while. The underside is all done including arches and I'll be mounting the arch liners the next time I'm down.
(I hope the NCT doesn't pull me for covering the brake lines but there are no joins and you can see in the bay and arches they are brand new lines so fingers crossed.)
I also tidied up some wiring... My lambda just had some electrical tape holding it on.
Today I tacled replacing the damaged AC cooler case causing the car to permanently blow hot air.
While I had the dash out I took time to tidy up some of the wiring behind the dash. I have just 3 aftermarket gauges and the amount of wires is insane primarily due to the excess length of harness.
All done and back together and installed the turbo timer
Today I also made a start at getting the rear arches smoothed out after the welding repair and mounting the bumper flush.
I've purchased all new mounting hardware for the front and rear bumpers and arch liners which will all help tidy up the car nicely
There's quite a few angles in these arches that I'll need to wrap my head around. A parallel curve to the arch itself, a curve carrying from the lower door and also one from mid height of the door.
The camera shows it well but it's hard to see in person I'll need to figure out these lines
No huge updates.... I've not forgotten about you guys or the project.
I ended up pulling out the entire engine loom and swapping it out for a fresh one that ran a standard ECU as the standalone had too much risk of not running right.
Tidied up some wiring and now time to get the real show on the road....
The engine and gearbox are back in... The fuel lines still need to be run and the loom connected up then it's time to turn the engine over with the plugs removed to get oil through the galleries and pump out any missed foreign debris from sitting up or blasting once done.... in with the plugs, on with the plendum and lets fire this baby up
AND WERE UP AND RUNNING!!!!!
The turbo needs addressing there's either a pressure or airflow issue but she's running sweet with no leaks.
New intercoole and hardpiping added this week to finish the intake.
Still on my immediate to do list.
* Brake booster and purge lines need an in line 1 way valve
* Spring lock needed for dipstick
* Breather system upgrade and air oil separator.
* Turn fuel rail 180° & build out fuel system in front of RH suspension turret
* THERMAL MANAGEMENT!!
* Oil temp sensor install
* Oil pressure sensor install
* Aquasump plumbing
* Replaceme P clips with metal ones.
* Reset ride height
Other to do.
* Tow eye bracket
* Overall geometry setup
* MORE THERMAL MANAGEMENT
* Make a PNP harness to connect MAXXECU Race to OEM harmess
* Cavity wax the chassis
It's been 3 years this month since I started back at this project.. I don't know where the time has gone it's really flown by but having a running car to show for it and it starting to come together feels so rewarding.