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> The Red Devil's Progress Since April 2014, Project..
Ganz
post 17th July 2015 00:55
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Black 146.. you're right, you have to remove the center console just to get at the bolt.

Put in a real shift last three days. Just waiting for my Google photos to upload onto my Google Gmail...usually takes an hour or even a day!?

All the front disc retainer bolts sheared off when I tried to remove them last year (the two bolts that hold your disc on to the front hub, they also hold on to a 5mm spacer plate.

I had to drill a hole in each one and tap in a new thread with a tap and die set (using the die for bolts; tap is what you would use for cutting threads for nuts).

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I think I used a 5mm drill to begin with and then a 6mm drill. It was quite tricky to drill to from 5mm to 6mm as the drill kept catching. If I had the chance to do it again I would use one drill drill size only 6mm.

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The nearside final hole was really tight (no jokes please!!)

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Using a screwdriver to steady the hub made it easier to tap the thread.

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All the way through. You need a lot of patience doing this job. If you try to turn the die too fast too many turns you'll snap some teeth of it or worse snap the die! Best to oil the die and turn it a quarter turn take it out, clean the swarf, lubricate the die and then repeat the whole process with another quarter turn. I got impatient and started doing half turn and the result was a partial broken tooth on the die.

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I sourced some stainless steel flanged bolts and using some loctite bolted them in. The torque setting are 1.3kg but I decided to tighten them by hand to what I felt was about right (after torqing a shed-load of bolts on the sub-frame already). My torque wrench only went down to 2kg anyway so I had no choice but to tighten by feel.

This post has been edited by Ganz: 17th July 2015 01:02


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Ganz
post 21st July 2015 10:50
Post #62 | Print


1.6 16v
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Front end fully assembled.

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Decided to get new brake pads as the originals were really scored. Really happy with the calipers now.

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Put my new braided brake hoses on with fittings.

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I'm glad I went with the Kunifer brake piping in the end.
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Offside done

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Nearside assembled

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All new brake pipes connected to the rear end.

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The project feels like its moving now


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effkay
post 22nd July 2015 09:22
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Congrats! Some good work smile.gif Similar to what I had to go through on mine. Good work running those brake lines though...luckily mine were ok.
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Ganz
post 22nd July 2015 11:29
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Driving: 145 Cloverleaf 2.0L ts
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QUOTE(effkay @ 22nd July 2015 10:22) *
Congrats! Some good work smile.gif Similar to what I had to go through on mine. Good work running those brake lines though...luckily mine were ok.


Cheers! You know I think I like working on my car as much as driving it!!

I really didn't want to do the brake lines but they were corroded. Once I hacked the old lines out it was a point of no return. Really glad I did it now.

Did you get lowered springs and struts?


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effkay
post 22nd July 2015 14:20
Post #65 | Print


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QUOTE(Ganz @ 22nd July 2015 12:29) *
Did you get lowered springs and struts?


FK lowering springs front and back.

Adjustable Spax rear shocks.

Bilstein B6 front shocks (not the OE B4...unluckily for my wallet!)

New top mounting kit too.

Works well, but car sits nearly at the standard height still on the 15" wheels I've kept. Go for adjustable coilovers if you want a lower look.
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Ganz
post 26th July 2015 14:13
Post #66 | Print


1.6 16v
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QUOTE(effkay @ 22nd July 2015 15:20) *
FK lowering springs front and back.

Adjustable Spax rear shocks.

Bilstein B6 front shocks (not the OE B4...unluckily for my wallet!)

New top mounting kit too.

Works well, but car sits nearly at the standard height still on the 15" wheels I've kept. Go for adjustable coilovers if you want a lower look.


Cheers for that info. I got FK lowered springs and some dampers I brought from Germany through German eBay. The dampers are made by a firm called technick or something similar. Both springs and dampers are shorter than the OEM stuff. Hopefully it will look lowered.


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Ganz
post 30th July 2015 02:02
Post #67 | Print


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Driving: 145 Cloverleaf 2.0L ts
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Reassembling the interior and some touches to the front end.

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Attached my custom made Alternator guard (the shiny alu in the background).

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Got some new bleed screws from Parker's motor factors and some yellow dust caps from eBay.

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Ordered these plugs from eBay as I was missing two - or two went missing from my caliper sliders pins. Nice fit but let the pins slide.
http://www.ebay.co.uk/itm/151329086705?_tr...K%3AMEBIDX%3AIT

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Finally got the fuel pipe bracket bolt off. I had to hacksaw it and finally drill it off. The metal bracket it originally bolted on to rusted to dust.

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I fabricated my own bracket out of galvanised steel

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Riveted with some aircraft fuel rivets given to me.

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Started to put my interior back. But the driver and passenger floor mats (what's under the carpets) were like a jigsaw puzzle.

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Rather than piece them together I decided to purchase some floor matting from a firm near Peterborough called Woolies.

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Used the old mat as a template and cut some new stuff. Really easy to do.

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The Woolies one was the right thickness too. So that was cool.

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Very happy with the result.

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Assembled all the lower dash back on
Have to say that without my labelled bagging system of itemising every screw long or short there is no way I would have remembered what I took apart last year. Phew! huh.gif

Picking up my new alloy bushes for the rear sub-frame poly bushes later on today.


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effkay
post 31st July 2015 08:46
Post #68 | Print


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Nice progress. Its coming together! Will be a clean example smile.gif
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Ganz
post 2nd August 2015 22:08
Post #69 | Print


1.6 16v
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Driving: 145 Cloverleaf 2.0L ts
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QUOTE(effkay @ 31st July 2015 09:46) *
Nice progress. Its coming together! Will be a clean example smile.gif


Cheers!

I think it will be a lot cleaner underneath than outside. There is a year and half's worth of dust sitting on the car. Yeah, I'm enjoying the project as it comes along. Thing is I don't want the new front suspension sitting there for 6 months. Looking to get the rear subframe on this week so will post pics on this forum.


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black 146
post 2nd August 2015 23:05
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QUOTE(Ganz @ 2nd August 2015 23:08) *
Cheers!

I think it will be a lot cleaner underneath than outside. There is a year and half's worth of dust sitting on the car. Yeah, I'm enjoying the project as it comes along. Thing is I don't want the new front suspension sitting there for 6 months. Looking to get the rear subframe on this week so will post pics on this forum.





I think it would be nice to get it on the road be for the summer ends smile.gif
was there any to'do's from the last MOT ? or have you covered that with all that hard work you've put it worshippy.gif


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Ganz
post 3rd August 2015 23:06
Post #71 | Print


1.6 16v
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Driving: 145 Cloverleaf 2.0L ts
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QUOTE(black 146 @ 3rd August 2015 00:05) *
I think it would be nice to get it on the road be for the summer ends smile.gif
was there any to'do's from the last MOT ? or have you covered that with all that hard work you've put it worshippy.gif


Exactly what I was thinking. Before the summer runs out.. No to do's from the last mot so all good smile.gif

Got some more pics.


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Ganz
post 3rd August 2015 23:37
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1.6 16v
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Morning one and all!

Finally got my rear alloy sleeves made up for the rear polybushes!


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Going to do a home made short shift. Looking to take an inch of the top and add the inch to below the fulcrum point. Only thing I'm worried about is will the nylon ball get too hot when welding? You know, I'm just gonna go for it.

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The original alloy bush with all the rubber part missing. The steel bush that I got when I ordered the red polybushes. I think that there too much space for the sub-frame bolt. Also, the thinness of the wall.. that would bite into the chassis and I didn't want that.

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So I decided to buy some alloy tube and hacksaw to approx length and got them faced off to the correct length by a local engineer.

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The rear steel ones were a lot thicker but weighed a ton. Got alloy ones faced and reamed and made some sleeve inserts to match the clearance of the original 145 bushes.

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BTW I made sure at least one end of the alloy had a 45 degree chamfer to make the job of inserting in to the polybushes easier.

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The rear subframe. I had to use a mate's 2 ton press with three of us balancing the subframe whilst pressing the bushes in. Tricky getting a spacer to fit around the bush and having enough clearance for the bush to pop through. It wasn't easy.

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Sizing the alloy sleeve. I'm hoping to be able to stand on the sleeve and force it in. I'm almost 2 tons myself!

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The calm before the storm...

This post has been edited by Ganz: 3rd August 2015 23:41


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black 146
post 4th August 2015 16:31
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That skinny roflmao.gif


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Ganz
post 25th August 2015 21:36
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Some more work in August. I starter putting together the rear sub-frame back on the car.

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The sleeves when into the polybushes ok. I had to stand on them and the rear ones had to really force them in but once they went in they popped into place. I heated the polybushes and put the sleeves in the freezer. Lots of silicon grease and it was an easyish job.

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All in!

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Fitted the new fuel filter

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Cleaned up the fuel lines and holders

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Attached the sub-frame back on.

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Started to bolt on all the brake pipe bracklets

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Also, bolting the exhaust hanger brackets

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The nice powder coated handbrake cable bracket

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From the side..

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I've since created a bit of space between the brake pipes so they are not making contact like that.

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Looking forward to connecting all the rear brake pipes

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Brought a secondhand toolbox for a fiver and got it shot-blasted for free. I primered and spray painted it which took an insane amount of time but happy with the results.

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So much easier to find tools now

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The old plastic Stanley one didn't last very long and cost me over 17 squid. The linkages all broke in the end. Avoid!

This post has been edited by Ganz: 25th August 2015 23:33


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black 146
post 26th August 2015 18:09
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1.7 16v
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that's funny as i bought Brad a very large tool chest ' Of a make we all know .For his new joby
and i said would not one of them metal one's do & he told me where to go! HaHa
i had one of them in the 80's and they were the dogs nuts in them days lol


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Ganz
post 26th August 2015 20:35
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1.6 16v
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Driving: 145 Cloverleaf 2.0L ts
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QUOTE(black 146 @ 26th August 2015 19:09) *
that's funny as i bought Brad a very large tool chest ' Of a make we all know .For his new joby
and i said would not one of them metal one's do & he told me where to go! HaHa
i had one of them in the 80's and they were the dogs nuts in them days lol


My garage life has been so organised since I've used the red box smile.gif


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black 146
post 26th August 2015 21:03
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1.7 16v
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From: norfolk



QUOTE(Ganz @ 26th August 2015 21:35) *
My garage life has been so organised since I've used the red box smile.gif




i've got a works Bag but once it starts to rain it all goes t*t's up and just gets throwen in what ever goes in first thumbdown.gif huh.gif


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Ganz
post 30th September 2015 23:06
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1.6 16v
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Been busy in the last month.

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Bolted the ARB on

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Ready for the brake lines and pipes to be attached

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From the back. Still got to attach the ARB sensor on the nearside

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Attaching all the brake lines

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The trailing pad is missing on far-side. I'm going to mold my own polyurethane pads.

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Can't believe it's a year and a half since I garaged the 145

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Best bit was connecting all the brake lines up.

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Finally, all connected up!

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Bolted on the rear-brake compensator

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The Fiat brake clips fitted a treat.

It's getting there..


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black 146
post 30th September 2015 23:19
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1.7 16v
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looking really smart mate coolio.gif worshippy.gif worshippy.gif i would never take it out in any wet weather . wacko.gif Did you make new rear dust covers or blast the old ones they look new ?


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Peadar
post 1st October 2015 12:41
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This is ridiculously good work, I'd never have the patience
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