Surface Rust

Wait a second...

No, really, @MrsJuular noticed that the Volvo branded spark plugs (which weren't cheap) looked like they were held together with glue.
I was doing a (yet another) spark test with them all lying out on top of the engine block, except this time it was starting to get dark outside. This time I noticed how thin and crappy the spark looked, which prompted a closer look.
Ironically I bought these spark plugs last year to try and sort the running issues that were likely caused by the burned #3 valve which I have now fixed. I hadn't thought those "genuine Volvo" plugs would contribute their own issues.
So I chucked on an old set of NGK plugs I had lying in the boot, and...
 
Running perfectly!
MOT time now.

I often forget how much and why I love my alternative motoring-lifestyle.
Running* six heaps is all too often just a never ending barrage of jobs of varying priority and can easily leave you wondering “why?!”
</fate_tempted> The Mini is a joy and recently I had to make a 150 mile journey - in the words of Ewan McGregor, Choose Shite

Rewire complete. 

Have made a few changes. The switched fusebox is fed from a master 100A relay which is triggered from the ignition key. This takes the heavy load off the ignition barrel which could get extremely hot with all of the current for all systems passing through it.
The coil is fed straight off the barrel and is unfused, as it should be, so even if the relay fails the engine won't stop.
Apart from that I made sure all cable ends had good quality spade connectors and heat shrink wrap with adhesive. This way they're pretty tough and reliable and eliminates some of the nasty and corroded original connectors.
The engine bay is much cleaner now without the fusebox, relays, and associated wiring nests.

Wiring for the reverse lights and overdrive now run inside, and I've packed the gap around the gearstick with insulation to cut down on road noise.

Important upgrade done to the brake lights. The original brake light switch is a fluid pressure switch which tends to only activate when you're standing on the pedal. 
I've changed it for an electrical pedal switch, which needed a bracket made up.

A real pain to drill the bolt holes for this in the pedal box so the top hole is in at an awkward angle.

Still it does the trick and is a massive upgrade. The lights now come on as soon as you touch the pedal.
While the steering wheel was off I swapped the steering column coupling bush as it was really sloppy.


The steering column shroud also got a coat of paint after I did some repairs to the cracking brittle plastic with some epoxy.


Last few bits done inside. A new hazard switch.

I then remembered I bought a set of instrument panel stickers off Demon Tweeks.

So I then did what I originally meant to and sorted the dash light graphics.
Before.

After.

Before doing any welding whatsoever, I made an extra long lance from 3 originals joined together. 

This is so I could arrange it in the correct position for optimum coverage, before putting the panel in position.

I used mini G clamps to hold the 3 layers together.

And here you can see how the holes in the outer panel are lined up with those in the middle layer, which I'd previously only tacked into position and ground back.

This meant I could create a decent plug weld, and tie all 3 layers together.

Once I'd done all the plug welds and tacked the front edge, I ground them all back ready for seam welding in stages.

I was trying to minimise the gap to make life easier for myself when it came to welding 1mm steel. I found that on a current sufficient to get good penetration on the first pulse, by the time I'd laid down 3 or 4 more pulses, the localised heat build up meant I was in danger of blowing through, so I just moved on to another location. And repeat...

Finally, it was a case of taking the flap disc to it, followed by the power sander to flatten out any imperfections. This should still be under the seal, so I dont think I need to use filler.

Then a coat of etch primer to protect while I treat the surface rust which is around the rest of the frame.

Lastly I used my new lance to spray cavity wax on the rear of the weld, which did reveal two pinholes...easily dealt with though. Time for bed now!

Results are in ... Not troubling the podium any time soon 
We missed a few boards which let us down.  Will know better for next time!
 

Spot on! 1959 93b 

Another 400ml donated to the incinerator and viewing completed. Needs a bit more work than the seller let on, but still pleased with it. It is the opposite end of the spectrum from the Cobra  

Last night was the navigation rally. 
What can I say but what a hoot.  
For anyone who hasn't tried it, I highly recommend it. 
The premise is simple - get from point A to point B within the speed limit. 
The hurdles are that you get penalised for being too early, penalised for being late and penalised for approaching the checkpoint from the wrong direction. 
Along the way there are signs with numbers or codes on them.  Miss these and guess what - you are penalised. 
It's mostly B roads, in the dark and being Scotland it is flooded/rutted throughout. 
The other cars were pretty much rally prepped with massive front lights


We took part in beginners category that got us a marked map 

If you go for Novice (next level up) these are the type of instructions you get 

These have to be deciphered and plotted on the move. 
 
Some of the rules

It's incredibly difficult to convey the fun that is had.  The first half took about 2 hours, in which time it is unrelenting. Navigator has by far the hardest job, being chucked about, trying to read a map, keep eyes open for signs and then watching the clock. 
We finished back at HQ around midnight to a feast of rolls and cakes.  
Managed to finish without breaking the Merc and still speaking!
My major issue this morning is that I fancy doing more in future but don't think the turbo Mx5 will cut it.  Might need to upgrade to more of a rally car. 

Today is actually spring and warm, so can now open up the garage for the first time since October.
The first job was to add a diesel additive and then change the fuel tank cap as the old one was leaking.
Old one don't look so good.
 
The only new one I found was this which a Mercedes specialist said would fit and it did.


 
Then it was time to start it for the first time since October and it started quickly this year, faster than last year but as always was a bit grumpy in the first few minutes.

 
My current phone doesn't film as well as the last one so this isn't the best but it's something.
 
Now got the charging tested after I made a completely new charging system this winter and the result is 14.56 at idle without headlights and 13.10 at idle with headlights, so can call this a success. The next thing is to look at the cooling system and change the coolant and maintenance and it is ready for the road again. Hope it happens within 2 weeks waiting for the roads to be clean and safe from salt.

I’m not  
Destination achieved, nice cup of tea with @jonathan_dyane and then headed south. Stopped at my old university friends place in St Helens to top up with LPG and now waiting for another shiter to finish work so I can make my second collection after which I can start heading north. Only as far as Preston tonight
Picture near the next shifters place

The weather was looking ok, it was time to take the Sierra out for a test drive.
Even with the battery disconnected, the fuel gauge was showing that the tank was nearly full. Bearing in mind that I only put about 5 litres in when I first bought the Sierra, the gauge reading looked very wrong.

With the battery reconnected, the Pinto fired up first time and the exhaust spat out a mouthful of moisture. More on this later. 
Whilst walking out of the workshop, to move the E46 out of the way, I noticed that the brake lights were permanently on.

I quickly got changed, removed the bottom of the dashboard again to gain access to the brake pedal switch.

I removed the switch to check and clean it. It looked ok.

I refitted the switch and adjusted it to the correct position. Evidently, I must have disturbed the switch whilst fiddling with the pedal box yesterday.
All pre-flight checks done, it was time to set off. I got as far as my local Esso fuel station.

I managed to squeeze 5 litres of petrol into the tank before the filler neck was full. It looks like the gauge was showing an almost full tank because the tank was almost full. On the basis that the tank holds 60 litres and I've added about 10 litres since buying the Sierra, there must have been about 50 litres of fuel in the tank. At approx £1.50 per litre, that's a £75 gift. Thank you previous owner.
Before leaving the fuel station, I was approached by three people, who commented on how immaculate the Sierra is and who asked how old it is and how many miles it has done. How nice that the posh folk of Beaconsfield appreciate old Fords.
Approx 5 miles into my trip, I stopped off at a garden centre to check vital fluids and to give everything a once over. No problems to report. The pretty setting provided an opportunity for a couple of photos.



Back on the road, I headed for the A404. If you've ever watched Wheeler Dealers (the GB episodes), you will have seen Mike B towing or driving something along this famous* dual carriageway. 
Without any struggling, the Sierra got up to 60MPH.

I came off the A404 at the A4 junction and drove through Maidenhead, Cookham, Wooburn Green and towards home. I stopped off at Glory Park for a couple more photos.


I arrived back home almost exactly 20 miles later, as confirmed by the trip meter. This is good news, it means the trip meter and odometer are both reading just fine.

Ok, I've only driven the Sierra for 20 miles along local traffic free roads but my first thoughts are very positive.
Engine - I adjusted the idle speed at the garden centre, once the engine reached full operating temperature. Throughout the trip, the engine ran fine, quickly reached operating temperature and the needle didn't budge from the mid point. It pulled well from low revs, with no missing or spluttering. Nothing has leaked out, however there is still a whiff of paraffin / old engine oil / mucky residue from where I've been tinkering, which will need time to burn off. 
Gearbox - All gears go in and out just fine, synchros are strong. The gearbox is silent and I love the mechanical feel of the gear change.
Clutch - Biting point spot on. No dragging, no slipping, no juddering. Perfect.
Prop & Diff - Silent, no vibrations.
Steering - Noticeably heavy at parking speeds, otherwise works well and feels adequately light at speed. Steering wheel is on straight, no pulling, no issues.
Suspension - Smooth! No knocks, no bangs. Ride comfort is superb, on par with my W123. Handling is roly-poly, as expected. 
Brakes - Needed a bit of time to bed in, however once the pedal firmed up, they worked just fine. I tried a couple of emergency stops, no pulling, no issues.
Exhaust - Drill holes failed to allow any moisture to escape overnight and I could hear a significant blow from both silencers. Bollocks. Evidently, drilling holes in silencers is not a good idea. I will plug both holes with chemical metal and self-tapping screws this afternoon.
Radio - Played Greatest Hits Radio (105.8FM), including Popmaster at 10:30am. All six speakers work ok and the FM reception is better than expected, bearing in mind I live and drove the Sierra through The Chilterns.
Summary - I love it!
@N19 I am sure that I will find something to write about soon. There are a few more bodywork related issues that I want to attend to and I expect the forthcoming MoT test will reveal something wrong with the old Ford. 
 

Well, the ferry was an emotional experience - key lowpoint was out overtired 2 year old just wouldn't go to sleep, and kept getting up, and wanting to wander about. I totally understand that, she'd been sat in the car seat for nearly 11 hours at that point.
They all eventually fell asleep, leaving me to stay too wired to follow them.

We got out of Dieppe ferry port around 0515, and immediately happened along the Alpine factory 😁

Didn't realise just how poor the lights got after the beam deflectors were fitted, they were like bloody candles!

Thankfully, a reinvigorated MrsH had planned ahead and filled a thermos of tea, which was still piping hot the following morning!

Can tell the British influence in the Rover, it was practically made for this purpose!

This only worked on the French roads, which were impeccable, with only two potholes observed. Belgian roads are a different kettle of shitey fish altogether.
Entered NL, and took a quick photo whilst adding to the PC.

And triumphantly arrived 45 minutes later at my destination, staying with my brother @chatsharris and his wife who has recently had a baby.
The Rover was absolutely faultless, it worked an absolute treat the entire time and I definitely made the right call to take it. Even the seats that were a bit firm at the beginning, became supportive in the end.
PC: 7, with one false start.

I've driven it a few miles around Bristol and so far I like it. I havent driven a P38 for 10+ years but remembered instantly why I liked them. 
It is in rough condition and that's why it was cheap, however the important things are good. Steering feels just how it should, engine is how it should be and I'm amazed how good the gearbox is. You cannot detect gear changes apart from by watching the rev counter. The air suspension is just right too - these cars really lose part of their character when they're on coils. The air suspension is excellent 
 

HMC's P38! 
 

Deepest darkest Herts. July 2021. Just out for a drive on a pleasant evening.

I miss Fred, I don't know how you'd even get that built let alone stand on it 

You'll have to wait for the sound video because I just did this.



The wiring on this was getting on my tits.  Had a lot of instances whereby things work but not quite all the time, or fuses randomly blowing.  The original factory wiring is shite. I have now ripped out EVERYTHING.
You can see on the right here that the back of the fuel gauge stands in as an unfused positive terminal for almost everything under the dash including the wiper motor, indicators, heater fan and who knows what else, held on by a piddly 6mm nut. That is going to change.

I present the main light switch. Again, unfused and permanently live, with the permanent live cut and twisted into the feed to the small footwell lights, from factory.

The big feed to the wiper switch. Again, some dodgy chaining of big positive wires going on here.

The circuits which are fused are run off a shitty engine bay fusebox which is riveted together, and the rivets are starting to come loose causing random dropouts. That and the small issue of continental/glass fuses being total shite and hard to come by when you need them most.
Solution : bin off the fusebox in the engine bay, and run everything off a pair of blade fuseboxes inside the footwell.

The fusebox on the left is the permanent live one, which will run the interior dome light, indicators / hazards, and headlamps.
The box on the right will be ignition switched, but I am also going to add a main ignition relay so that the ignition switch isn't constantly handling all of the current running through the entire car.  I know it's designed to take it, but the switch (and key!) can get very hot and I'm just waiting on the contacts burning out, especially if I decide to add any more load in the future.
The important thing is that everything is going to be fused, and that the fuses are going to be easier to replace when needed.
I seem to be doing this all off the top of my head, WCPGW.

As its mostly pensioners on our street I like to go first and put the wrong bin out so they all copy me, then swap it round about midnight when they're all in bed - I'm going to hell aren't I?🤣

Well that didn’t go well!
On the way back from Flowers Farm the Sigma temp gauge started rise but as I was on a dual carriageway with no hard shoulder I carried on the 2 miles to the first layby. When I stopped there was steam wisping from under the bonnet.
The AA arrived and diagnosed a split water hose to the oil cooler. He had the right size hose and soon fitted a bit. Unfortunately when I went to restart the Sigma it simply pushed water out of the radiator and the diagnose was head gasket. He towed me to FoD on his dolly.
After all I have said about the service of Recovery firms the AA after a shaky start trying to contact them were great. The roadside patrol turned up in 40 mins was helpful and fixed the original problem. When that didn’t work he towed me to the FoD and then took the wheels I was carrying for @Flat4 and me home.
9/10 with the 1 point lost for the hard time trying to contact them 4 times, listening to all the spiel and press 1 for a long wait, 2 to be cut off..........

From the world bollard association twitter page.

I've copied and pasted these initial updates from another forum.   
 
This goes back to 2021/early 2022. First two posts will cover the back story and then I'll add what I've been doing to it this last month.  There's been quite a delay on this because my wife became very ill in mid-2022 and all life turned to making sure she came through her illness (which she has, all-clear been given etc etc).  Life is sort of back to normal (although i'd argue that something like that changes life and perspectives across the entire family.  Not sure what normal is now tbh).  
So back to 2021..............I've wanted to have a build thread of my own for years but I've never had a car that I felt had sufficient interest (or age) to warrant a thread.  But Covid changed my attitude - felt that life can be so precarious that I really had to step up my search for something.  I live in West Wales and alot of my local friends are electricians or carpenters or plumbers.  They go to a lot of houses and farms.  I told them all to look out for anything under a cover or tarpaulin or looked a bit forgotten that to give me a ring.  In 2022  I got a call about this car from one of the lads.  He didn't know what he was looking at, just that he knew it needed saving and 'it looks quick'!  

I met the owner (whom used to use it quite often but then his life took a turn for the worse and it had to be set aside to prioritise other things going on - totally understandable) before xmas 2021 and agreed a deal and paid a 10% deposit....then  xmas and life got in the way and it was only today that I was able to go and pick it up.  The plan is to ignore the exterior for the moment.....and just get the interior dry and all fitted out (I've got all the parts but he did the headlining and then life got in the way and some of the interior needs putting back). 
 
I've got a couple of dehumidifiers coming to help with the drying out too.  I then am going to get the car mechanically fettled and then MOT'd.  Once it's MOT'd then I'm going to use it for business meetings, day trips with the kids, charity runs, going up to North Wales to see my Dad and Devon to see my mum etc etc..  

Some initial pictures - bear in mind it was under a tarp(for 3 years, with the passenger window open..........) right up until the point you see these pictures. 
 
We got it into my shed and onto the ramp to see what we had.  The interior needs a lot of fettling.  On to the next instalment.  

Slow drive down. The M25 was horrendous. However, a collection has occurred. I'm in love already!
 

I've been looking forward to this day for the past two months.
Once the Sierra was back on its wheels, I undersealed the jacking points that were concealed by axle stands / ramps.


The other side is the same.
It was time to pull the Sierra out of the workshop. As the underseal was still fresh and the car isn't taxed, I only drove the Sierra to the end of the road and back to outside my house to take photos.
At this stage, I recommend that you rewind to page 4 of this thread and remind yourself what the Sierra looked like on the 30th January, the day it arrived from Northern Ireland. I am pleased with the results and I'll let the photos do the talking. Please note that I haven't washed or detailed the bodywork and trim yet, hopefully I will get a chance to do that next weekend.






The bonnet, roof and boot lid look much better in sunlight than they do under a LED lamp. Yes, if you look closely and at the right angle, you can see the fine scratches but overall, the paint looks great.



Remember how the four corners looked? The tarpaulin that the Sierra was stored under rubbed the blue paint off down to primer / bare / rusty metal. My masking off and dabbing of blue paint has worked well. Up close, you can see the touching up but I am pleased with my low cost solution.




The sills and inner sides of the rear wheel arches look much better too.




The boot lid and rear valance now gleam.

I left the engine to idle for about 15 minutes and it ran well, nice and quiet, with no smoke. The temperature gauge reached half way quickly (and stayed there) but the coolant level was still low. The idle speed is a little too fast, I need to work out which screw needs a tweak.

With the Sierra outside, it took me two hours to clean the workshop. EVERY surface was covered with a layer of black overspray dust, which spread when I was painting the bumpers. Got there in the end.

I put the Sierra back in for another week, until it can be taxed and driven from the 1st April.

The 1st April is a Monday. According to the forecast, the weather should be dry. Let's hope so.

 

Nice!

Last few days has seen a bit more done to various models.
FG recovery truck has been converted to rhd. Quite easy to do on this one, just a bit of messing around to get the steering column out of the floor on the other side. Just need to sand that big lump of moulding flash off the instrument cluster!

  
Lada Riva got painted in authentic Lada Adriatic blue!

  
Which strangely dried overnight darker!? I wish it’d have stayed the lighter colour.

Sierra estate is now in Ceramic blue. It looks brighter on the photo than it really is, but I hope the grey trims etc help tone it down a bit! 
Im pretty sure this shade must have faded quite a lot with age, as it seems to have a slightly purple-ish tinge to it on real cars. But I suppose the paint is going on 40 odd years old on them now!

 
Dodge RAM pickup is being put back together. 
I did the bumpers in molotow pen chrome and the grill unit in silver paint as that’s normally in that duller painted plastic silver on real ones. Cab back wall is painted too. I’ve had to paint the inside of that black as it’s made from clear plastic and you get lots of light bleed through it if the suns on it.


 
Dinky Volvo has had its wheels refitted and new tyres. Wheels are Dinky Transit wheels.


Ford F100 is about ready for being put back together. Hard to photograph this and get the metallic sparkling from it but you can just about see it in places. 
I had to paint the cab twice! Had it sat on the side while I was painting the Sierra, shook the can of blue to mix it and the nozzle must have been on loose and a jet of the blue paint and propellant shot out and landed directly on the F100 cab side! Being fresh paint it melted and went funny. I was mighty pissed off I can tell you. Lots of words that rhyme with ‘duck, ducking and hunt’ were said…


 
Converted a few interiors to rhd too ready to refit.

 
And stripped one of those cheapy DelPrado mk1 Capri’s which came from some collection or another. 
These aren’t actually too bad with the old paint gone. Originally they’re in a horrible gun metal grey colour. Why they picked that colour for these is anyone’s guess as it really doesn’t show off a Capri’s shape at all. A Capri wants bright blues, greens, reds, yellow etc etc not dull boring dark grey! 
I think with a bit of extra detailing and a better colour paint job it’ll look just fine!
No prizes for guessing what colour this one will be getting! 
A clue is: I conveniently already have a can of it…