fordperv

I've not been able to do anything due to the weather piddling down, but i have got my replacement rear shocks
 

Another couple of hours spare and another job ticked off unfortunately no pictures because im pants, today I have had the interior in bits to run the wires for an electric fuel pump, to the relay and mount it under the dash, the live feed is now in the boot ready to be plugged into the pump, i then put the interior back together, also thought about the position for the pump, im thinking of putting in the boot under the false floor on the passengers side, it just seems a safer place to pop the pump rather than have it sitting under the car due to their being no decent places which aren't too close to the exhaust or the axle, I've just got to get some fuel hose, gromets and a step drill to make the holes for the hose then I can put the pump in

Well A couple of hours spare earlier, the vinegar bath on the headlight connectors did the job, after I washed it off and dried I gave the connections a thorough clean with electrical contact cleaner to make sure they were spotless, I also had to clean the stalks as main beam was working on the flash but not on the click forward position, I now have a full compliment of lights

 
Also I got around to replacing the tca to crossmember bolts as one of them was worse for wear, I also wired up the replacement electric aerial I've fitted, I also replaced the CD player for a tape player.
 
I'm trying to chip away at the little jobs while im waiting for a few bits

I had an hour or so to spare earlier so hoovered the crap I could access in the engine bay, re ran the wiring to the headlights etc, checked and changed wiring earths that looked suspect, also as a funny gift the in laws got me some Dixie horns so I fitted these for a laugh as well, found a little problem with plug for the passengers headlights and the indicators while I was there they had corrosion but that's where I left it today as the dark was coming in and it was blooming cold, next time I'm going to give them a few hours in white vinegar then contact clean them to see how it goes before I replace them

Well it's been a while on this unfortunately it took the back burner while I was welding mrs fps rs turbo up, now the weather is turning crap for welding and that's under cover im going to try and focus on getting the engine in this
 
Since I last updated ive decided to go carbs, so got a bogg bros manifold with a correctly jetted set of zx9r carbs, fuel pump and pressure regulator and the all important ignition controller, I went for the nodiz unit which comes with a terminated loom for the XE
 
Look how small the unit is, it will be easy to hide

I suppose the difference of length is made up by being a higher pound rating so they compress less

Well since photobucket has gone all hostage situation with pictures ive been reluctant to update build threads, I have been chipping away at this,
 
I've rebuilt the front suspension with new inserts and -2" springs (it's what I already had in the shed so have spent no actual money)
 
The difference in length of the springs
 

 
I also have prepped and painted under the front wheel arches to tidy it up a bit, here one is with the strut built back up in it, ive still got to paint up the arb, it's having caliper spacers and 2.8i discs thats why I havnt painted the caliper yet or put new disks on (im also replacing all the pipes while im at it and fit the 2.0 servo and landrover master cylinder I have)
 

 
Back on its wheels this is the arch gap im left with
 

They aren't the wheels that are staying on
 
I have done more than i can remember to tell everyone about, all the welding at the front is complete and the only welding left to do is the rear panel when I buy one, but im going to focus on the engine conversion next.

Even though I havnt been updating my thread i have been cracking on with jobs, I have finished the welding to the drivers inner wing where I needed to repair the strengthening plate and behind in the engine bay, but to gain access i had to remove the radiator mounting panel, then fitted the new slam panel,
 

 
I also repaired the passengers strut top
 

 

 
After this I cut off the sill back on the passengers side, the lower quarter, also repaired the inner wheel tub where there was a peppering of rust, I also cut a rust scab from the bottom of the quarter where it meets the arch just above the sill
 
This was a scab until I hit it a few times with my corrosion assessment tool
 

 

 
I've still got to do those 2 scabs in the arch lip, for information purposes it appears to be on its original rear arches
 
I have also stripped the interior out to check for any areas requiring repair, cut out corrosion on the rear floor pans both sides just where the double skinned area is before the rear spring hanger, where they all rot but it wasn't too bad to be fair, I reproduced both skins and zipped it all up, I didn't take a picture of this though
 
While the seats were out i cleaned them up, these were from the LS breaker i bought to cut the front corner off so I could repair this
As you can see they were minging
 

 

 

 
A side by side comparison

 

 
Earlier on i cleaned the carpet and plastics then built the interior back up
 

 
 

 
Under the rear drivers sound deadening i found the remains of an original build sheet, the car mustve got damp years back and damaged it, mrs fp put the pieces back together for me while i was working on the car
 

 
 
There might be a couple of jobs ive done that ive missed off

Cheers mate yeah my eye is sound, ive done it a few times in the past, the ski mask type goggles failed me, they were a generic no brand though, seen some decent looking dewalt ones online so will get them ordered up

Today's job was to repair the inner wing and under the scuttle, again this side i had to replicate the 3 separate skins, this is what I cut out
 

 
After I welded that up i proceeded to cut the wing rail off, unfortunately whilst i was doing it i got a bugger of a spark shoot through my goggles and lodge itself in my right eye so a trip to a&e was required to remove it, when I got back i popped back out and welded the replacement rail on and added the inner wing to strut strengthener as per the other side
 

 
I'll grind the welds back another day, the only part i ground back was behind where the strengtheners is mounted so it sits nice.

While there's been radio silence I've been chipping away at the old girl, she is now a runner thanks to a nodiz gen X ecu and a new bosch crank sensor, i was having an issue with the other ecu which was out of warranty, it wasn't recognising a crank sensor on vauxhall trigger pattern, I tried numerous crank sensors, sutty2006 kindly let me borrow his crank sensor which was the correct VR type but still no joy, i sent it away to get tested they could find no fault it fired correctly on the test rig, it had us baffled the only thing came up with if the signal wasnt clean enough so it was saying computer says no, the kind chap at the manufacturer offered me a good discount on the gen X which has a diagnostic function and a better software on the laptop to set it up so would show up any issues and it would have warranty also gives me access to support if any issues arise, it was a nice and easy with no fuss installation and it fired up, since the video I have messed about with the carbs as the air valves had been blocked and it was overfuelling like a bitch so now runs a little more even, I suspect there's a little air leak through the silicone hose between the carbs and manifold as the flouro lining is damaged on a couple of them so I will get some ordered up so I can balance the carbs and set the fuelling.

20220720_215750.mp4 getting the car running showed the radiator was no where near man enough for the C20XE so ordered up an alloy rad from ebay, the delivery was speedy, initially they sent me the thinner one when I had ordered the thickest core diameter they list but they soon sent me out the correct one and collected the wrong one
A little difference in diameter 
looks well in the engine bay, a small modification was required with the grinder to fit but nothing major
i also fitted the electric cooling fan and wired it up, got a choke cable and installed it in the original dash blank grabbed a grommet for the wiring and installed the ecu in the glovebox so it's all tidy

While the forum was down i added a strengthener from inner wing to strut turret the same as were fitted to v6 shells, it was roughly the right shape but required dollying to get the correct shape you can see the difference here
 

 
All fitted
 

 
Today when I had finished at the gym the rain had stopped so I cracked on removing the drivers wing, I had no nasty surprises under there, in fact it was better than I expected
 

 
I sprayed a little primer to protect bare areas id made, it rained shortly after this picture so got to wait for the next dry opportunity

Well today's job was to remove the rest of the old slam panel sort the fitment of the wing and trial fit the panels, the wings i am using are pattern because this is not a money no object build, im simply making a tidy usable car they are old pattern not this new Shoite they are selling now, I had to hammer and dolly the back edge where it fits to the scuttle to close up the gap at the top edge of the door and the edge at the bottom by the door gap to bring it in line, as with any great magician i utilised my glamourous assistant (mrs fp) to help me put the replacement bonnet on and to get the gap right to the drivers wing that hasn't been disturbed so I know it's true, then proceeded to offer the front panel up, get the gap for the wing then drill and bolt it in place, im quite chuffed with the results
 

 
I'll have to do a little dollying around the headlamp aperture to make it as perfect as i can, im around 50 hours in on it now which I don't think is bad going

Well it was dry today so i decided to fire into another couple of jobs on the front panel, both ends where it meets the wings were rotten
 

 
Repair section
 

 
Welded in

 
2 patches were required lower down as well, ive got to trim the length of the repaired parts at the top as well
 

 
Whilst I was doing this mrs fp popped out with a parcel for me, it was the sill end repair panels from danthecapriman (thanks alot bud) so i proceeded to do the passengers side to complete the repairs there
 

 
I cleaned up and sorted the rest when i had took the picture
 
Repair patch i made up for the edge
 

 
All done, i may have to cut the lower lip off a little but that can come when i fit the wing and ill grind the welds down another day
 

A couple of hours to kill earlier so decided to do a bit on this, i made 1 or 2 small holes on the a pillar behind the wing so cut the area out
 

 
The inner structure cleaned up nice, most of the area i removed was shiney steel but there was a rust peppering
 

 
A bit of hot metal glue
 

 
Welds flapped back a bit and primered, i havnt flushed them properly, this will get done at the prep and paint stage
 

 
I also let a patch in just under the scuttle but it was that small its nothing to write home about, next up the bulge at the front of the sill, i hit it a few times with a hammer and made a hole but im in no way surprised, the kind offer of the repair panels from danthecapriman is a godsend, i am surprised at how good the regular capri rot spots are though I expected to weld much more

This car is pretty solid as they go to be fair, i peeled the carpets back and its still nice under there so it's mainly cosmetics, originally it was a 1.6 but i popped a 2.0 in there, i am putting a C20XE in for a bit of a giggle, im going to run it on it's original injection, it will probably upset the purists but im not doing anything thats not reversable, ive got everything now for the conversion except a clutch and exhaust manifold, i havnt dug at the sill end yet but it will no doubt have some grot in them they all do, what do you want for them? Drop me a pm if you want

Right folks its about time i introduce you all to my capri project thats been sat at my mums for a few years, ive had this car since 2008 as all of you will remember this was before they became subject to omgoldfordtax
 

 

 
I loved driving this car looking down that long bonnet
 

 
 
 
it was my daily car up until 4 years ago when i had an unfortunate accident, a roundabout was covered in diesel, i went around and understeered and hit a railing, there was nothing i could do
 

 

 
The accident crumpled the inner wing, headlamp bowl, wing, valance, bumper, it bent the steering arm, buggered the rack and arb mount, a good mate popped up and we heated the headlamp bowl and pulled it straighter with a chain and pulley on a telegraph pole, another mate whose a breaker raided his parts for replacements for me and i got it looking like a car again so i could drive it, my insurance cat c the car but i wasnt too fussed, i drove it up until the m.o.t ran out then parked it up at my mums to work on as i had no space, i started collecting as many new parts as i could for it, i even bought another to break in my neighbours drive which i cut the inner wing out of as a repair section, the only downfall is mum works nights so i cant start tin bashing in the day, so i mainly did mechanical things, she used to get no end of people door knocking to buy it, a week ago I decided to make some space and actually fire into it, so i popped up put a battery on and she fired into life, the brakess were still free, it's like it was just waiting to be saved
 

 

 
I then proceeded to strip it down, Look at the twist in that headlamp bowl
 

 

 
surgery begins
 

 

 
I also had to do a rust repair to the inner wing and the strengthener but havnt got a picture
 
 
 
Bring in the replacement
 

 
Grafted in
 

 
You notice the wing rail is rotten but before i could replace that i had to repair a common rot spot, i replicated all 3 skins as i wanted it to be spot on
 

 

 
Then it was time for the wing rail
 

 
The rust marks you can see in the pictures on the crossmember etc are literally that, a tickle with the flap disk and its clean steel
 
 
We're pretty much up to date with the repairs, i'll update when i can, when everything is done metalwork wise, im going to be doing an engine conversion to give it a little more go

That looks a lovely machine, picked up its 5 door brother for a mates Mrs a month or so back, drives absolutely beautiful 
I can confirm it's a 205 with a working analogue clock 

That looks a lovely machine, picked up its 5 door brother for a mates Mrs a month or so back, drives absolutely beautiful 
I can confirm it's a 205 with a working analogue clock 

That looks a lovely machine, picked up its 5 door brother for a mates Mrs a month or so back, drives absolutely beautiful 
I can confirm it's a 205 with a working analogue clock 

While there's been radio silence I've been chipping away at the old girl, she is now a runner thanks to a nodiz gen X ecu and a new bosch crank sensor, i was having an issue with the other ecu which was out of warranty, it wasn't recognising a crank sensor on vauxhall trigger pattern, I tried numerous crank sensors, sutty2006 kindly let me borrow his crank sensor which was the correct VR type but still no joy, i sent it away to get tested they could find no fault it fired correctly on the test rig, it had us baffled the only thing came up with if the signal wasnt clean enough so it was saying computer says no, the kind chap at the manufacturer offered me a good discount on the gen X which has a diagnostic function and a better software on the laptop to set it up so would show up any issues and it would have warranty also gives me access to support if any issues arise, it was a nice and easy with no fuss installation and it fired up, since the video I have messed about with the carbs as the air valves had been blocked and it was overfuelling like a bitch so now runs a little more even, I suspect there's a little air leak through the silicone hose between the carbs and manifold as the flouro lining is damaged on a couple of them so I will get some ordered up so I can balance the carbs and set the fuelling.

20220720_215750.mp4 getting the car running showed the radiator was no where near man enough for the C20XE so ordered up an alloy rad from ebay, the delivery was speedy, initially they sent me the thinner one when I had ordered the thickest core diameter they list but they soon sent me out the correct one and collected the wrong one
A little difference in diameter 
looks well in the engine bay, a small modification was required with the grinder to fit but nothing major
i also fitted the electric cooling fan and wired it up, got a choke cable and installed it in the original dash blank grabbed a grommet for the wiring and installed the ecu in the glovebox so it's all tidy

Holy thread resurrection batman
 
Well folks I've not been on here for a while, life has happened, thought I'd update this as I've recently dragged it from my mums where I covered it up and forgot about it.
 
So where we are at currently 
I dragged it out to set on with the engine conversion, fitted longer studs and spacers so i could put the 7 spokes on, then washed all the crap off it
I then got the engine in the hole, I used a 1.8 manta sump and pickup pipe, knocked up the mounts, the passengers side is a 4 cylinder capri mount cut and welded, the drivers side is a 2.8i mount cut and welded so the engine sits right, the head in this picture was just a mock up head
 
for the exhaust I have used an Ashley mk2 escort item with a 2.5" outlet, the only down fall is the tail of it pointed at the floor so modification was needed, I cut a wedge out of the tail pipe of the manifold to get it in the correct position then I re welded it, the exhaust system is a stainless one meant for a pinto cut at the centre section then pipes welded to suit so it all connects
 
i didn't like how the tail sat so chopped that off and re welded it at a more aesthetically pleasing position 
 
the cylinder head i fitted was a ported one which i had replacement valve guides fitted then put back together 

 
It needed the distributor mount cutting off the rear as it would have fouled the heater bubble, so did this, blocked the hole in the back with a suitable size core plug, chopped the back of the cam tapped it then blocked with a bolt, tapped and bolted the oil feed for the dizzy, and fit a 90° water outlet in the back of the head, so I can feed the heater
The fuel lines are sorted as is the starter wiring, throttle cable modified, knocked up a few bits and bobs and sorted the top coolant hose, I'm waiting for a hose joiner and then can finish the bottom one, it's literally a case of finish that, fill with coolant, connect up the wiring, set the ecu up on thelaptop then fire it up

I have modified the engine to fit the car, nothing on the cars structure or crossmember have been modified to fit it, it can quite easily have a pinto put back in it if I wish.
 
Thats us up to date I may have missed a few steps and bits I've done but I tried to condense where I'm up to.
 
 

While there's been radio silence I've been chipping away at the old girl, she is now a runner thanks to a nodiz gen X ecu and a new bosch crank sensor, i was having an issue with the other ecu which was out of warranty, it wasn't recognising a crank sensor on vauxhall trigger pattern, I tried numerous crank sensors, sutty2006 kindly let me borrow his crank sensor which was the correct VR type but still no joy, i sent it away to get tested they could find no fault it fired correctly on the test rig, it had us baffled the only thing came up with if the signal wasnt clean enough so it was saying computer says no, the kind chap at the manufacturer offered me a good discount on the gen X which has a diagnostic function and a better software on the laptop to set it up so would show up any issues and it would have warranty also gives me access to support if any issues arise, it was a nice and easy with no fuss installation and it fired up, since the video I have messed about with the carbs as the air valves had been blocked and it was overfuelling like a bitch so now runs a little more even, I suspect there's a little air leak through the silicone hose between the carbs and manifold as the flouro lining is damaged on a couple of them so I will get some ordered up so I can balance the carbs and set the fuelling.

20220720_215750.mp4 getting the car running showed the radiator was no where near man enough for the C20XE so ordered up an alloy rad from ebay, the delivery was speedy, initially they sent me the thinner one when I had ordered the thickest core diameter they list but they soon sent me out the correct one and collected the wrong one
A little difference in diameter 
looks well in the engine bay, a small modification was required with the grinder to fit but nothing major
i also fitted the electric cooling fan and wired it up, got a choke cable and installed it in the original dash blank grabbed a grommet for the wiring and installed the ecu in the glovebox so it's all tidy

Holy thread resurrection batman
 
Well folks I've not been on here for a while, life has happened, thought I'd update this as I've recently dragged it from my mums where I covered it up and forgot about it.
 
So where we are at currently 
I dragged it out to set on with the engine conversion, fitted longer studs and spacers so i could put the 7 spokes on, then washed all the crap off it
I then got the engine in the hole, I used a 1.8 manta sump and pickup pipe, knocked up the mounts, the passengers side is a 4 cylinder capri mount cut and welded, the drivers side is a 2.8i mount cut and welded so the engine sits right, the head in this picture was just a mock up head
 
for the exhaust I have used an Ashley mk2 escort item with a 2.5" outlet, the only down fall is the tail of it pointed at the floor so modification was needed, I cut a wedge out of the tail pipe of the manifold to get it in the correct position then I re welded it, the exhaust system is a stainless one meant for a pinto cut at the centre section then pipes welded to suit so it all connects
 
i didn't like how the tail sat so chopped that off and re welded it at a more aesthetically pleasing position 
 
the cylinder head i fitted was a ported one which i had replacement valve guides fitted then put back together 

 
It needed the distributor mount cutting off the rear as it would have fouled the heater bubble, so did this, blocked the hole in the back with a suitable size core plug, chopped the back of the cam tapped it then blocked with a bolt, tapped and bolted the oil feed for the dizzy, and fit a 90° water outlet in the back of the head, so I can feed the heater
The fuel lines are sorted as is the starter wiring, throttle cable modified, knocked up a few bits and bobs and sorted the top coolant hose, I'm waiting for a hose joiner and then can finish the bottom one, it's literally a case of finish that, fill with coolant, connect up the wiring, set the ecu up on thelaptop then fire it up

I have modified the engine to fit the car, nothing on the cars structure or crossmember have been modified to fit it, it can quite easily have a pinto put back in it if I wish.
 
Thats us up to date I may have missed a few steps and bits I've done but I tried to condense where I'm up to.
 
 

While there's been radio silence I've been chipping away at the old girl, she is now a runner thanks to a nodiz gen X ecu and a new bosch crank sensor, i was having an issue with the other ecu which was out of warranty, it wasn't recognising a crank sensor on vauxhall trigger pattern, I tried numerous crank sensors, sutty2006 kindly let me borrow his crank sensor which was the correct VR type but still no joy, i sent it away to get tested they could find no fault it fired correctly on the test rig, it had us baffled the only thing came up with if the signal wasnt clean enough so it was saying computer says no, the kind chap at the manufacturer offered me a good discount on the gen X which has a diagnostic function and a better software on the laptop to set it up so would show up any issues and it would have warranty also gives me access to support if any issues arise, it was a nice and easy with no fuss installation and it fired up, since the video I have messed about with the carbs as the air valves had been blocked and it was overfuelling like a bitch so now runs a little more even, I suspect there's a little air leak through the silicone hose between the carbs and manifold as the flouro lining is damaged on a couple of them so I will get some ordered up so I can balance the carbs and set the fuelling.

20220720_215750.mp4 getting the car running showed the radiator was no where near man enough for the C20XE so ordered up an alloy rad from ebay, the delivery was speedy, initially they sent me the thinner one when I had ordered the thickest core diameter they list but they soon sent me out the correct one and collected the wrong one
A little difference in diameter 
looks well in the engine bay, a small modification was required with the grinder to fit but nothing major
i also fitted the electric cooling fan and wired it up, got a choke cable and installed it in the original dash blank grabbed a grommet for the wiring and installed the ecu in the glovebox so it's all tidy