Jump to content

Korean Cortina - WTF is going on with my cooling system?


Recommended Posts

Obviously not:


The vehicle details for E591 BRM are:


Date of Liability 01 12 2014

Date of First Registration 10 05 1988

Year of Manufacture 1988

Cylinder Capacity (cc) 1597cc

Vehicle Status Licence Not Due

Awesome!! You hearing this Felly? It liiiiiivvvvveeeessssss!

Link to comment
Share on other sites

Best wishes with the resto of the Stellar, mat_the_cat! :)


Restoring a Stellar - good stuff. The last ones were on a J plate although the supposed replacement (Sonata?) was launched well before then.


The Stellar was replaced in 1991/2 by the Lantra. The Sonata was introduced in 1989 as a rival to the Ford Granada although priced more in line with the Sierra.

Link to comment
Share on other sites

I did see a pretty minty looking gold Stellar at Stanford Hall last summer





Didn't that end up getting raced?



Obviously not:


The vehicle details for E591 BRM are:


Date of Liability 01 12 2014

Date of First Registration 10 05 1988

Year of Manufacture 1988

Cylinder Capacity (cc) 1597cc

Vehicle Status Licence Not Due


I just googled "e591 brm banger racing" and it came up with a load of links to some darryl hanah porn-o-like films

Link to comment
Share on other sites

So I'm not the only one then...although that is considerably tidier than mine!


I've been Googling this evening for the nearest Hyundai dealer as there are a couple of bits I need which I'm struggling to find elsewhere. The handbrake cable is similar to that for a Cortina, but not a direct swap so I'll try and find a genuine one before I modify the brackets on the floorpan. The other thing is the choke cable, which IIRC (when I last changed it several years ago) is moulded onto the knob, which contains the switch for the warning light. Plan B would be Speedy Cables though.


Anyway, I've just noticed there is a Hyundai dealer in Aberystwyth, and seeing as the plan is to have it ready to bring to Shitefest, this might be worth a detour for the photo opportunity!

Back to the car - I've just welded in a patch at the back of the rear wheel arch:
Not my neatest job, as I blew through in a couple of places...I cut the patch too small and had to grind back rather than cut out some rust on the surface.
The area above the fuel tank is now free of rust and coated in underbody wax, so that can go back in shortly:
And the propshaft is now fully rebuilt with 3 new Ujs and a new centre bearing & rubber:
New UJs fitted with grease nipples, which pleases me immensely :-)
Link to comment
Share on other sites

Question time for any Cortina experts - I'm putting the tank back in after about 8 years, and I have a problem. It seems like the tank straps are too short, and WAAAY too short at that, like a good 8". From what I can tell it looks identical to a Cortina set up, and may even be the same tank. Basically two hockey stick bolts hanging down at the front and two straps, each with a kind of fat T shape at the rear end.


As I remember(!) it, they just engage directly into slots in the rear crossmember. But then it doesn't reach the front! Only thing I can think is that there is another piece missing, which goes between the strap and the shell. But I don't remember this, and there is nothing like this in the box I got the straps out of.


Off to do a Google image search, but if anyone has any bright ideas I'd be grateful...

Link to comment
Share on other sites

A picture paints a thousand words and all that...






You can see how much longer the straps need to be, but I just don't understand it! It did cross my mind that maybe they're from another vehicle, but they were in the back of the Stellar, and painted at the same time as the tank (I can tell because I was running short of black Hammerite at the time, so the first coat was yellow which I had lots of!)


I'll just have to cut and weld them, but it doesn't feel 'right'.

Link to comment
Share on other sites

Looks pretty much identical to mine, aprt from the fact they fit that is! There must be something missing at the rear end to go between the strap and the crossmember - even though the strap fits in the crossmember, when it does the right angle at the front end of the strap won't reach to the front edge of the tank. Cut 'n shut will sort it!


Bad news is that both the handbrake and choke cables have been discontinued, and I don't even have the original handbrake cable as a pattern. Slightly better news is that I got the part numbers, and did a spot of Googling. No joy with the choke, but I was able to find a list of OE manufacturers who made the cable for Hyundai, and their part numbers. So I searched for those in turn, and bizarrely found one (made by Kavo) listed on UK Amazon. I duly bought it, but the delivery time is given as 3-4 months, so I guess it has to come all the way over from Korea!!! Presumably by rowing boat.


Still, plenty of stuff to do to keep me busy...

Link to comment
Share on other sites

Back when I stripped down the front suspension, I used an oxy acetylene torch on the lower wishbone bolts, bending one and shearing off the other when I tried to undo it. I wasn't especially worried, as everything up to then had been Mk 3/4/5 Cortina and hence easily available. But no, they apparently had a plain hole in the crossmember and a standardish bolt. Even 10 years ago Hyundai had discontinued the bolts, although they helpfully charged me an arm and two legs for the wrong part.


The Stellar has a slotted hole in the crossmember, so the correct bolts have an offset washer on each end so the position of the pivot point can be adjusted. Nothing for it but to get something made up!




When it came to moving house and getting the car on the trailer, I had to just put standard bolts in to assemble the suspension and roll the car - now I can finish the job properly. As well as replacing all the ball joint boots!


It might seem like I'm taking a fairly random approach to working on the car, but I find that if I have several jobs on the go at once, if one goes badly or starts pissing me off, I'll always have another to start on. So it keeps my motivation up, which is partly what caused the whole project to stall in the first place. That and getting married, moving house twice, and two house renovations...

Link to comment
Share on other sites

Today's job was a bit of a bodge, but at least I've sorted the petrol tank straps! We have lots of galvanised joist hangers around left over from some DIY on the house, so cut a couple of pieces from them as they were similar thickness, then cut the straps and welded them in.




Folded the edges over and welded the other side:




It'll all be hidden by the rear bumper anyway, so I'm not too worried about appearances. Paint should be dry by tomorrow so the fuel tank can be fitted properly.

Link to comment
Share on other sites

Chipping away at things bit by bit - fuel tank now in properly:




Put a fair bit of tension in the straps, and it is rock solid; I can shake the tank and the whole car moves. One more job crossed off. But before I can put the back bumper on there are a few areas needing welding - the back of the other wheel arch, and a spot below the nearside rear light. Managed to pretty much weld a patch in, but ran out of gas right at the end hence the splatter!




I'll rig up a mini bottle tomorrow, as it's an 80 mile round trip to anywhere doing decent sized gas bottles.

Link to comment
Share on other sites

  • 2 weeks later...

It's not very exciting, but so far this week I've replaced a couple of exhaust manifold to downpipe studs, which I'll use brass nuts on. That way any thread damage should be confined to the nuts and not the studs - plus if they round off or won't undo, they'll be a piece of cake to cut off.


I've also painted and refitted the engine under shield, which is surprisingly weighty!




Still loads of welding to do, but I reckon I'll take a few days off work to tackle that. In the meantime I'm working away at small jobs to keep my motivation up - if it feels like the rest of the car is nearly there when I start the metalwork, it'll be an added incentive to get it finished.

Link to comment
Share on other sites

Bugger. Spent a couple of hours trying to bleed the brakes (and finding all the unions which needed tightening!) with my Easybleed kit, but still got a soft pedal. I'm almost out of fluid now, so think I'll get a spotless container so I can reuse what comes out next time I try! Might see if I can rope in an assistant too, but pressure bleeding has always been quicker and more effective for me before. This is the first time I've started with a completely empty system though - recon front calipers, new rear wheel cylinders, new stainless hoses and 95% of the pipework is new - so it may be normal to be a PITA getting all the air out?


No photos, as I'm sure you can imagine what brake bleeding looks like...

Link to comment
Share on other sites

I bought a vacuum bleeder for my motorbike - it can be used on cars as well.


A piece of piss to use and a one man operation.


You can get one for around £20.


As for the earlier "not very interesting", on the contrary, I am really enjoying the thread.


The stellar was underrated and now very rare.

Link to comment
Share on other sites

Thanks for the kind words :-) Hoping to have more positive stuff to report next week when I can get back to it. I've got a section of ball joint boots which I need to fit, and hopefully a handbrake cable on the way.



What is he building in the dormer?? - some welding/grinding action sparks LOL


Ha ha! I should have asked!

Link to comment
Share on other sites

Had a bit of trouble getting a firm pedal on an estate car once - after a bit of a think, it was the rear balance valve (allows more pressure to the rear brakes when the car is loaded) this needs to be held in the open (loaded) position  whilst bleeding 

Link to comment
Share on other sites

If only I had such advanced technology! Good shout though, but I'm sure that with a fresh look at it things will be better. I often find that I'll walk away from a problem, come back to it and sort it straight away. In which case why do I find it so bloody hard to walk away in the first place?!

Link to comment
Share on other sites

The interior has actually held up pretty well for its 186k miles (the majority driven by me) - OK the steering wheel has worn smooth but the only fabric wear is a small patch on the edge of the driver's seat base. I actually have a piece of matching fabric which I will probably use to get it repaired at some point. The strange thing is I can't remember how I obtained it! I'm guessing I cut it from a scrap car but certainly don't remember doing so...


The £12 bargain handbrake cable arrived today so I set about seeing whether that would fit. At first it all looked good and fitted all the brackets perfectly. But when I came to attach it to the lever it turned out it was slightly too short (being for the '86 onwards models). At least that was an easy fix, as I just drilled out the head of an allen bolt and welded it on the handbrake rod to extend it a touch:




And now for the first time in 10 years, it has working brakes! Another photo of shiny bits:




I haven't had another go at bleeding the brakes (you can see the tubing in the above picture) but I have at least found out where the air is. Pretty sure it's in the rear wheel cylinders, as I can compress then easily with my fingers. And I'm wondering whether it's down to the way I've plumbed them in? The only other beam axled drum braked vehicle I have is the van, and that has the flexi hose going to a T piece, and then rigid lines going to each cylinder.


I really can't remember what arrangement the Stellar used to have, but now I've plumbed it with the pipe going to one cylinder, then a second pipe coming out from where a bleed screw would normally be and on to the opposite cylinder. It's so long since I did the pipes I haven't got a clue whether I simply replicated what was originally there, or decided to try something different! Can't see why it wouldn't work hydraulically, but I'm starting to have a nagging doubt...

Link to comment
Share on other sites

  • mat_the_cat changed the title to Korean Cortina - WTF is going on with my cooling system?

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now
  • Similar Content

    • By 320touring
      A long time ago, in a galaxy far away, The Burd and I went to see the Skizzer to start getting a MK1 Golf Convertible that had been off the road for 10years..
      After a couple of sessions in deepest darkest Wales , coupled with some sterling help and fettling by Skizzer himself, it was time for us to head down and bring the thing back up.
      This went well:
      New tyres were procured and fitted

      The in-game tank pump was pulled out and a new filter fitted

      Then I got in touch with my Inuit side, using brand new* magnets to undertake "tank shite" fishing

      A full check over and a couple of test drives showed it fit to play.
      We set off for sunny Oswestry, only to have both front calipers sticking after 120 miles. Some water and time to collect down saw them free off and cause no further problems.
      Upon getting just past Tebay, it started running rough - nicking into Todhills rest area and luzzing in 10L of fuel had it running bang on for the next 70miles before it died.
      This was the final scene on the way home.

      I got to bed at 00:45, and left it to sit until today.
    • By SiC
      So to recap. After a painfully long time (well a month) I finally bought a MGB GT.

      I've always fancied one and after seeing one at a local garage (which turned out to be a bit shit) the urge sprang up again. Anyway after a lot of searching I ended up with this. Seems pretty straight and underneath don't appear to not been welded too much. Worst point that I've found in the leaf spring mount. I'm not going to cover all the different things and stuff just yet as its already in the thread, so I shouldn't make this too long!
      I've not owned a car this old and never something with a carburettor. So I don't quite know what I'm doing with a lot of this, and will have plenty of questions! Part of the reason why I bought it was so I had something that I could fiddle with and learn on. As the other thread got a bit long, I thought it would be a better idea to split and start here.
    • By cobblers
      Right so! I was looking to lease an EV through the business, but completely failed due to hating new car dealers, hating touchscreens and eventually settling on a hybrid which is out of stock until mid-late 2022. 
      So I gave up and decided to get a Land rover. I failed at that too, after my mate sent me a link to the advert for this on ebay, at about 9pm. Ten minutes later I had arranged to drive down to see it the next day.

      I'm a glutton for punishment, and I really miss my last t25 so it was pretty inevitable that I'd buy it. It was more money than I'm used to spending on these, but overall I was pleased with the deal.
      A dawn raid by our very own @worldofceri had it delivered on Friday morning:

      It's a Swedish van originally, and was imported in 2006. Incredibly solid, never been painted and a fantastic "worn in" look. It's a 2.1 "DJ" engine which is pretty healthy but as usual is weeping coolant from various places, they all do that sir. A friend has a rebuilt engine on his shelf so I budgeted that into the purchase - We'll see how it goes.
      Totally original other than someone put some mega Fox/Gowesty suspension on it, proper mega bypass shocks with external reservoirs and stuff, so I reckon I can probably take it off jumps or something. I won't.
      My plans are to (after cleaning the filthy interior) to just run it about, more or less as it is. It would benefit from a set of tyres - these are worn very ridged on the fronts that makes it even more noisy and harsh to drive, and has no spare wheel.
      I've rotated the tyres so now the front ones are smoother, we'll see how I get on. I do need to source another matching wheel for a spare as these are full time 4wd so you need to keep the tyres rotated regular and within a very similar tread depth. look - there's even a sticker telling you to:

      I really need to get some new number plates for it! If anyone knows a place who could make some OE style ones with that font all the VW dealers seemed to use in the 1980s, that would be grand - I want some with the dealers logo putting on the bottom:

    • By Zelandeth
      Well I've been meaning to sign up here in forever, but kept forgetting. Thanks to someone over on another forum I frequent poking me about it recently the subject was forced back into my very brief attention span for long enough to get me to act on the instruction.

      I figure that my little varied fleet might bring you lot some amusement...

      So...we've got:

      1993 Lada Riva 1.5E Estate (now fuel injected, as I reckon the later cars should have been from the factory...).
      1989 Saab 900i Automatic.
      1987 Skoda 120LX 21st Anniversary Special Edition.
      1985 Sinclair C5.
      2009 Peugeot 107 Verve.

      Now getting the photos together has taken me far longer than I'd expected...so you're gonna get a couple of photos of each car for now, and I'll come back with some more information tomorrow when I've got a bit more time...

      Firstly...The Lada. Before anyone asks - in response to the single question I get asked about this car: No, it is not for sale. Took me 13 years and my father's inheritance to find the thing.

      Yes, it's got the usual rusty wings...Hoping that will be resolved in the next couple of months.


      Next, a proper old Saab. One of the very last 8 valve cars apparently, and all the better for it. I've driven two 16v autos and they were horrible - the auto box works sooooo much better with the torque curve of the 8 valve engine. Just wish it had an overdrive for motorway cruising...

      Next up a *real* Skoda...back when they put the engine where it belongs, right out the back. In the best possible colour of course...eye-searingly bright orange.

      Seat covers have been added since that photo was taken as it suffers from the usual rotting seat cloth problem that affects virtually all Estelles.

      Then we have possibly the world's scruffiest Sinclair C5...

      Realised when looking for this that I really need to get some more photos of the thing...I use it often enough after all! We have a dog who's half husky, so this is a really good way of getting him some exercise.

      Finally - again, I really need to take more photos of - we have the little Pug 107.

      Included for the sake of variety even if it's a bit mainstream! First (and probably to be the only) new car I've bought, and has been a cracking little motor and has asked for very little in return for putting up with nearly three years of Oxford-Milton Keynes commuter traffic, before finally escaping that fate when my housemate moved to a new job. Now it doesn't do many miles and is my default car for "when I've managed to break everything else."

      I'll fill in some more details tomorrow - I warn you though that I do tend to ramble...
    • By robinmasters
      Yes, one of those. You've seen the car before, and I've already used up my best jokes (so I'll repeat them).
      An epic journey, including:
      - TRAINS
      - SHANKS' PONY
      - And possibly a pastry-encased but disappointing meal
  • Create New...