Star garages - The Good, the Rusty, and the Delayed - FoD, revisited

[IronStar]

Engine goes out leaving an empty bay

 

Two that need to become one

Sharp eyed will notice that it’s on the ramp, which allows for rust inspection. I brought drinks, and conversation went something like this

- Is it terminal doctor? 
- Well, all the usual weakspots are rusty. Rear beam is toast, rear strut towers, front strut towers. Needs works. Take off what you need and scrap the rest. 
- So terminal? 
- It can be done, but it’s…. 
- Right. Let me rephrase. If we scrap this and buy another one, will it be a better starting point? 
- They’re all fucking fucked. 
- So no? 
- No, it will be as bad, probably worse. Look, are we talking cutting out the rot here or a full blown nut and bolt resto like Cabrio? 
- Just the rot and some reinforcements. We’ll polish it to make it seem nice. 
- You are an absolute fucking nutjob. Fine, I’ll do it, make it sound on a budget. 
- So I should go buy a Bravo/a? 
- Yes. Fine. Go buy another donor car. Let’s make a stupidly fast Yugo. 

End result - another Yugo gets to live, albeit in a modified form. I saw 1.6 16v ECU has pins for check engine, so the dash light will also remain operational. 😄

Have a bonus photo of Cabrio with windscreen back on and both front fenders attached if you made it this far in the post.
 

[IronStar]

Two arrivals today:

Early this morning, on the back of the van, straight from Germany

I originally wanted this for Mini, but as we’re wiring in a stereo into Cabrio, might as well have a proper thing. To be fair, the OEM Yugo one looks cool, but leaves a lot to be desired as far as the sound quality is concerned. Maybe I’m getting one and swap it for the meets or something?

Came back home, went to the gym, then got into a car and drove to Bosnia to pick up a thing I found on their classifieds:

RSL Cult 2x 14x7J, 2x 14x8J.

They need a new coat of paint, screws (that don’t hold anything) are missing, and new tyres, but seem fine overall. I wanted set of these on the car, but couldn’t find any for sale in Serbia. As the project is close to the finish line, I started looking in the neighboring countries and found these. Some messages were exchanged, and thankfully got home without being hassled by the customs. 

 

[hairnet]

On 24/01/2025 at 00:06, IronStar said:

 

Two that need to become one - OMG spice girls lover

. We’ll polish it to make it seem nice. 
- You are an absolute fucking nutjob.

 

 

0.13

 

[IronStar]

You know how I said between 700 and 1000€ to get the 159 fully fixed? Just got the invoice.

A smidge under 1600€. 🤯😱😱😱😱This is sending it straight into top 5 mechanic bills I ever had. On a car worth 3-4 grand. Fuck me. 

They could’ve at least called me for an approval for spending this much. I would’ve probably still said yes, but fuck me! I absolutely did not plan or budget for this. 🫣

Have a rusty shock absorber.

 

[IronStar]

2 hours ago, IronStar said:

You know how I said between 700 and 1000€ to get the 159 fully fixed? Just got the invoice.

A smidge under 1600€. 🤯😱😱😱😱This is sending it straight into top 5 mechanic bills I ever had. On a car worth 3-4 grand. Fuck me. 

They could’ve at least called me for an approval for spending this much. I would’ve probably still said yes, but fuck me! I absolutely did not plan or budget for this. 🫣

Have a rusty shock absorber.

 

Well to their absolute credit, first impressions are that it’s a much nicer car now. Handling seems better, all the small knocks and rattles I’ve been hearing no longer seem to be there. The knock from the rear has disappeared. There is no longer a concerning DMF knock on shutdown with the working flap. Shifter that had an odd movement to it no longer moves. Engine is no longer greasy and they can’t find any leftover leaks. Last, but absolutely not least, the cumulative effect of all the work is - it’s no longer shaking in the 2nd gear. This is something I’ve been trying to weed out for almost 4 years now, and this alone makes any price they could’ve named worth it. Absolutely lovely!

For a small grump, insignificant to the wider satisfaction with the car, left HID shat itself in their custody and is intermittently blinking on and shutting off. 

Overall, I’m chuffed!

[grogee]

I just noticed the EFi marking on the intake - I never realised they made it that far. Incredible tech. Did they nick it from someone else or is it all Zastava's own work? 

Well done on your Alfa. I think I did similar jobs to mine (well, Mrs Grogee's) at various points. The only thing I paid A Man for was a gearbox bearing which might be related to what you were talking about - gear lever movement on/off throttle. That was a big bill. 

I never did get to the bottom of it eating front tyres despite several wishbone replacements and tracking sessions. 

[IronStar]

4 hours ago, grogee said:

I just noticed the EFi marking on the intake - I never realised they made it that far. Incredible tech. Did they nick it from someone else or is it all Zastava's own work? 

Well done on your Alfa. I think I did similar jobs to mine (well, Mrs Grogee's) at various points. The only thing I paid A Man for was a gearbox bearing which might be related to what you were talking about - gear lever movement on/off throttle. That was a big bill. 

I never did get to the bottom of it eating front tyres despite several wishbone replacements and tracking sessions. 

EFI is Zastava’s work. It’s running Bosch Motronic 3.1 for the early ones and 4.6 for the later ones.

Gear lever was a bushing on the shifter cable. The original one has double bushing in the linkage allowing some play in it, so it doesn’t transfer any movement from mounts, or anything else really, onto the shifter itself. It has failed at some point, and as Alfa doesn’t sell just the linkage, in theory you need an entire shifter cable at €€€, so it was replaced with an aftermarket unit that doesn’t have the same double bushing. There was some slack in one of the gearbox mounts, and that movement was most visible in 3rd gear. What they did (other than replacing the mount) is buy a Grande Punto cable, at 1/8th of the price of 159 part, that has the same linkage, swap the linkages to an existing cable, and scrap the rest of it. 

I’m still trying to wrap my head around parts pricing, 4 years into the ownership of this car. Does FCA Stellantis think Alfa owners are made of money? Or that we just like the cars enough to shell out for anything? It’s the same quality and materials as parts that go onto Fiats, just at 5x the price. 

[IronStar]

The last time I saw both Yugo engines, they were on the back of tame Zastava mechanic's Fiat Stilo estate, and on the way to become one engine. Not before they get a full check, so I end up with a properly sorted engine, not something that goes pop in 3000 kilometers.

Just got a call they're disassembled, and it's all fucking fucked m9. There's scoring on the cylinders of the engine block that needs to stay, so depending on parts availability it will either be re-bored or re-lined. Camshaft, that is, of course, EFI-specific is missing lobes. 

Will this car ever stop resisting? Is there a single part on it that's not completely broken and/or overdue for a replacement? 

I can't wait* for a final bill in an already super-expensive month, for a project that blew its budget ages ago and is now absolutely rinsing my wallet.

[Yoss]

14 minutes ago, IronStar said:

The last time I saw both Yugo engines, they were on the back of tame Zastava mechanic's Fiat Stilo estate, and on the way to become one engine. Not before they get a full check, so I end up with a properly sorted engine, not something that goes pop in 3000 kilometers.

Just got a call they're disassembled, and it's all fucking fucked m9. There's scoring on the cylinders of the engine block that needs to stay, so depending on parts availability it will either be re-bored or re-lined. Camshaft, that is, of course, EFI-specific is missing lobes. 

Will this car ever stop resisting? Is there a single part on it that's not completely broken and/or overdue for a replacement? 

I can't wait* for a final bill in an already super-expensive month, for a project that blew its budget ages ago and is now absolutely rinsing my wallet.

Liked for the update, not the news within the update. I kind of know what you're going through but on a much smaller scale. I've only got one car giving me endless grief and to be fair it was my fault in the first place. The other three seem to be working fine. For now. 

[IronStar]

13 minutes ago, Yoss said:

Liked for the update, not the news within the update. I kind of know what you're going through but on a much smaller scale. I've only got one car giving me endless grief and to be fair it was my fault in the first place. The other three seem to be working fine. For now. 

It’s just so frustrating not having anything actually finished, in what seems like an eternity, and having thousands upon thousands of euros in bills to show for it.

I did take the Mini for a spin last night, and despite some things still being unfinished and rattling, it’s at least a proper giggle driving it. So shades of gray I suppose. 

[IronStar]

Another of these boxes arrived tonight 

 

This time destined for the Mini

The difference in the shade of orange is much more subtle in person. I think this is a perfect match for BMW orange, but it’s close enough. 
I have aphantasia so I couldn’t really picture the set in the car, and I was too lazy to Photoshop it in, but I’m happy with the result. It’s not perfect, and Blaupunkt Frankfurt would be a better match, but it’s over 500€ and they can fuck right off with that price. Sounds really good as well, much much better than cheapo Chinese special that preceded it and was ripped out due to the excessive rattling. 
Oh, and it doesn’t rattle around which is lovely.

Overall verdict - chuffed with the purchase.

In other fleet news:

155’s overhaul of braking system and suspension is finished. I honestly expected a nastier bill, so that went well. Next up - engine recommissioning. They’re obviously in no rush, I’m in no rush, so it will be done at some point. I’ll take that. 🤷‍♂️

Yugo’s engine was retrieved from the machine shop, and is now being assembled back together. Back together and delivered next week maybe? Then it’s just* getting the car back together, but as a pause was made, I can imagine it will also take a while to be finished.

159’s headlight isn’t just ballast, the connector itself has oxidation on it, and the bulb seems to be on the last legs anyway. Projectors were retrofitted into the headlight, and the screw holding it all together is stuck, so I’m not touching it for the fear of breaking it. I called the shop that retrofitted it ages ago, but the guy couldn’t be arsed, and told me to call back next week. Rather stupid reason for going to a shop, but I’m really hesitant to force it and possibly break the projector and end up with a huge bill over a stupid item. 

[IronStar]

Tonight’s treat - short horror story in 5 pics

Detached from the manifold. Thankfully I had 13 spanner to gracefully remove it from the singular mount, and it detached some 500m from the garage. 
When I said I wanted a new exhaust, I didn’t mean I want to drop this one in the middle of the road FFS. 🤦‍♂️ 

[IronStar]

Mini, the annoying git, got a new exhaust, after some begging of the custom sports exhaust shop to fit it in ASAP so it can be driven again. They remade the section from exhaust manifold back, added a flexi, made center muffler and attached a placeholder original Mini rear muffler they had sitting used behind the shop for ages. DTM backbox is due to be made by them on 20th of May, which should make it look good and stop it from sounding like it has no exhaust (the one that fell off situation) or Yugo 45 (the current state of affairs). 
No photos as I didn’t get there in time to take photos while the car was on the ramp, and forgot to take any afterwards. Oh and we also found part of the reason for the gear knob rattling - rear gearbox mount failed and the nut holding it unscrewed. We’ll swap it out when it goes back on the ramp for the back box.

Remember the two engines that went away to become one and turned out to be shit? Well, it’s finally done and back together!

Brand new or machined next to everything. 🤦‍♂️ Oh and a new clutch kit, because why not while we’re at it. Price? I refuse to add it up.

Back at the bodyshop, some wiring got reconnected , and it now has a singular US spec headlight mounted. 😄

It’s waiting for a date with an electrician to get wiring for heated seats, power antenna, remote central locking and stereo added, so it can be reassembled. Trunk, bumpers and few other plastic bits need a respray, and then it’s just* a small* matter of getting it back together. But we’re almost at the finish line, and the end is in sight. 
Bodyshop guy will probably be happy to finally see the fixture out of the garage, and I couldn’t be more excited to take it for a spin.

Next car is lining up for the treatment as well. He agreed to work on the Saxo VTR next, and it will be delivered to his shop in the next few days from FoD 1.1.

Speaking of FoD 1.1, Bravo is also next up to be recommissioned. MoT place close to where it’s currently parked is happy to have it tested (with the super friendly tester willing to take a look before the test so it doesn’t get failed on something silly), so I can get it re-registered and then promptly sent off for belts, water pump and clutch cable. Watch this space! 

[IronStar]

Today was the day to send off Saxo to the bodyshop, and look at what’s going on with Bravo.
Called my brother’s friend that runs the local techncical inspection station to ask for recommendations for a tow and book an inspection. Tow truck booked for 10ish AM. Plugged the spare battery in last night to top it up for Bravo. Jumped in the car, and drove away.

Saxo wants to live. Reconnected the baterry,  turned the key, fuel pump went bzzzzzz and it fired right up. It’s absolutely filthy on the outside, but tires were still inflated and it happily drove onto a truck. 1 car down, one to do.

Onto the Bravo next. Let me get the bat…oh….no. No. I forgot the battery in the garage home. I am not fucking driving for two and half hours over a fucking battery. I’ll just buy another one. Surely everything else will be right, it was last time I saw it?

All the tires held air for ages, so it’s…oh, that’s fucking flat. Out comes the compressor! Battery in, ignition to acc, compressor works and…it’s not taking air. Fucksticks. Work the valve a bit maybe? Still no. How old is this tyre anyway? DOT 2905! Old enough to vote then, no fucking wonder it’s not taking air. I’ll just pop the spare on and take it down to the village to get this pumped up and back on. Spare is…a fucking spacesaver. Unscrew the wheel, try to take it off, and it just went and fucking welded itself to the hub. Cue a lot of swearing and wiggling:

Let’s try that tyre one more time now it’s off the car, in case it was just VERY unhappy squished flat. Compressor on, and…well fuck me, air is going in. Well ok, refitting it is reverse of putting the space saver on. Amongst the other shit that was in the trunk there is a bottle of DOT4 brake fluid. I noted this but ignored it and charted under “there’s some other spares in here as well”.

Let’s see that HID that’s not working. It’s usually the ballast, and I have another one in 159. Switch the ballast, and…nope, bulb is dead. Yes, you guessed it, not availible in the village. Meh, I’ll just put back halogens in to pass the inspection.

Turn the key, and it’s on! It’s VERY unhappy with stale fuel but works, and brake discs are completely corroded, but it just needs to drive for 2 kilometers to get some fresh petrol and I’ll brake hard a few times to clear up the corrosion. Reverse, stall, combination of shit aftermarket clutch cable and stale fuel. Took me a few attempts but I got it out of the gate.

Next up - brake corrosion. Mash the gas, brake. Mash the gas, brak…HOLY FUCK IT’S NOT STOPPING AND THE PEDAL IS ON THE FLOOR! Thankfully I didn’t hit anything while handbrake stopping it. Pop the back, I’ll just add some more brake fluid and…oh that’s empty. Of course it is. This is an existing issue and the brake hose has probably just rotten through completely whilst sat up.

I managed to limp it down to the village gas station for some fuel and brake fluid. Pour it in, mash the brake and….that puddle in front of driver side rear wheel wasn’t there seconds ago. Cue another call to brother’s friend to cancel the inspection and ask for a shop to fix this. Turns out the guy that towed Saxo also runs a car repair shop, so all I had to do is drop it off with him once he comes deliveres Saxo and comes back.

Even gave it a wash whilst waiting for the guy. This good deed was greeted by the interior mirror falling off.

I left it with this guy to get it roadworthy, do a onceover, and take it to the inspection once it’s done. I was quite happy to see the back of it. Judging by the amount of smoke belching from passenger side front wheel that caliper probably needs a rebuild as well. His eta is 2nd half of the next week.

Total score for today:

PC - 1 (brake failure almost made this 2)

Cars moved out of FoD - 2

Self service wash tokens used - 4 and the car is still filthy

Times I was wondering if I should just scrap Bravo instead - 15

Times I wished I was into birdwatching instead of cars - 5+

Cars that will live to see another day - 2, against my best judgement and Bravo’s unwillingness to live

 

[mat_the_cat]

I shouldnt laugh, but it's the way you describe the situation rather than the situation itself!

[IronStar]

23 minutes ago, mat_the_cat said:

I shouldnt laugh, but it's the way you describe the situation rather than the situation itself!

Nah, you should. It is so ridiculous we might as well laugh at the entire endeavor. 

If someone was recording it and cutting out the right bits, it would probably look like a shit Monty Python knockoff sketch. 😄