44: Saturday 15th August 2009
Despite the heat I got the template for the gearbox adapter cut out using my jigsaw.
43: Friday 14th August 2009
Had an email from Erick in China saying to send the vacuum switch back and then he would send me another. He also said that another customer had the same problem. He sent me a diagram showing that the pump needs to be mounted horizontally, mine is mounted on its side and it is causing more vibration because of this.
42: Thursday 13th August 2009
I spent about 3 hours cleaning the gearbox. Where the old engine had an oil leak, the gearbox was really dirty. So with spirit, a paintbrush, a stainless steel brush and kitchen roll I cleaned the gearbox so I could handle it without getting dirty. I started making the template for the gearbox adapter from plywood. Got the markings from the outer edge and drilled through where possible. I sprayed the gearbox with suntan oil and pressed the board to it to mark the face.
41: Wednesday 12th August 2009
Re-mounted the vacuum pump on the right chasis near the front of the car. I found three threaded holes and fixed to them. I used anti-vibration mounts and 4 this time instead of 3. The vacuum switch was controlling a relay this time. It was working again, but still not working right. Once vacuum had built up, the pump would cylce about once per second. I thought this might be due to using old fuel pipes, so I swapped these for proper vacuum hoses but it was the same. Still suspect the switch.
40: Tuesday 11th August 2009
Made a mount for the vacuum pump. I tested the pump first and it worked and switched off via the vacuum switch. I mounted the pump on aluminium 'L' sections that I made special. I also made a small tie bracket to the brake block, so 3 of the 4 mounts are used. The 4th was too close to the gearbox mount. It was a lot more noisy than I expected and the switch stopped working, so 2 steps forward, 1 step back. I will get some 6mm anti vibration mounts and ask my supplier in China to send me another switch. I pulled the last pipe off while the pump was stopped and there was a whoosh as the air rushed in, so it is working o.k., but noisy and won't cut out when the vacuum is achieved.
39: Sunday 26th July 2009
I remebered the earth terminal on the gearbox, so fitted this and added it to my collection of ground wires hooked to the battery by a jumper lead. Now the headlights worked. Next the blower, I took out the glove box and pulled the connector from the motor. The circuit shows a live connection through a fuse and a relay. The speed is controlled on the ground side of the motor. I checked the motor connection, no live supply. Checked the fuse, live o.k. I eventually found the blower relay in a rubber mount by the hood hinges, this was not energized. Checked the supply to the relay and this was o.k. Shorted across the the relay contacts and the blower worked, so the problem is with the relay. Took the outer casing from the relay and operated it with my finger, the blower worked, so the relay contacts were o.k.. Tested the supply to the relay coil and found 12v on the ground side as well as the supply side, bad ground. I had removed another wire too many. Made a new ground and now the blower works fine. The right speaker was just some dubious connections, fixed it. Just the airbag light now, probably another bad ground. I pulled the trim from the 'A' pillar and made a cut out for the battery gauge cable. Trimmed the gauge pod to the shape of the 'A' pillar trim. This took a while to get it to fit nicely. Connected the gauge in the pod, fitted the 'A' piller trim back on then screwed the pod to the trim.
38: Saturday 25th July 2009
Had to do some DIY jobs round the house (build a pergola in the garden), so I just put the battery on charge.
37: Sunday 19th July 2009
Fitted the heater, and heater unit and the dashboard. As I had routed the battery gauge cable out behind and round the 'A' pillar trim, when I tightened the dashboard, the force of the wire squashed behind the trim cracked the windscreen. So that's another job to add to the list. Connected the 12v battery to check out the vehicle electrics. Things that didn't work included the blower, headlights, right speakers and the airbag warning light was flashing code 1-2 that translates as low battery voltage.
36: Saturday 18th July 2009
Scotch locked a wire to the reverse lamp and routed it round by the gear shifter. Also routed wires for the forward, reverse relays and 12v from key position 2.
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