Bognor Lean-to Project

[ViperKen]

Hi Mazza, looks like you are going to be busy over the next few months, but as long as you enjoy the the process of stripping down and rebuilding the car, as I did, then I'm sure you will find it rewarding. If you do decide to go down this route, I hope you will create a progress thread, really enjoyed reading your rear end rebuild on the 1.9, from which I learned so much.

 

[Mazza]

First morning ...started at 10.30.......now its 12.00 so stopped for tea !! So.....once upon a time..........

Started in the boot....stripped out all the panels etc to get a look in case anything lurking beneath.... but pleasantly surprised. Lost a few clips etc on th the way but overall ok.
Everything dry, so no boot leaks. Wiring looks ok, no rust , just a bit dirty.

Have no idea how full this reservoir (?) should be. I wont put the roof down yet until I know

All the pile of bits removed will just need cleaning and can all go back.

I have started making a list of parts that I will need
Most of the tools missing, except I have the Jack, chock, and a 10mm socket.
Also the boot lid is heavy to lift so need the two hydraulic stays.

Drivers side definitely, but possibly Both rear wings need replacing, so next thing is to remove rear bumper, wings, and boot lid. So onwards and downwards !!!

 

[TrevD66]

@Mazza good luck with your new project.... looking forward to reading your progress

 

[Mazza]

The afternoon faltered a bit due to rusted and rounded bolts.....but made some progress.
Disconnected all the wiring in the boot lid.....And removed the lid, removed the wheel arch liners.....what a pain, and got covered in crap !!!, Undid the side clips and bits on the bumper, then disconnected the lights, and just undid the three nuts on each of the damper units and lifted off the whole lot in one go......forgot how bloody heavy those things are.

I would have had the wings off but for one bolt at the back end of the sill on both sides. Rusted and rounded
Everything else is undone except for the aerial, and not sure how that comes off.
Removed all the door trim and lost a lot of clips, but easy enough to replace when the time comes.
Undid all the top sill screws ok , but everyone underneath is crap and a socket wont shift them.....

Piling up more bits

It started to get a bit cold so packed up and put most of it back in the boot.......but Found one part that was in excellent condition.....

Depending on the weather tomorrow, I will jack up the rear end, take the wheels off to get better access, and use a cutter to remove all the screws so I can get the rear panels and the sills off. Probably remove the spare wheel carrier etc, while access easy .
Once the sills off , I will refit the wheels , so its sitting on the floor when I take out all the interior ......that will be fun
I did enlarge to hole in the sill to see behind it, and doesn’t look good , as there was loads of debris and dirt in there.

One thing I did see is that the beam bushes are sitting on the plate.....so there’s a trip to Basingstoke to do at some point...............it will probably end up as a full rear end refurb again.....

 

[Mazza]

Spent 3 hours wrestling with the 8mm AF screws that seem to fix all the panels and sills on.
What a nightmare......
but in the end after using an angle grinder, multitool, and lots of swearing got everything off.....
Only to find the tin worm had been very active......

There was no wheel arch liner on the front o/s so found loads of crud behind the sill.

P

Now need to get the interior out and see what sort of condition that is before I do anything with this mess !!

The only up side is that although it looks pretty grim, I did tap over it all the rusty areas with a hammer and its still sound underneath.

 

[Bazza]

What about just swooping the engines over may be easier mate

 

[Mark Parrish]

I recon you got to that just in time Malc

 

[Shelly]

Good luck on your project
I’m looking forward to seeing the end result

 

[Mazza]

Today started with removing the jacking point rubber mounts. One of the screws was a bit stubborn, but realised I could spray release fluid through a hole in the sill to get to the other end of it......a useful trick which I will repeat when I get to the stage of removing the 4 ‘screws of doom’ that hold the the beam plate.

First thing roof down......very slow and needed help......something for another day!!!

Removal of the interior went pretty much went as I though, having done this on the other car.
Getting the radio out was a struggle , even with the correct tools.
Managed to remove the gear knob without smashing it into my face.....once bitten...

Had a swearing match with it trying to remove the two roll bars, until I remembered there is a third screw located behind a cover plate in the storage box.

Other than finding additional cables, and electronic stuff that I didnt have on the 1.9 , and wrong fasteners used, it was just undoing loads of screws and putting all the bits out of the way, and moving on to the next bit.

Sum total of finds .......a dead AA battery and 55p in change.

Found out why the seat wouldn’t go up and down.....the silver looking bit is not connected to anything and is jammed against the frame.

Carpet was soaking underneath....and so is the front one

The two seat belt guides are broken so will have to be replaced, so if I have to take the covers off.....might as well retrofit heated seats as I did in the other car....just need the two switches , a relay and the heat pads....

I was defeated in the end as I couldn’t work out how to get the front carpet out. I removed all the panels etc, but there is a big plastic stud that looks like it has a cross in the middle for a screwdriver ( but damaged !!!) and I cant see how to get the carpet away from the accelerator pedal ????
I dont want to cut it but does anyone know how it come out ?

Other than that it was a good five hours
Other than wet, the floor looks in good condition. A few surface rust spots but they are easily treated .
Be nice to get the front carpet out this week, ( as cant work on the car next week) , and it can then just sit and dry out over the week.

 

[t-tony]

That plastic thing is just a “knock on” carpet fixing by the look of it Malc.

Tony.

 

[Mazza]

That plastic thing is just a “knock on” carpet fixing by the look of it Malc.

Tony.

I’ll put a claw hammer on it.....and give it a tug......... and then just replace it

 

[t-tony]

Thats what I would do mate unless a small pair of grips would turn it. I'm fairly sure the stud has a coarse sort of thread.

Tony.

 

[g8jka]

The plastic thing is a clutch pedal stop. It should unscrew, or maybe pull out. I removed mine and put an extended clutch stop in to stop the pedal travelling so far. The new clutch stop was a mainly a bolt and a couple of nuts plus a rubber stopper which screwed in, which makes me think the old one should screw out rather than pull out so I'd try unscrewing it first.

There is a way of removing the accelerator pedal out of the carpet so the carpet can then be taken out but I can't remember the procedure for this.

 

[Bazza]

your a gluten for punishment Malc but watching with admiration mate, or is this a lock down project ?

 

[Mazza]

The plastic thing is a clutch pedal stop. It should unscrew, or maybe pull out. I removed mine and put an extended clutch stop in to stop the pedal travelling so far. The new clutch stop was a mainly a bolt and a couple of nuts plus a rubber stopper which screwed in, which makes me think the old one should screw out rather than pull out so I'd try unscrewing it first.

There is a way of removing the accelerator pedal out of the carpet so the carpet can then be taken out but I can't remember the procedure for this.

Thank you for that.....now I know what it is, I looked on realoem under clutch pedal and found it. There appears to be two versions listed and that one should have a rubber cap of some sort.....it looks like its a push fit, but I’ll try to see if it unscrews first before I introduce it to my claw hammer!!!!!

 

[Mazza]

your a gluten for punishment Malc but watching with admiration mate, or is this a lock down project ?

The neighbours suggested it to me ........after 10 hours a day , 7 days a week, practising with the guitars and keyboard....

 

[g8jka]

Thank you for that.....now I know what it is, I looked on realoem under clutch pedal and found it. There appears to be two versions listed and that one should have a rubber cap of some sort.....it looks like its a push fit, but I’ll try to see if it unscrews first before I introduce it to my claw hammer!!!!!

Looking at some google images of them, they look like a push fit as you say. Similar to the clips that hold the boot carpet in. A good tug should release it.

 

[Althulas]

Don’t you also have to disconnect the pipes to the heater matrix after draining the system or cut the carpet there?
https://www.zroadster.net/forum/viewtopic.php?t=15979 see point 13 @Mazza

 

[Mazza]

Got to where I wanted to be today , as it will now have to be put on hold for a week.

Started this morning by knocking out all the fixings in the sill and will replace them all after its been derusted and treated.
Also removed the remnants of some sort of plastic guard (?) in front of the rear wheels underneath the car. Dont know what they are??

And so on to the carpet.......the round clip succumbed to my claw hammer.....but having wrenched it out , it appears to be threaded Then removed the accelerator pedal. Just the bit thats attached to the floor. You pull back at the top to line up a ‘nib’ with a slot and slide the top off, then pull the pedal towards you and you can feel a clip at the bottom. Push the clip away from you and the pedal lifts out from the floor mounting. Bit tight but not too bad.
Then unbolt the accelerator stop. ( would a been a good idea the measure the length of it from the floor before unbolting it )
The carpet itself had to be cut. Looking Into the drivers footwell, you have to make a cut in the top right hand corner of the carpet where there is a square cut out, and you cut from the hole to the top edge of the carpet about an inch.
Getting it out ...you have to push all the wires that go to the centre console through, and lift the carpet over a couple of brackets under the heater unit . ( I realised this after it would move when I was pulling it.

Being saturated with stagnant water it's bloody heavy and pretty disgusting to lift out.....but out it came

Dried out the car with a sponge, lifted the wiring up to dry out, and cleaned and treated the surface rust.

Vacuumed the carpets, but might steam clean them before they go back.

This was the only place to put it so it will hopefully dry out

This is the panel above the pedals, and it had the white sensor attached but not connected??

Well thats it now for a week so it will give it time to dry out completely. Then it will be angle grinder / flap wheel / and wire brush attachments, and see what the sills come up like.

 

[Ianmc]

What amazes me is how you know how to put it all back together. It's black magic to me.