Project TVR Chimarea

ACT Race manifolds and race cats

noreply@blogger.com (Matt) — Fri, 03 Oct 2008 19:09:00 +0000

Fed up with my crap manifolds leaking all the time - I took the plunge bought a set of ACT Products Race manifolds and race cats.

http://www.actproducts.co.uk/shop/index.php?main_page=product_info&cPath=65_67&products_id=313

I also had to purchase a gasket/bolt set http://www.actproducts.co.uk/shop/index.php?main_page=product_info&cPath=65_67&products_id=318

Fitting was a doddle, they look awesome in the engine bay

I'll try and record the exhaust note if I can get the video camera working.

Just when you thought.....

noreply@blogger.com (Matt) — Mon, 21 Jul 2008 20:48:00 +0000

...it was safe to turn on the heater.

I have been traveling a bit in the Chimaera - quite a bit of motorway driving. All of a sudden I smelt burning and then the heater fans stopped working.

I took the dashboard apart and found this:

Yes that is what you think it is :-( that's the heater control unit under the dashboard. This is the second time it has burnt out. First time I suspected the unit itself but now I think the current draw on it is increasing because the heater blower is seizing up - or is packing up.

More to follow next weekend - when I can get my head into the passenger footwell again

Sweet!

noreply@blogger.com (Matt) — Mon, 28 Apr 2008 20:53:00 +0000

BRILLIANT
Everything seems to be working.

New rad and themostat installed.

Temp constant through the town in traffic and drops on the open road.

I am really pleased as all the restoration work I wanted to do is now done.

No clacking exhaust manifold noise.
Perfect cooling system.
No PAS leak.
Car is completely water tight.
Speakers upgraded.
Alarm sounder fixed.
Dashboard squeaks fixed.
Tidied up dashboard leather.
Re-trimmed doors.
Re-sealed doors.
Fixed window closure.
Windscreen sorted out.
Idles well - mixture is perfect.

The only things I'd consider doing now are:

New seat belts (the old ones got wet and now stick a bit sometimes)
Respray - paint work is looking rather tired
GAZ or Nitron shock absorbers
New discs and pads
Remove precats - (maybe)

When I get time I'll take some proper pictures and get some PDF tutorials up and online.

From great to opps in one easy step!

noreply@blogger.com (Matt) — Fri, 25 Apr 2008 12:51:00 +0000

New radiator fitted, also replaced thermostat (74 degree) and otter switch (88 degree) to lower temp ones (just because whilst I'm sorting the cooling system out - why not).

Fired it up and bled the system.
Took it out for a drive and heard something 'ping' off - followed by a worrying rumbling noise.
Was only up the road from home so pulled up on the drive and had a look - OH DEAR.... looks like I didn't tighten up the alternator pulley bolt enough - luckly it's just stripped the thread on the alternator and ruined the pulley.

Got a new pulley and have put the alternator in for a repair.

The final job?

noreply@blogger.com (Matt) — Tue, 08 Apr 2008 22:46:00 +0000

Ok - the end is nigh!

I took the radiator our today and dropped it off at Gloucester Radiator Services - 140.00 next day radiator recore - great guys really know their stuff.

Will post some pictures of the finished article and a guide on how to fit it.

The windscreen is sorted! (finally) also known as the story of the ridiculous dealership and the brilliant dealership

noreply@blogger.com (Matt) — Tue, 08 Apr 2008 22:34:00 +0000

Well over 6 months after taking the screen to a windscreen replacement company that operates nationally, the screen, hood and seals all fit properly.

Granted 3 months wasn't the windscreen companies fault as the car was off the road whilst I was doing a the things on this blog, but, they did manage to screw up fitting the screen 3 times.

The 3rd time the roof came back and the passenger side roof was a great fit - the drivers site had a 1cm gap! I too the car to a so called TVR specialist in Worcestershire. Their ridiculous diagnosis was that the body needed to be lifted from the chassis! Quite frankly the most outrageous thing I've heard in a LONG LONG time.

I spoke with the MD of the windscreen company - he agreed things needed to be put right. I took the car to David Hendry - a dealership I trust and can recommend highly. They managed to whole process and sorted out the roof by fitting the CORRECT seal and supervising the installation. They charged to windscreen company and I got the car back and it looks great.

All I had to do to finish things off is adjust the door alignment because the door had dropped slightly and it's now perfect.

So to the dealership in Worcestershire - you didn't get your 'blank cheque' to work on a horror story - I took my car to professionals that know what they're doing.

Viper stripes

noreply@blogger.com (Matt) — Sat, 16 Feb 2008 17:01:00 +0000

I thought I'd get a practice in for Le Man. I bought a vinyl cutter off of ebay a few months ago with the view to selling some stickers etc - so I cut myself some cobra style viper stripes.

Not sure if I'm 100% keen on them, but they'll do for Le Man!

PS.I've just noticed my TVR badge is a bit wonky. I'll sort that in a bit.

We're getting there...

noreply@blogger.com (Matt) — Thu, 07 Feb 2008 15:25:00 +0000

....Pretty much all the jobs I wanted to do are finished now.

Just got the windscreen and radiator to do - then a full service and it's all good.

I've done about 300 miles now since refitting the manifolds. Going to have to tighten them up again shortly, but oil pressure is good - temp could be better (due to knackered rad), power seems fine. Ticking has gone. (Horay)

New rear speakers

noreply@blogger.com (Matt) — Wed, 30 Jan 2008 00:28:00 +0000

Here is my step by step guide to fitting rear speakers to a Chimaera.

You will need:
Balls!
Speakers (pair)
Speaker wire
Hacksaw blades (wood)
Wood drill (small)

1. Unbolt cd changer (if you have one)
2. Remove carpet from above fuel tank
3. I choose to loose my vents and put the speakers in their place - remove vents and drill holes from the boot into the cabin around the edge of the speaker template.
4. Carefully cut and break the fibreglass between the holes you've made.
5. Fit speaker.
6. You *might* have speaker connections in the nearside panel between the rear wheel and the door post. - If you do pickup your speaker connections here, run them over the wheel arch (tape in place).
7. Connect speakers
8. Enjoy

It's alive.....

noreply@blogger.com (Matt) — Sat, 26 Jan 2008 14:40:00 +0000

Horray!

After weeksmonths of work, pain, bad advice, crap workmanship and cold weather the Chimaera is back together.

Started first time.
Next job is to get the radiator replaced/recored and switch the alternator our with my spare, because the charging light fails to go out.

Brilliant to have it back on the road.

Nearly there

noreply@blogger.com (Matt) — Fri, 25 Jan 2008 22:05:00 +0000

My friend has been really busy so only just got the heads back.
Heli-coils look good.

Bought yes another head gasket set - head bolts and valley cover and started putting things back together today.

Heads are on - inlet manifold is on.

Just got:

Rocker covers
Injection system
Pas pump
Heater pipes
the dreaded exhaust manifolds
and poly vee belt

to put back on then I should be ready!

The leaking manifold bolt saga continues

noreply@blogger.com (Matt) — Wed, 02 Jan 2008 11:47:00 +0000

What a nightmare!

After getting the manifolds off. I gave the heads to a local garage to remove the studs make sure the threads were ok.. Big mistake. They drilled and tapped the threads (badly).

I put the heads back on and found that 2 bolts (one on each side) weren't tightening up.

I removed the heads again.... and low and behold the thread was totally chewed through.

A friend (who works for an engineering firm) has kindly taken the heads and put helicoils in - I should now be able to finally get her back on the road.

One thing I have found is my radiator needs replacing. Oh well

Leaking exhaust manifolds

noreply@blogger.com (Matt) — Sat, 01 Dec 2007 00:00:00 +0000

Joy of joys.

One of the hardest jobs I've had to do on the car yet.

Ended up having to grind all of the bolts off using dremel (total nightmare)
Then had to remove both cylinder heads, send them off to have the studs removed.

Now all that's left to do is refit them......

Lazy cam follower

noreply@blogger.com (Matt) — Tue, 16 Oct 2007 17:45:00 +0000

Looks like the source of all the tapping was a lazy cam follower.
All the valve train gear is in remarkably great condition given the age/mileage of the engine.

We've checked all the rockers, lifters, push rods valve seats, guide and the camshaft and nothing is overly worn. Decided to clean out and refit the followers.

Restarted it last night - god awful clatter for about 10 seconds then the followers pumped up with oil pressure and things were much better. I used a mechanics stethoscope to have a listen to the rocker covers and there's a massive difference. The engine is quite and all I can hear is the faint (normal) tapping of the valves. Oil pressure is much better now too. There is still a minor tapping which I think is an exhaust manifold - got a set on order.

The reassembly went well with the exception of one water hose that was a bit loose causing a minor water leak.

Tonight I'm going to replace the oil pressure sender and do a full oil change. Also going to try and get the motorbike up and running and ready for sale.

What lies beneath

noreply@blogger.com (Matt) — Sat, 29 Sep 2007 19:13:00 +0000

...the rocker covers?

Today I set about looking under the rocker covers to try and track down a tapping noise.

So far I've managed to get the passenger side cover off (I'll post some pictures later).

I've started on the drivers side but that's quite a bit more involved.

The passenger side looks good - no rocker arms are missing any pads and the engine looks clean and very well cared for despite it's high miles.

I'm hoping the drivers side is the same - which would point towards my failure to identify a blowing exhaust gasket - that would be considerably cheaper than new camshaft, tappets, lifters, rockers etc.

Photos to follow...

V8 OHH

noreply@blogger.com (Matt) — Sat, 29 Sep 2007 19:12:00 +0000

As a birthday/christmas present I've been given the registration number V8 OHH - Brilliant - It suits the TVR perfectly (and it wouldn't look out of place on the rangerover either!)

Winter tasks

noreply@blogger.com (Matt) — Tue, 11 Sep 2007 08:57:00 +0000

I am planning to take the car off of the road for the winter. This is not because I'm precious about it being damaged in the winter, or that I'm scared about driving it on slippery roads but simply because it needs some work and winter is the best time for me to do it from a finance and time perspective. (Road fund license is about to expire so now is a good time!)

I've noticed a constant tapping at idle and when driving - this has been looked at by at least 3 people now and each has even me conflicting advice. I suspect the Camshaft and lifters, but I'd rather it was just an exhaust manifold problem.

According to my research the noise could be any of a number of things.

Hydraulic lifter problem
Rocker seat(s) missing
Exhaust manifold leak
High-tension arcing
Camshaft/Valve train problems

I've also got a 'knocking' noise coming from the rear whenever I pull alway, again this could be a number of things.

Exhaust mounts
Diff mounts
Loose propshaft bolts
Rear ARB drop links

Finally there is an minor oil leak - but I suspect it's something inaccessible it could the source.

Rear rocker cover gasket failure
Head gasket leak
Core plug(s) leak
Sump plug leak

All these are going to require some time and effort and undoubtedly money to fix.

I'm also looking to:

replace rocker covers with some nice refurbished ones
Replace anti-roll bar drop links with some of Steve Heaths' replacements
Sell my motorbike to fund a respray and parts
Sell lots of old electronic (hifi etc) that I don't need
Finish tidying up the interior
Look at tidying up the hood

Lot and lots to do but very enjoyable.

Broken bonnet mount

noreply@blogger.com (Matt) — Sun, 09 Sep 2007 15:42:00 +0000

I noticed when fitting my alternator that the passenger side bonnet mounting was broken. I have been wondering why it was rubbing so badly.

I purchased a pot of P40 Isofix and re-fibreglassed the mount back into place.

It's a two person job getting the bonnet off. Pretty simple as it's held in place by 4 allen bolts.

Here she is with her bonnet off.

I took the time to paint the exhaust manifolds with Very High temperature matt black paint whilst I had good access. A few more inaccessible bits to do - but need to get under the car for those. (note shinny new alternator and poly vee belt)

Agggh - Charging Light On

noreply@blogger.com (Matt) — Sun, 09 Sep 2007 15:32:00 +0000

This is a scary light on a Chimaera.

My engine is a V8 serpentine which means it has a single 'poly-vee' belt that runs ancillary components. In my case:

PAS Pump
Water pump
Alternator

The scary thing about this light when it's lit is that it might mean that the water (which gets bloody hot) might not be circulating quickly enough.

I pulled straight over and popped the bonnet. Belt intact and looks ok (a bit old) but ok.
Restarted car and it was fine....strange.

Went home and thought about it - possible alternator - possible 'poly-vee belt'

Decided I'd get the alternator out and replace it.
Also replace the poly-vee belt - I couldn't get hold of a 1850mm poly-belt so had to settle for 1855mm. (I bought 2 - one as a spare)

New alternator arrive and it had a strange cover - I managed to modify it so that it looked OE and fitted correctly.

Fitted belt and alternator. Started up and light flickered and went out..... superb.
Left it for a bit - thinking all was fixed, came back and restarted and OH NO light back on!

P*ssed off and tired I posted to the Pistonheads TVR forum - from the suggestions it turns out it might be the 100A fuse.

Looked underneath the car at the 100A fuse and viola - look what I found.

Cleaned up terminals and fitted a new fuse - perfect!

Door cards part II

noreply@blogger.com (Matt) — Tue, 04 Sep 2007 15:18:00 +0000

Carpet arrived around 10am - exactly as described.

Looks good

I went straight out to the garage to set about re-trimming the doors.

Door card removal is a complete swine, will be replacing holding nuts with M8 Wingnuts.....

Here is a shot of them half way through - the top part is a cut piece of carpet ready for gluing, the bottom is the door card it's going onto.

Will upload some images when I've got them back into the car.

Door cards part I

noreply@blogger.com (Matt) — Mon, 03 Sep 2007 15:11:00 +0000

Decided today that I don't like the magnolia leather door cards and prefer the carpeted type that I had on my previous Chimaera.

So I have ordered some Blenheim midnight blue Nylon backed carpet from Coverdale Carpets.
I ordered 1.5mx1m which should be enough to do both door cards and leave some spare if I screw it up.

I popped down to B&Q and bought some evostick spray impact adhesive.

Carpet should arrive tomorrow!

Hoor and door seal fitting

noreply@blogger.com (Matt) — Mon, 20 Aug 2007 15:27:00 +0000

This is a surprisingly easy job!

I ordered 12m of seal - more than I needed just in case.

Here's what I did for the targa hoop:

Remove hood
Open doors
Drill out rivets on targa hoop
Pull off old seal (gently)
Fit new seal to targa - cut to length and re-rivet

Here's what I did for the door/roof:

With hood removed and doors open
Drill out rivets behind drive and passenger seats at top of 'door posts'
Fit new seal and cut to length
Rivet into place

Noticed windscreen damaged - so got it replaced under insurance.

Leaking PAS

noreply@blogger.com (Matt) — Mon, 20 Aug 2007 09:08:00 +0000

One of the jobs I knew I'd have to sort pretty quickly was a leaking low pressure PAS hose.

Turns out that the PAS hose is available from my local Pirtek retailer - I bought 2 sizes - one for the flow and one for the return.

It's an easy job to do - the hardest part is getting to the jubalee clips under the PAS pump - that done it's a simple swap - new fluid and a few lock to lock turns to bleed the system.

Took about 2 hours (start to finish) and now the PAS system is leak free!

Short girlfriend modification

noreply@blogger.com (Matt) — Wed, 15 Aug 2007 15:23:00 +0000

The problem: short girlfriend + TVR = girlfriend can't see over dashboard.

The solution: remove passengerseat, and put body fixing spacers in between seat bottom and floor.

The result: happy(ier) girlfriend...

Rain and TVR canoe

noreply@blogger.com (Matt) — Fri, 10 Aug 2007 15:15:00 +0000

This month has seen me bailing out the Chimaera.
Drivers side foot well - totally soaking - probably 3 inches of water in there.

Removed carpets and seat to dry out.

Ordered hood and door seal rubber from TVR Shop and set about waterproofing the hard top and mohair back with Fabsil.