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PollyMobiles Rebuild

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pollyp

pollyp

Club Member
2019-04-23 Rewire Nistune

even after replacing the ECU and eliminating NATS, the random & really annoying electrical hiccup / glitch has returned until the engine light barely connects. there's a loose wiring somewhere πŸ€”

wondering if it's the nistune ribbon cable, I tried reconnecting it with individual wires with no frustrating success 😑

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as a last resort, during an MSC trip to Sweden to visit ralph & iris new home for Ralphfest 2019, he helped rewire my nistune ECU with his better solder kit

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back at home I reconnected the ECU and was pulling my hair when it still didn't work ARGHH! 🀬🀬

ok I maticulously traced & tested every single circuit in the Nistune connection from pin-to-pin chip-to-chip

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until finally I discovered this tiny single track had a dry faulty solder connection. I bridged it with wire and behold she WORKS! πŸ˜ƒπŸ˜ƒπŸ˜ƒ thank god

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pollyp

pollyp

Club Member
2019-03-31 Delete Sunroof #1

I decided to remove the sunroof cos:
  • I rarely use it
  • it takes up head room where my trackday helmet kept banging it,
  • wanna lower CoG
  • eliminate water draining into the sills below

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gave the electric sunroof to ralph

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traced & cut a sheet of steel to cover the exposed hole

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tried spraying it with weld-through-primer to see if it both protects against rust & allows welding

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tacked on

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attempted to weld continuously through this primer for the 1st time and NOPE it's horrible stuff. welding was an absolutely poor mess, it's more like normal insulating primer tbh. guess it teaches me it's best to weld on bare shiny metal

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sealed with tigerseal inside

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grinded the messy welds flat & painted

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during welding, I burned the seats 😬🀬

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also the spatter landed on the windscreen and cracked it πŸ€¬πŸ™„

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pollyp

pollyp

Club Member
2019-04-09 Omex 600 Standalone ECU

Dave who has the blue turbocharged CGA3DE facelift (was previously James) sold me his Omex 600 ecu πŸ˜ƒπŸ˜Š
now I have the oppurtunity to tune it properly and safely with knock sensors, air temp sensors, multiple maps etc
compared to my current Nistune on the micra ecu which has zero protection against knock.

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dave has nicely included this coilpack too which eliminates the dizzy

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this is inside a crank pulley harmonic balancer

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the ecu will need a crank position wheel anchored to the solid core of the pulley to follow the crank precisely rather than the dampened outer pulley section

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machined the inside bore straight & round

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a sleeve follows this smooth bore

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and the crank wheel is welded to the sleeve, so the relative angle can be adjusted by loosening the crank pulley bolt

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pollyp

pollyp

Club Member
2019-04-21 Malton breakfast car meet

went down to Malton with car friends for a big car meet

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throughout the day, my wideband was randomly glitching/restarting on/off so at the next local car meet I began to investigate the loose wiring

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traced the issue down to these 3-pin PC fan connectors I used for powering the wideband which vibrated loose over time

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soldering the connection made it better

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pollyp

pollyp

Club Member
2019-04-28 Rigid Seat Belt Upper Mount

to eliminate any movement in the seat belt whenever I lock it during trackdays, I made the upper sliding mount fixed

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pollyp

pollyp

Club Member
2019-05-09 new smoother 2.25" cat-back exhaust pipes

I'm gonna rebuild the nasty old, botched, kinked rear exhaust pipes to improve flow and clearances from the axle.

brought some stainless lipped v-bands

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chopped the old kinked pipes apart including the huge exhaust tip

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welded a much nicer flowing bends

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attached to the powerflow silencer, which now has a normal 2.25" straight tip

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now she has a good flowing and subtle looking exhaust :cool:

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pollyp

pollyp

Club Member
2019-05-12 North East Auto Show with CCS club

attended the sunny NE autoshow with the local club

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m8 matthew brought another car but sprang a big water leak πŸ’¦πŸ˜„

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pollyp

pollyp

Club Member
2019-05-15 Cracked Piston #1

ever since replacing piston #3 and fixing her ECU glitches I noticed she gradually tends to lean-out dangerously during full boost till one day cylinder #1 began misfiring. oh no not again :rolleyes:

tried swapping injectors around to see if it's sticky, nope it's always cyl #1

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plug #1 alot richer

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tons of blowby getting into the intake

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replaced the fuel filter and that's where I discovered the cheapo crap filter has actually collapsed! 🀬
won't be surprised of all the crap had also contaminated the injectors & regulator

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I grabbed all my spare regulators and tested them.
turns out that yes the ruined filter debris had jammed the regulator open unable to hold 0psi (while the rest are 3.0bar - 3.25bar) therefore there wasn't enough fuel pressure at max load, making it lean out and thus knock till ringland #1 cracked

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inside a regulator

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cleaned and re-tested this faulty regulator and the reading was back to normal now

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the huge blowby was leaking past the catchcan lids

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so I made a simple extra seal inside

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connected all the crankcase breather & PCV breather to a single pipe to test blowby and yeah it's certainly undriveable now and requires another piston

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I haven't been on here for a while and I come back to some great updates form you.

You certainly won't regret going standalone, (I've been banging that drum for years but not many seem to take notice).
I haven't used an omex myself but hopefully it's a chance for you to ditch the MAF sensor and go MAP. You can also fit a nice simple throttle body!
 
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pollyp

pollyp

Club Member
2019-05-19 Datalogging R33 Skyline & given spare GT1549 turbo

m8 Simon needed help with datalogging his R33 skyline.
I hooked up my laptop to it, do a few smooth pulls and we found that the injectors are almost maxing out and need upgrading

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as a bonus he also donated this new spare GT1549 turbo meant for his scrapped MX5 πŸ˜ƒπŸ˜

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this smaller unit would be interesting for developing a sequential compound charging setup to reduce that low-end lag 😜

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pollyp

pollyp

Club Member
2019-05-20 Carbon Fiber wiper motor for Ralph

Ralph gave me a mission to machine a lighter motor housing for his project car.
so I remodelled the enclosures

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machined the carbon fiber tube he supplied and then transferred the magnets over from the original housing

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machined new aluminium ends

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I love precision πŸ˜€

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remounted the contact brushes

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all done and works nicely 😎

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pollyp

pollyp

Club Member
2019-05-22 Assess broken engine

running the cracked #1 ringland for soo long as a result of many previous issues, it's time to remove and fix this engine AGAIN πŸ™„

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lots of LSD diff bits

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removing engine

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clutch is ok

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exhaust manifold is wet with oil probably from the blown piston #1 and oily blowby

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compressor side was also very oily. worried if the turbo seals were ruined, I decided to find a shop to rebuild this turbo

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ripping apart the clean engine

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and there we are, cracked #1 piston 😬

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pollyp

pollyp

Club Member
I haven't been on here for a while and I come back to some great updates form you.

You certainly won't regret going standalone, (I've been banging that drum for years but not many seem to take notice).
I haven't used an omex myself but hopefully it's a chance for you to ditch the MAF sensor and go MAP. You can also fit a nice simple throttle body!
still tricky trying to find a good local tuner who can map this for me.
yes a big +ve is ditching the obstructive MAF for a MAP sensor and I can use my smooth larger bored TB for more flow & less turbulance πŸ‘Œ
 
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pollyp

pollyp

Club Member
2019-05-26 Spare engines from Andy

since meeting Johns garage down hull we were in discussion about buying a ported & flowed CG head with larger exhaust valves for Β£150 which he made for another customer.
I heard nothing back from john for weeks but then I discovered that the middle guy who referred me to john was a well known scammer in MSC and other clubs. you can imagine how deeply upset I was from being scammed :mad:🀬🀬

my m8 Andy down Lincoln said he had some spare CG13 in his garage that he was gonna scrap but I could have em for free instead πŸ˜€(y)

went down to visit for a looong chat and collected the spare engines :cool:

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so here's the collection of engines I have to play with 😁

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connected the gearbox & starter to check their compression. one was ok but the other was absolutely seized solid with rust inside

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Spare Engine #1

this one was supposed to be an Auto CG13, had a flex plaste but oddly had a solid non-dampened cg10 crank pulley πŸ€”
cams looked clean and compression was ok

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but ahh it turned out to be a CG10 with the flat piston tops 😬 this is no use to me

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Andy thought he brought this fake CG13 from another garage and guess they scammed him by "badly" restamping the CG10 label into a CG13

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Spare Engine #2

the second CG13 engine was badly rusted. cams were abit coked

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opening inside, these CG13 pistons were left in the rain and stuck with rust πŸ˜•

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removed the bottom end

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wirebrushed all the rust off the cylinders so it doesn't damage the pistons

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and managed to remove & salvage the CG13 pistons πŸ˜ŒπŸ˜ŽπŸ‘Œ

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pollyp

pollyp

Club Member
2019-05-29 Rebuild CG13 Engine

so with all the required spare parts gathered, it's time to rebuild the engine with good bits.
I measured all the cams in detail and selected the best pair

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checked all the end gaps from the collection of piston rings from all 3 engines and picked the ones closest to OEM spec

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the spare engine bearing shells were all scored & trashed so I re-used my current good shells

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cleaned up all the corroded pistons

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reassembling the block

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checking the crank end-float is perfectly snug

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assembling the top end

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shimming all the valve clearances till they're all perfectly within spec with good compression

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engine all build & ready to fit

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reinstalled in her N/A setup while the turbo's being rebuilt and she fired up perfectly and smoothly πŸ‘Œ

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pollyp

pollyp

Club Member
2019-06-02 Broken Gripper LSD

whilst the engine was being rebuilt, I strip & checked the LSD to see why it's lost preload again

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unbolted the diff cover, pulled it off and WTF!? the bearing section came off the cover plate, that's not suppose to happen 😲😬

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FFS it looks like these two useless drilled holes in the cover caused a stress-point πŸ™„πŸ˜Ÿ

with the spider gears repeatedly pushing against this plate over the years every time torque is applied, it eventually fatigues & cracks all around the center bit and weakening the preload

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this will need sending back to gripper to rebuild under lifetime warrenty πŸ™„πŸ™„
 
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pollyp

pollyp

Club Member
2019-06-09 Mod Panhard Rod Adjuster

the old whiteline panhard rod had an annoying adjustment which always require you to remove it off the axle each time. so instead I used the two-sided adjustment shaft taken from my old OMP strut brace and make it into something similar to a Nodspeed or Gizfab rod that's much easier to adjust.

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pollyp

pollyp

Club Member
2019-06-10 NA Cold Air Intake

since rebuilding this engine and running NA setup, the air filter was simply plonked on top which ain't good for sucking in hot air

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so I extended the plumbing over to a cooler section

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made a better support to fit onto the clutch cable mount

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pollyp

pollyp

Club Member
2019-06-13 Tyre puncture

shortly after fixing the engine, she had a screw puncture, which I tried patching with tigerseal πŸ™„

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sadly it didn't last long and driving home from work, the screw flew off and ran flat 😫

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the tyre shop fixed it up though it still leaks a tiny bit

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meanwhile I also shined up the wheels with rubbing compound and took forever to do but looks good 😎

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pollyp

pollyp

Club Member
2019-06-14 Loose gear linkages

the gear stick's been abit sloppy so I overhauled the bushings

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and replaced the rubber mounts with solid ones for a sharper feel

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pollyp

pollyp

Club Member
2019-06-17 Re-packing Powerflow exhaust silencer

the exhaust has been rather loud & droning over the years and insulating the interior had little effect.
wondering if the old silencer had collapsed inside, I brought a reel of stainless wool

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chopped open my silencer

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and yeah the fibres are clogged full of heavy soot and falling apart

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wrapping it full of stainless wool

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welded up

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and tbh sounds roughly the same πŸ˜„

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pollyp

pollyp

Club Member
2019-06-22 New GTIR Brakes

replaced the worn out black diamond predator pads & discs with fresh OEM discs & pads and using em on the street the low temp compound bites alot better

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pollyp

pollyp

Club Member
2019-05-16 > 2019-08-02 Turbocharging Lukes Corrado

m8 Luke needed help fitting this huge turbo into his Corrado 😁

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mounted all the new manifolds and made this stainless downpipe

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then we began plumbing everything in

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all plumbed and working but he soon had a nightmare refining his ECU chip when his tuner is down the other end of UK

I also remachined the oil filter shaft shorter for fitting an oil cooler sandwich plate

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during our test drive we came across this wonderful Jag C type 😎😍😍

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pollyp

pollyp

Club Member
2019-06-28 Machine BMW BBS trackday wheels to fit

I had these BBS alloys with R888 storing cob webs in the garage for many years now cos never got round to fitting em due to this smaller center bore lip

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got a straight router bit and removed that lip

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and they fit nicely and look really really mean 😍😈

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pollyp

pollyp

Club Member
2019-06-28 Monkey Polly

my "now ex" gf brought me this crazy monkey on our first date at the arcades cos it reminded her of me :p
so I attached monkey polly to kassandra now

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pollyp

pollyp

Club Member
2019-07-27 Rebuilt Turbotechnics S116

few months ago I took my oil stained turbo down to The TurboShop based in darlington in a hopes it'll be an economical repair

the problem is he could no longer source the exact compressor wheel since it's unmarked and discontinued.
I was left with a hard choice:
  • either buy a brand new S116 for Β£550,
  • TurboShop can fit a bigger wheel into my current turbo for Β£600! keeping the same 12.3psi boost therefore run the same mapping but air temps might be cooler from the bigger wheel,
  • buy a brand new bigger stage2 20psi turbo for Β£600 but needs remapping and more likely to either break the engine/gearbox or become more laggy
I bit the bullet and had it rebuilt with a bigger wheel for Β£600 πŸ˜¬πŸ’©
really hurts my bank account 😫

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the new wheel is approx 14% bigger

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Low Rider

Poindexter
Moderator
Club Member
Yes a 'replica' based on a 1962 Jaguar saloon, or possibly E type, running gear..... A mate of mine has an authentic looking replica Le Mans Ecurie Eccosse D Type..... While not 'real' both are still very nice (and not cheap) cars....
View attachment 65680
You'd be lynched if you chose to wreck a Series 1 E-Type to make a C-Type replica :LOL:
 
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pollyp

pollyp

Club Member
2019-08-15 Delete Sunroof #2

the first attempt at covering the sunroof was unsightly so it's time to try again properly.
stripping the interior out

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chopped the entire sunroof section out

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new sheet was welded in

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reattached the support beam

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added this extra beam to stiffen it

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welded another sheet on top to make the surface flush

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body filled

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painted 😎

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pollyp

pollyp

Club Member
2019-08-18 Correcting log manifold from Andy

when I visited Andy to collect a pair of spare engines, he gave me this TIG welded log manifold which'll be useful for improving flow into my new turbo, thanks Andy :DπŸ‘Œ

a minor issue is that the #4 port is welded slightly off-center, which ain't good for gas flow

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so I cut that section off

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and welded it in a better spot

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much straighter now πŸ‘

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welded this 2-piece oval column to the flange which'll join smoothly to the manifold

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pollyp

pollyp

Club Member
2019-08-25 Repair Windscreen Rust

before getting the windscreen replaced, which was damaged by spatter from welding the roof, now is a good time to fix the rusted windscreen surfaces

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cutting the windscreen out with a long stanley blade along the sealant was easier than I thought 😊

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the rust is worse than I thought, needs a lot of work

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removed the dash for better access

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chopped all the rusted sections out

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welded new sections in

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grinded smooth

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red oxide primed, primered and painted black

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arranged AutoWindscreens via my insurer to fit my new windscreen in the morning for £90 😎 gr8 job

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pollyp

pollyp

Club Member
finally got myself a long overdue cellular gps alarm so that it'd silently text my phone whenever it's triggered and I'm far away from the car, or need to locate my car πŸ˜ƒ

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pollyp

pollyp

Club Member
2019-09-14 Rebuild Both Sills

both of the sills are now rotten and with her MOT coming up, it's time to take on the challenge of rebuilding them.

Wirebrush the rusty sections

sills are completely porous

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the rear of the floor also needs repairing

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Cutting rusty panels off

all of the rusted panels will need to be chopped out. removed the wings for better access

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Bending new Sills

slowly forming new inner sill panels

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painted the inside with red oxide

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to bend the long outer sills, I welded some round table columns together, clamped it to the workshop table and formed the bend by hand

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Hey bud great to see you back updating again :) enjoyed readying your recent posts and good to see all the rot being chopped out and patched properly. Awesome work as always. Not sure if it's my phone but all your pictures are coming up twice anyone else have the same ?

Love the Kenco oil cap!

Sent from my EML-L29 using Tapatalk
 
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pollyp

pollyp

Club Member
Hey bud great to see you back updating again :) enjoyed readying your recent posts and good to see all the rot being chopped out and patched properly. Awesome work as always. Not sure if it's my phone but all your pictures are coming up twice anyone else have the same ?

Love the Kenco oil cap!

Sent from my EML-L29 using Tapatalk
cheers for liking the work, good to be back :)

and yeah it's wierd that on the desktop browser the pics show up fine whereas on the MSC app all my images are doubled πŸ€”πŸ€¨πŸ€·β€β™‚οΈ
 
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pollyp

pollyp

Club Member
painting the whole roof is a real PITA so I brought some matt black vinyl to wrap it soon

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oh god WHY, why did my ratchet slip off and ruin my nice powercoated alloys 🀬😭😭

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both sills now grinded and painted with red oxide before undersealing next.
the red sills is quite an eye catching contrast to the grey body ey? πŸ˜›

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pollyp

pollyp

Club Member
wirebrushed the rear floor pan clean

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but here I discover that the factory seam sealer in this corner simply trapped moisture from the wheels and rusting it inside out πŸ™„

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chopped all the rusted bits off

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great job Paul. Reminds me how rusty mine was...

I've used... (dunno how to translate this) 90' metal beam to restore "factory lookalike" jacking points. It was also easier to weld everything to this beam



those vertical parts works as super stiff jacking points,also metal beam looks quite stock. Another thing it will be superb to mount some getto side skirts- holes will be through beam, not through sill



best wishes with bodywork! I know how PITA it is o_O
 
Got the same with my other yellow one, sills,rear floor, bits on the rails, two trailing arm mounts inner arches crossmember, n/s front floor inner sills and mounts
And that's the same with my d21 :( lots of rot , rust and ventilation lol ,
But she's looking good now paul

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pollyp

pollyp

Club Member
great job Paul. Reminds me how rusty mine was...

I've used... (dunno how to translate this) 90' metal beam to restore "factory lookalike" jacking points. It was also easier to weld everything to this beam



those vertical parts works as super stiff jacking points,also metal beam looks quite stock. Another thing it will be superb to mount some getto side skirts- holes will be through beam, not through sill



best wishes with bodywork! I know how PITA it is o_O
using that L-bar is a gr8 idea, much easier, stronger & quicker than me trying to manually recreate those inner sill panels from scratch.
nice work :DπŸ‘Œ
 
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