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PollyMobiles Rebuild

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pollyp

pollyp

Club Member
2021-05-06

finished work only to see this damn marking on my bumper. initially thought it was bird poop but soon realised it's a friggin deep tyre mark 😡 either some fecker had went full lock while being too close and rubbed their tyre hard against it or some motorcycle twat bumped into her

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tried buffing it off with rubbing compound but it looks deep and will need a respray 😒🙄

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checking the cctv at work has a few issues:
-only the manager has access to the cctv,
-he won't check it for me cos he's busy or not there, so I'd have to check myself during free time,
-but I don't have much free time to look through hours of footage cos I'm either out delivering, lunch or toilet 🙄
-I dunno the exact date it happened cos only noticed the mark when car was parked the other way round,
-shop only opens 9-5pm
-recordings only last for a week

so all these factors were against me, didn't find out and I gave up in the end 🤬


on the night I shortened up my stereo adapter loom for less clutter

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OP
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pollyp

pollyp

Club Member
2021-05-10

the exhaust often felt kinda choked at high end with the 2nd cat in place for last years MOT, so it's time to resort back to de-cat.
but first one of the v-band flange needed swapping around

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I cut the female flange off the downpipe

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grinded the old weld down

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welded the new male end on

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and then I could make the new stainless de-cat pipe

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now with only the primary manifold cat in place, the mid & high end feels slightly faster
 
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pollyp

pollyp

Club Member
2021-05-11

for the last few months my mini lathe seems like it's shocking/tingling me whenever it's powered and my hands brush against any steel surfaces 😬⚡

time for a well overdue clean up

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and yup looks like all the swarf had gone into the motor and causing a slight short from the live parts to the casing to the steel frame

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after clearing the swarf it's no longer as shocking 😅
 
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pollyp

pollyp

Club Member
2021-05-12

another gr8 busy wednesday car meet on a warm sunny evening this time 😎

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later on I discovered someone with a clean 02 1.4 facelift, preface superS front end, march style boot lid, gizfab bits, BC BR coilovers 😃

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me m8s frankie & zara also found a good gathering of their red MX5's 😁

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pollyp

pollyp

Club Member
the cheap £6-8 Dunlop FP-M12C tie-rod ends don't last long (only 1yr) and the one I replaced recently was defective and already too sloppy 🙄

so I brought these more pricey £16 XFRM12 joints which has previously lasted 2+yrs

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cut & machined the threaded part off some spare old tie-rods to weld onto the short rod-ends

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realised they have m12x1.75 threads so I had to retap them to m12x1.25

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so I can join em with a spare tie-rod for welding

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OP
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pollyp

pollyp

Club Member
the slower TIG welding puts soo much heat into the metal so I had to weld 10mm at a time immediately followed by quenching in water so the heat doesn't damage the teflon lining and then do a rapid pulsed final pass to even out the surface finish

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removed the old worn cheap rod-end

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double checking the clearances of the new joint

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added the dust boot to the new joint

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realign & test drive it tomorrow
 
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pollyp

pollyp

Club Member
assessing the old worn tie-rods, the spherical ball is quite corroded with heavy deposits of the teflon lining

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cutting it apart and I'm surprised to see that the cheap rod-ends consists of a separate spherical bearing pressed into a thin-walled tie-rod housing. so during a trackday, all the steering tension forces is going through a 2mm thick ring 😬

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inside is a brass mesh coated in teflon? which has clearly worn through and deposited onto the polished sphere over a short time

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I wasn't happy with only 15mm of thread engaging :oops:

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so I welded an extra piece of threaded end to lengthen the tie-rod end

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applied an updated CCS sticker with new letters

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pollyp

pollyp

Club Member
on sunday the CCS club had a convoy trip from a rainy teesside park going upto a sunny scenic Clay Bank park

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with no idea where we were all going, following behind each car was quite stressful whenever we get stuck at the red lights and having to rush to catch back up 😧

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the next destination at Saltburn was abit easier when I overhead the postcode to plot onto my satnav beforehand.

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pollyp

pollyp

Club Member
the bathroom tap has been leaking for a few yrs, so i tried to unscrew & pull it apart only to end up snapping the rusty parts off 😧😳

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when a 5min job turned into a "Oh crap it might be a big repair job" 😬
there's lots of corrosion and small bits to maybe TIG weld🤔

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checking my spares plumbing toolbox I discovered this used valve from the kitchen tap is compatible with the bathroom tap housing

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and it worked. saved hours of work and no longer leaks 😎

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andy

Ex. Club Member
Man balances pool cue on forehead for 2 hours, 16 minutes

That's was a Interesting news
But I want to tell you something important
I am sure you heard about Palestine and isreal ?
You know I did research then I found Israel is a terrorist country
They are killing innocent people in Palestine
We should stand and boycott Israel and those who are supporting Israel

You know I can't hate them just becouse they are Muslim
We should show we have a soft heart and we love humanity
I am sure if you are a not a terrorist or hater
Then you will agree with me

#support Palestine
#boycott Israel


Sent from my TECNO KC2 using Tapatalk
where is the fxxxing mods and admin on this site, this is spam, ya need to up ya game a bit lads and lasses
 
OP
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pollyp

pollyp

Club Member
m8 Daniels new carbon spoiler wasnt sitting flush to the boot due to the petruding screw head underneath the base panel

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so I carefully countersunk the cheap ebay fiberglass base panel holes to make the screws sit flush

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ran out of sealant so I applied some foam tape

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cleaned the old gunk off the boot too

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sits slightly better on the boot lid

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pollyp

pollyp

Club Member
peeled off the temporary 'electrical tape' sun strip but looks like the sun had cooked the glue onto the glass 🙄

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cleaned the glue off the glass after a lot of messy rubbing with acetone

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applied the new new vinyl sun strip to align with the horizon

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gave her a wash for tomorrows cruise & car meet

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OP
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pollyp

pollyp

Club Member
had this spare dash cam with a small lightweight reversing camera, which is perfect for filming my front tyre flexing under load.
the CCD inside was wonky by 6deg so I printed this mount which holds it angled on the end of a threaded rod

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rod is bolted to the tow bracket and is at the perfect angle. can't wait to test it on a dry day

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pollyp

pollyp

Club Member
went for a run after sunset and it worked ok

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the long rod zip tied to the bumper obviously vibrates with the engine at low rpm but is fine at high speeds, so I may use a lighter/hollow/big diameter tube to reduce movement.

the dash cam captured the interior shot & tyre cam in 'meh' quality but the highly inefficient file system was a pain to process.
it records each camera in 5min segments, each being 700mb and each had to be slowly converted from MOV into MP4 for the PC editor to import (otherwise it crashes) 🙄

 
OP
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pollyp

pollyp

Club Member
got myself a compact digital oscilliscope which will come handy for electrical diagnosis.
plus a new 17mm impact socket cos the 17mm in my impact socket set was seriously made wonky and would wobble badly

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and now this new 17mm spins perfectly centered 😎

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decided to paint a subtle red lip around the white wheels to divide/transition between the bright white and grey/black tyres 😎

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pollyp

pollyp

Club Member
replaced the terribly rusty old bonnet with the spare blue one

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kinda looks alright & shinier but really does highlight just how wonky her entire front end is too cos nothing lines up well to the bonnet 😅 🤪

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pollyp

pollyp

Club Member
ducktaped this perspex to the tyre camera mount in an attempt to stiffen support & reduce shaking.
if anything it actually made it shake even more lol

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good thing the shakey footage is downsized smaller compared to the stable HD GoPro camera.
went for another sunny weekend drive to test it out 😎

 
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pollyp

pollyp

Club Member
Daniel wanted an Odyssey gel battery fitted to his Audi TT turbo, so I removed the big old heavy battery

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drilled & bolted the battery enclosure onto the car

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reattached the battery cables

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pollyp

pollyp

Club Member
Michael Stanhope needed a hoop making for hanging his steering wheel off the roll cage, so with a few dimensions I modelled this up

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and printed it off

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good results. hope it works well for him :cool:

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OP
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pollyp

pollyp

Club Member
took a covid self test on thursday, eeeks its like shuving a tickly feather down my throat & nose, made me gag & sneeze :sick:🤧 but at least it was negative :)

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Friday the next day after work I drove all way up to Hexham to get me 1st Pfizer jab.
overall it was a pleasant experience, friendly ppl, honestly the needle was sooo tiny I didn't even feel it.

18:30 I had the jab

21:00 the muscle around the jab area was only slightly beginning to ache a bit

09:00 Saturday next morning the jab area was still slightly aching and had a dull tension headache, but that was normal for me on weekends which was fixed with ibuprofen

Sunday I was all fine (y)
 
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pollyp

pollyp

Club Member
over the weekend I went to get a whole load of grey paint, white etch primer & laquer and decided to strip apart all her doors to fix all the rust

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to remove the rear door window, I lower the window & unbolt the metal divider

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the rear 1/4 glass simply swings off

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it sat in this groove

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I quite like this pillar-less look :cool:
since I never use the rear windows, I think I'll just tigerseal some perspex over it instead

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removing the window reveals all the rust holes 🙄

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rust #1 on the right door

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rust #2 on the right door

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this one's the worst on the right door

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rust #4 on the left door

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finally the front passenger door had bubbling rust

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pollyp

pollyp

Club Member
Daniel in his Audi TT turbo needed a stainless intake pipe making, so here's the original plumbing with the black plastic elbow pipe leading from the MAF down to the turbo inlet

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gathered all the stainless materials

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trimmed & tacked the pipes together

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drilled hole for the breather port

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the original pipe had this sharp bend near the turbo inlet whereas the new stainless pipe has a smooth gentle bend

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bolted up neatly and looks gr8. he said it spooled up slightly sooner too which is good news 😎(y)

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Craig

Unofficial Member (Gold)
Club Member
Making the rear window one piece is pretty smart, quite like the symmetry of that and the front windows if you decide to do it
 
OP
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pollyp

pollyp

Club Member
removed all the doors, wings, bonnet, bumpers so that I can wirebrush & rattle can the rear wheel arch, scuttle panel & sills.

then repair the doors & sand all the panels down in preparation to take them all over to Luke on saturday to respray them properly with his spray gun & 500ml tin of base coat

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pollyp

pollyp

Club Member
welded & smoothed the rear offside door rust patches

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for the lower corner, welded the vertical backing plate 1st

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and then weld & smooth the curved edge

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weld & smoothed the rear nearside door

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time to fully strip apart the doors, wirebrush & treat & bodyfill the rust patches

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on the nearside door this is where the water drain got under the seam sealer and started bubbling the inside & outside edge

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slightly bubbling around the rear drain hole

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stripping the drivers door

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the rubber strip was oddly glued to the door here, which of course torn it :rolleyes:

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once again the bloody seam sealer just trapping moisture on both drivers side doors till it rusts

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the rear door also having the same rusty seam sealer

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going to a labour intensive delivery job 9-5 followed immediately by these long nights stripping & repairing kassandras rust in a rush to make the yorkshire modified show on 20th june is beginning to strain my body stamina & mind 🥵😓

dunno if I'll have the energy to get it all done in time or collapse or simply throw the towel 🤷‍♂️
 
OP
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pollyp

pollyp

Club Member
I had 500ml tin of base coat plus 4 spraycans but felt this wasn't enough for all the doors & big bonnet & wings,

so this early saturday morning the plan was to go order another 1L of base coat to be sure I had enough, return home to further sand the bonnet & wings before luke arrives on afternoon with his compressor.

that plan was ruined when the store was very busy and had a 2hr waiting list!
so I wasted some time buying an orbital sander to aid sanding the big panels & go for lunch, collected the 1L of paint at 12pm and got home for 1pm where luke just arrived

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this was gonna be a huge task which was stressing my tired head. while luke paints the doors & bonnet with the 1.5L of paint (which was thankfully enough) I prepped the bonnet with the new sander

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it was a very messy job with paint fumes & dust going everywhere and very limited space to carefully hang the freshly painted panels :unsure:

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the painting was ok, wasn't perfect and a few flies trapped in the layers but it'll do

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he told me it takes days to fully harden before any buffing so I gotta store em round the house carefully 😬

the rest of the rusty wings, rear 1/4 and both bumpers I'd have to rattle can em myself.
so I bodyfilled the rear arch, but the cheap stuff I got from work was absolute pigsheet, didn't mix proper or harden, so I gotta brush it off tomorrow, get the proper p38 and start again 🤬

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the 1x1m of polycarb sheet arrived for covering the rear door

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OP
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pollyp

pollyp

Club Member
the cheap bodyfiller I brought from work was definately old & dried up cos the filler was actually thick like scooping frozen ice cream and very difficult to mix properly.

so this morning I brought some fresh P38 from halfords and wow huge difference. it's much softer like honey and a lot easier to mix thoroughly.

now I can body fill & sand down the rear 1/4

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masking

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on this hot day, I began spraying with what I assumed was white etching primer that the paint shop gave me.
but to my horror it immediately started cracking apart as it dried, looking like a desert floor 😧

the hell !!
I tried sanding it off, which was tricky cos it kept clogging the sand paper 🙄

degreased it with brake cleaner and tried again with the white primer, only to happen once again 😠😡😤🤬
FFS

was talkin to Luke about it only to realise the can said it was High-Build white etch primer which wasn't suited for the hot temps and needed thinner layers.

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well, I'm fuming, frustrated I messed up, I don't have time to slowly sand this mess down to respray with normal primer, so I just carried on spraying basecoat over this wrinkly mess and it's an eye sore 🙈

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nothing I can do bout it yet cos I have a show on Sunday, but I'll respray it with normal primer soon afterwards.

wirebrushed & treated the rusty front wings

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smoothed bodyfiller.
the new orbital sander I brought yesterday makes the job of flattening the bulk of the excess bodyfiller a lot easier & faster compared to previously doing it all manually by hand 🥵

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sprayed it with normal halfords grey primer and it looks a lot better & smoother than the rear 1/4 mess

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sprayed 500ml cans of base coat & lacquer per panel and the result is nice 😎
all the wobbly inperfect sanding is obvious with a glossy finish now but at least it's no longer rusty 😅

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to end the long day, all 4 doors were bolted back on

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it's taken a full exhausting week to strip, repair & paint all the major body panels 😩
half way there and now I'm on the home stretch,
reassembling everything over the next 5 days,
make a new polycarbonate rear door window,
clean all the dust out of every friggin surface of the car,
then polish all the nasty orange peel off the new paint ready for sundays show 🥵
 
Polly, I would have rather you stayed focused on a slow job and skip the deadline. Maybe just go with a mate next time a deadline approaches? I've stopped with the crazy deadlines now, and my life is much more balanced!
 
OP
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pollyp

pollyp

Club Member
Polly, I would have rather you stayed focused on a slow job and skip the deadline. Maybe just go with a mate next time a deadline approaches? I've stopped with the crazy deadlines now, and my life is much more balanced!

I already paid for and commited to going to the show, chosing to fix this rust 2weeks ahead but as usual the job always ends up bigger than expected.

was determined to do whats neccessary to get the car ready for the big show (maybe only show of the year if covid gets any worse) even if I'd have to push my body hard.
 

Craig

Unofficial Member (Gold)
Club Member
The black underbonnet is pretty smart, like that - is it a satin?

Re the polycarb windows - how is the 3mm - is it rigid enough? I measured my Humphris set - they're 4mm which is (relatively) a fair bit thicker?

Craig
 
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