no idea where the old thread has gone but I have news
One step forward a more expensive one backwards.
Ordered the tilton hydraulic throwout bearing for the T5 gearbox about 18 months ago knowing I still needed the correct thrust bearing. Ordered that during the week to discover when offered up to the piston/carrier that the bearing was right the carrier was wrong. Hadn't opened the box and discovered an incorrect part. Too long ago to chase up so ordered the new carrier/piston.
Anyhoo nothing cash wont fix.


Had the cosworth T5 bell housing modified to suit the bearing base which also replaces the input shaft bearing retainer. why it didn't fit I don't know but the bell housing hole needed opening up by about 5mm. Had the faces of the belhousing machined, 10 thou one side and 60 thou to get the faces parallel so now await the right part and I can mate the engine up to the gearbox.


JP

Looking good. So that's a tilton twin plate clutch you've got there?

AP 7.25 triple with sintered friction plates


should hold the power!
 
JP

So It gets worse before it gets better or so they say.
Doors Off, for the first time since manufacture in 1971 I guess

8mm pin punch and a dremel made light work of 3 of the roll pins. the 4th needed a bit of heat. and the doors surprisingly aren't that heavy, well compared to falcon and suzuki ones anyway.
Front guards off, this was easy as they were already bolt on

Engine and gearbox are out, driveshaft and exhaust removed, engine wiring and ECU out rear parcel shelf lining pulled out...bent it a bit, damn alloy. Will be welding a new steel bulkhead in so big loss

Will hopefully be getting it onto  a rotisserie in the next few weeks for the following.
List is really for me;
New new front floors,
6 link rear boxes,
rear turrets.
diff tunnel
gearbox crossmember,
new rear bulkhead
Roll cage door bars, through to strut tops
dash bar to hold steering column
remove old and replace with new seat bars
tidy general welding throughout
modify dash to suit 6 dial dash
tidy front bulkhead and transmission tunnel.
engine chassis mount
weld up about 50 holes
manufacture new exhaust to suit turbo.
rewire fuse box, relays and switched to passenger side floor mount tower incorporate new engine ECU
Build up bilstein struts to be adjustable
fit intercooler somewhere
mount remote oul filter, cooler and new oil system
All for this!



 
Damn long list now I type it all out. Fortunately I have all parts except the intercooler

Justin

No going back now!


All glass out, all wiring removed from cabin, oh and the seat rails and side intrusion bars from the cage cut out!
Never liked the cages side bars as they prevented the seat getting low enough. Well I cant see the bonnet and Im 6+ foot but I could go 50mm lower. What was good to see was I did get penetration in the welds...
Looks like I should be able to clean most of the old welds and remaining stubs up pretty easily before the new lower bars go in. Looks like I was going to have to get the cage redone anyway due to the new regulations.
Bought a sandblaster so going to strip the interior, engine bay and underside again! have ordered new front floors and mounting rails so they are getting done too.

Cheers

JP

slow progress with Christmas and work and heat



more parts on their way including new seat rail boxes.
have started the cut-it-out process, having unpicked the two wings of the tunnel stiffener to free up the floor space for cutting and welding soon. Post Christmas holiday period cant come soon enough. spare time and cash to spend!

JP

Hey JP. Excellent progress mate. Keep the pictures coming, its going to be very interesting seeing how your project goes. And tell me how you find some of that spare time and cash
Also, I noticed the rear springs are out of the car now. Are you still interested in selling them?

Hak.
I might hold onto them for a bit, someone made a very good point towards keeping the IP rear end. Already sold the shocks to the guy who bought most other parts in a 'bundle'.
Will let you know if I re-change my mind
 
Justin

FFS,
Christmas holidays almost over and barely anything to report. How do I get myself so involved in others business!.

Bigger holes cut. I like to call them exploratory but the reality is they are cutting my previous amateur mess out. Hope my new found patience and belief I have skill through Knowledge pays off. 6 months on its side to return to the same point I was a month ago would be um disappointing.

All I can say is who did this!

But nice new shapely bits

Still after an Auto tunnel. Or I might re-repair this one or go aftermarket

JP

Update seems pitiful but hey I also have two nice new ceiling fans installed, a new driveway, assembled the Christmas gift BBQ, welded in a drivers footrest to the subazuki and installed new speakers and amp in the ute!
Slowly unpicking the mess. Spent 2.5 hours grinding of seam welds to help undo a previous repair

After grinding away old welding I had to panel beat the front firewall 'tub' after it warped, has better shape than ever before. And lots of measuring before cutting. Im going to try and save this tunnel. Well the top anyway.


JP