PollyMobiles Rebuild

[pollyp]

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

gave the electric sunroof to ralph

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

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

tacked on

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

sealed with tigerseal inside

grinded the messy welds flat & painted

during welding, I burned the seats ??

also the spatter landed on the windscreen and cracked it ??

 

[pollyp]

2019-04-09 Omex 600 Standalone ECU

Dave who has the blue turbocharged CGA3DE facelift (was previously James) sold me his Omex 600 ecu ??
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.

dave has nicely included this coilpack too which eliminates the dizzy

this is inside a crank pulley harmonic balancer

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

machined the inside bore straight & round

a sleeve follows this smooth bore

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

 

[pollyp]

2019-04-21 Malton breakfast car meet

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

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

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

soldering the connection made it better

 

[pollyp]

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

 

[pollyp]

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

chopped the old kinked pipes apart including the huge exhaust tip

welded a much nicer flowing bends

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

now she has a good flowing and subtle looking exhaust

 

[pollyp]

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

attended the sunny NE autoshow with the local club

m8 matthew brought another car but sprang a big water leak ??

 

[pollyp]

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

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

plug #1 alot richer

tons of blowby getting into the intake

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

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

inside a regulator

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

the huge blowby was leaking past the catchcan lids

so I made a simple extra seal inside

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

 

[l_jonez]

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!

 

[pollyp]

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

as a bonus he also donated this new spare GT1549 turbo meant for his scrapped MX5 ??

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

 

[pollyp]

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

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

machined new aluminium ends

I love precision ?

remounted the contact brushes

all done and works nicely ?

 

[pollyp]

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 ?

lots of LSD diff bits

removing engine

clutch is ok

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

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

ripping apart the clean engine

and there we are, cracked #1 piston ?

 

[pollyp]

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 ?

 

[pollyp]

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 £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 ??

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 ?

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

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

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

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 ?
cams looked clean and compression was ok

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

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

Spare Engine #2

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

opening inside, these CG13 pistons were left in the rain and stuck with rust ?

removed the bottom end

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

and managed to remove & salvage the CG13 pistons ???

 

[pollyp]

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

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

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

cleaned up all the corroded pistons

reassembling the block

checking the crank end-float is perfectly snug

assembling the top end

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

engine all build & ready to fit

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

 

[pollyp]

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

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

FFS it looks like these two useless drilled holes in the cover caused a stress-point ??

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

this will need sending back to gripper to rebuild under lifetime warrenty ??

 

[pollyp]

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.

 

[pollyp]

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

so I extended the plumbing over to a cooler section

made a better support to fit onto the clutch cable mount

 

[pollyp]

2019-06-13 Tyre puncture

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

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

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

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

 

[pollyp]

2019-06-14 Loose gear linkages

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

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

 

[pollyp]

2019-06-16 Yorkshire Modified Show

had a gr8 day out at the modified show with the CCS club

 

[pollyp]

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

chopped open my silencer

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

wrapping it full of stainless wool

welded up

and tbh sounds roughly the same ?

 

[pollyp]

2019-06-22 De-Strip Doors

removed the bump strips off the doors which looks a lot better now ??

 

[pollyp]

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

 

[pollyp]

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

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

mounted all the new manifolds and made this stainless downpipe

then we began plumbing everything in

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

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

 

[pollyp]

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

got a straight router bit and removed that lip

and they fit nicely and look really really mean ??

 

[pollyp]

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
so I attached monkey polly to kassandra now

 

[pollyp]

2019-06-29 Overhaul heater fan motor

the fan wasn't blowing as hard so I reoiled the motor inside

 

[pollyp]

2019-06-30 Ormesby Hall classic car & bike show

attending a cool classic car show. the oyster sauce air filter can certainly drew attention lol

 

[pollyp]

2019-07-07 Cumbria Auto Show

going to the cumbria auto show with the Distinct car club stand

 

[pollyp]

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 £550,
• TurboShop can fit a bigger wheel into my current turbo for £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 £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 £600 ??
really hurts my bank account ?

the new wheel is approx 14% bigger

 

[SuperUno]

Great to see you back posting your work on here Paul

 

[Low Rider]

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

View attachment 65624View attachment 65626View attachment 65627View attachment 65628View attachment 65629View attachment 65630View attachment 65631

If only it were a real one

 

[John_D]

If only it were a real one

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....

 

[Low Rider]

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

 

[pollyp]

Great to see you back posting your work on here Paul

thank you

 

[pollyp]

If only it were a real one

either one would be a rare delight to see up close ?

 

[pollyp]

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

chopped the entire sunroof section out

new sheet was welded in

reattached the support beam

added this extra beam to stiffen it

welded another sheet on top to make the surface flush

body filled

painted ?

 

[pollyp]

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 ?

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

so I cut that section off

and welded it in a better spot

much straighter now ?

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

 

[pollyp]

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

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

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

removed the dash for better access

chopped all the rusted sections out

welded new sections in

grinded smooth

red oxide primed, primered and painted black

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

 

[pollyp]

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 ?

 

[pollyp]

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

the rear of the floor also needs repairing

Cutting rusty panels off

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

Bending new Sills

slowly forming new inner sill panels

painted the inside with red oxide

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

 

[pollyp]

Rebuilding inner sills

Weld Front Outer Sills On

Weld Outer Sills On

 

[Thelegg]

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

 

[pollyp]

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 ???‍

 

[pollyp]

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

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

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? ?

 

[pollyp]

wirebrushed the rear floor pan clean

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

chopped all the rusted bits off

 

[Matiz]

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

 

[nissan boy]

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

Sent from my moto g(6) using Micra Sports Club mobile app

 

[pollyp]

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

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 ?

 

[pollyp]

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

Sent from my moto g(6) using Micra Sports Club mobile app

yup they're getting to that age of infinite rotting. hope this'll last for a while.

can't wait to see the end of all this welding chore and just drive