PollyMobiles Rebuild

[nissan boy]

Genuine Nissan or knock-off? If it's the latter, DON'T jack it up using the front jacking point or you'll turn it into a banana without additional reinforcement.

i got the Taiwan after market one and not had any problems jacking it up ,it's kinda thin but about the same as the original ,even welded ok with a arc welder when the mig broke, and surprised it held up without rusting it wasn't really sealed or painted except the welded.bits

 

[nissan boy]

sister was replacing her carpets so I grabbed the underfloor insulation she was gonna chuck away so I can insulate the micra again.
I first made a piece for the boot floor

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those stick on sound deadening packs seems to work, I've got 10 I think on atm ,rear wheel well, n/s.inner.arch , rear quarter panels, inner sill, and some on the main floor and the car seems more.quiet, except the exhaust lol, but the road and rattles seem less , as originally I had some sound deadening cloth in the boot and 3 pieces of the stick on does the same / better?

 

[pollyp]

i got the Taiwan after market one and not had any problems jacking it up ,it's kinda thin but about the same as the original ,even welded ok with a arc welder when the mig broke, and surprised it held up without rusting it wasn't really sealed or painted except the welded.bits

Yeah mine's the Taiwan one too good the hear

Sent from my Nexus 7 using Micra Sports Club mobile app

 

[pollyp]

those stick on sound deadening packs seems to work, I've got 10 I think on atm ,rear wheel well, n/s.inner.arch , rear quarter panels, inner sill, and some on the main floor and the car seems more.quiet, except the exhaust lol, but the road and rattles seem less , as originally I had some sound deadening cloth in the boot and 3 pieces of the stick on does the same / better?

Think I'll have to remove the dash to muffle the bulkhead where most of the noise comes from

Sent from my Nexus 7 using Micra Sports Club mobile app

 

[St0rm91]

hehe I'd never jack up from the middle of the crossmember

... Have another recommended spot? I've already bent my sills a bit

 

[St0rm91]

As far as sound deadening goes I found these fantastic (https://www.amazon.co.uk/gp/product/B00NVE013I/ref=oh_aui_search_detailpage?ie=UTF8&psc=1). Did the inside of the doors before changing speakers & notice an immediate difference. Definitively going to be getting more to do the firewall.

 

[nissan boy]

... Have another recommended spot? I've already bent my sills a bit

the front floor rails, and put the axle stands under the rear wishbone mounts, under the rear coils of the rear axle or can jack on the towing eye, then axle stands in front of the trailing arms on the chassis legs , check your crewmember first cause of its rotten or or damaged, they can bend lol

 

[nissan boy]

As far as sound deadening goes I found these fantastic (https://www.amazon.co.uk/gp/product/B00NVE013I/ref=oh_aui_search_detailpage?ie=UTF8&psc=1). Did the inside of the doors before changing speakers & notice an immediate difference. Definitively going to be getting more to do the firewall.

Yep using the same ones in mine, still got afew left to do the doors ect

 

[SuperUno]

how'd you recommend I reinforce it?
weld a few angled truss ribs inside the box section?

Maybe over kill on a non rally car. I used angle iron on the front faces and then flat iron to make a 'box' around the three faces of the box. Can get some pics at some point if you want. That then is braced to the chassis rails. It is the sump guard mount so is prone to a lot of force and abuse. But will very easily take whole weight of car on it.

 

[pollyp]

... Have another recommended spot? I've already bent my sills a bit

as Jack mentioned above, I use my trolley jack under the lower control arm rear bushing and the rear axle beam and then place the axle stands on the front floor rails and in front of the lower trailing arm mount or on the axle beam

 

[pollyp]

Maybe over kill on a non rally car. I used angle iron on the front faces and then flat iron to make a 'box' around the three faces of the box. Can get some pics at some point if you want. That then is braced to the chassis rails. It is the sump guard mount so is prone to a lot of force and abuse. But will very easily take whole weight of car on it.

yeah sounds like a ton of overkill for her
think I'll leave it cos I'll never jack up from that point anyway and its extra work

 

[pollyp]

welded up all the holes on the front panel so dirt/water can never get inside in the 1st place

chopped out these side sections for the intercooler plumbing

bent & welded back up

 

[pollyp]

at work I measured a few concentric clutch slave cylinders to see if they'll fit my CG13 gearbox.

item #510 0225 10 fits over the 27mm diameter input shaft coller but the diaphram facing collar is abit too large.
but all of them are simply too long at 57-63mm compared to the 34mm long release bearing / input shaft collar.

the other easier more reliable option is the traditional external slave cylinder operating the clutch arm.
coupled with a remote master cylinder this seems to be the best way to 'test trial' if a hydraulic clutch suits the setup and can easily revert back to cable.

 

[pollyp]

with a big spare roll of foam carpet underlay ready and afew sheets of rubber floor mats, lets begin stripping out the interior to prep & install the insulation

spotting a few little rust spots around the fan inlet, bulkhead rain channel

wondering whats inside this dimple cover?
ooh the angled foot well is hollow and allows access to the sway bar / rear bushing captive nuts

wirebrushing the rear floor pan and damn, more rust holes to fix

bent a new plates

tacked

welded

welded the boot hole

hammerite & painted

now I can finally begin laying the insulation tomorrow

 

[pollyp]

interior stripped bare, the roof & floor panels resonate so much like a biscuit tin

the roof panel was barely attached to the cross beams with afew tiny dabs of sealant. fill the big gaps with sealant to reduce any panel movement

begin lining the rear arches with foam carpet underlay using spray contact adhesive. it's relatively easy to fit with the foam being quite stretchy & flexible to mould around the curves

painted it black & stuck some on the roof

the whole rear end is now insulated, looks cosy

insulated the front of the roof

 

[pollyp]

after many labourious hours, I carefully trimmed the foam underlay onto the front floor/bulkhead

 

[John_D]

after many labourious hours, I carefully trimmed the foam underlay onto the front floor/bulkhead

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I thought that it was felt underlay Paul, have you done a fire test on a scrap of the foam with some contact adhesive on the back?
Bearing in mind how much welding you do I'd be very careful, I'd hate to see Kasandra go up like a Roman Candle!

 

[pollyp]

I thought that it was felt underlay Paul, have you done a fire test on a scrap of the foam with some contact adhesive on the back?
Bearing in mind how much welding you do I'd be very careful, I'd hate to see Kasandra go up like a Roman Candle!

yup I lit a scrap piece with blow torch and it melts abit & then extinguishes itself

 

[pollyp]

phew, finally finished laying down both footwells

and the rear end

apply some durable rubber matting tomorrow before reassembling it back

 

[St0rm91]

phew, finally finished laying down both footwells

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and the rear end

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apply some durable rubber matting tomorrow before reassembling it back

I’m going have to copy this at some point I think, the noise off of motorways in ridiculous. Every little bump and groove in the toad.

 

[pollyp]

even at silly'o'clock in morning, I finally applied rubber floor matting on the foot wells for a durable nice look

Sent from my HTC One X+ using Micra Sports Club mobile app

 

[pollyp]

assembled the dash

assembled the rear end and applied the rear floor mats

painted the parcel shelf black

interior all finished, insulated, painted black and looking awesome

went for a test drive and Wow! what a huge difference

at idle the cabin is nicely muffled from the clicking engine bay and there's just the very low freq purr of the exhaust.

at low speed it's very luxuriously quiet, the clicky injectors and turbo spool up below 0psi are barely audiable, you just get this surge of torque.
once I accelerate with higher boost, then the spooling noise comes up but still very smoothly muffled with non of that clicky diesel sound of the injectors and the exhaust ain't as boomy loud any more.

and now when cruising along motorway, especially on that insanely loud rippling carriageway to work, that deafening tyre roar is halved and exhaust no longer drones / boom / resonate inside the cabin. it's soo comfy I can actually hear my stereo, hear my voice without screaming, no longer need to wear ear plugs

wish I did this so many yrs ago

 

[Mrthc]

Polly you are my Hero.
You know Cassandra better that your pockets.
Wow what a jobs. ..

Inviato dal mio SM-J500FN utilizzando Tapatalk

 

[pollyp]

Polly you are my Hero.
You know Cassandra better that your pockets.
Wow what a jobs. ..

Inviato dal mio SM-J500FN utilizzando Tapatalk

thank youu

 

[scoobie23]

your blog awesome m8

 

[pollyp]

your blog awesome m8

thx scoobie

 

[pollyp]

catchcan caught 70ml after 1000 miles driving in summer, which is meh

stuck some spare reflective foam sheet inside the glove box to stop things rattling inside

 

[nissan boy]

Please put a led.in there on a switch, that would be brilliant haha

 

[Thelegg]

Wow! Just read your whole blog it's taken me over a year haha well worth it tho truly amazing work really inspiring only started reading it to see what gains could be achieved from fitting nistune but now I'm definitely fitting a turbo in the near future!

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[pollyp]

Please put a led.in there on a switch, that would be brilliant haha

noted

 

[pollyp]

Wow! Just read your whole blog it's taken me over a year haha well worth it tho truly amazing work really inspiring only started reading it to see what gains could be achieved from fitting nistune but now I'm definitely fitting a turbo in the near future!

Sent from my SM-G901F using Tapatalk

thanks m8
glad the lengthy blog helped ya

 

[pollyp]

briefly visited Jamie from 'LetsTorqueCars' to check out his recent micra purchase & to film more short videos

he brought this 1996 1L 5dr Shape as a daily runner and it's in fantastic state, only done 56k and paid just £550

we videoed the car doing a few cheeky launches

 

[pollyp]

gathered at Dragonville with a few m8s for the final E85 car meet there

 

[pollyp]

with the video shoot & car meet out the way, it's time to replace that rusted front end before her MOT in Oct.
began stripping the front off

to my shock, it turns out that the old botched front panel wasn't even fully welded on!
it was only attached with a few bolts, pop rivets and little poop tack welds

removed the rotten old front panel

now you can see the turbo setup and the state of the chassis legs

so this is where the past owner had smashed the left side

test fitted the new panel but something's odd

the sides don't meet

when I bolt up one side, the other side is really misaligned

noticed the panel is assembled unevenly

chopped it into pieces to align the seperate bolt holes before it's welded back together

things getting abit serious when I use the rotary laser level to measure where exactly it's deformed wonky

so it turns out the reason for kasandras wonky bumper is cos the past impact had bent the LH chassis leg down by 3mm and the weak LH bumper mount by 10mm!

notice the RH bumper mount is square & reinforced inside whereas the LH mount is just an open square section easily skewed downwards

straightened up & reinforced the LH mount

this headlight stud broke off

made a permenant metal bracket

wasn't happy with the way this new cheap panel was slightly wonky-jigged so I drilled it all apart

so now I can easily tweak the positions of everything till all the gaps are equal before I weld it back into place

 

[St0rm91]

gathered at Dragonville with a few m8s for the final E85 car meet there

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When the hell was this? This place is always empty!

 

[pollyp]

When the hell was this? This place is always empty!

Saturday last week

Sent from my HTC One X+ using Micra Sports Club mobile app

 

[St0rm91]

Saturday last week

Sent from my HTC One X+ using Micra Sports Club mobile app

I think Jack was right, I really need to get a life

 

[pollyp]

finally tack welded the whole panel back together

lots more tweaking to come but this is as straight as she's ever gonna be

 

[pollyp]

figured this mangled bit of flange where it was hit would be a waste of time to hammer into shape

so I chopped it out

and found these bits of the old seat rails had the same thickness plus the correct short edge to weld onto

wirebrushed & primed

welded up the new panel ready to grind em flat

 

[pollyp]

made this very simple bracket to support the radiator

ear's ringing from tediously grinding all the welds flat

sprayed with zinc-alu galvanising weld-through primer

 

[SuperUno]

Wear ear defenders, you only get one set of ears...

 

[pollyp]

Wear ear defenders, you only get one set of ears...

Maawp

 

[pollyp]

I'll need to tweak the bonnet struts which are touching the chassis and affecting how far the bonnet closes

undercoated & painted the new panel & chassis

repaired this damaged section

also repaired this old thin mangled top corner

fitted the front end to make sure all the gaps are equal

tacked & welded into place

LH section

RH section

grinded the welds flat and painted

welded these tabs to hold the wings solid from the headlights

yayy for the 1st time she has a nice level head

soo exhausted but I'm at the final stages of putting it all back together, fix the downpipe, before it's due MOT on friday

 

[pollyp]

got it back together in running form,
left out the catch cans & shield panel cos that needed tweaking to fit and I really wanted to test drive her,
bonnet latch is 10mm wayyy too high and needs yet more adjustments.

aligned the headlights, went for a night drive, boy I missed her

soo much more to finish but she's almost ready for MOT on friday

 

[Agent_Sm1th]

Lot of work you put in there Paul. Lots more years left in her now eh.

 

[pollyp]

Lot of work you put in there Paul. Lots more years left in her now eh.

hopefully I can keep up with Mr Iron Oxide

 

[pollyp]

bonnet latch was sitting wayy too high making the bonnet stick up by 10-15mm

discovered this top section for the latch was right-angled too steep & high

angled it down 45deg with a few sweet hammer blows and it fits back

front end assembled

ooh yeah looking spot on shweet parked at work

 

[pollyp]

beginning to suffer from the common old brittle expansion tank

with her MOT tomorrow, thought it's time to replace her rusty old downpipe flexi-pipe. how hard can that be?

top section of all the stainless strands have broken apart from the constant flexing

chopped & prepped the new section

welded

but a simple 2hr job actually ended up as a frustrating 6hr PITA cos the flange was off-angle by 1-2deg so had to mark / cut / reweld several times before I ended up welding it in-situ with pigeon poop at desperate times

fingers crossed at her MOT

she passed! barely

 

[pollyp]

ah shiiyte
bad news tonight. was just leaving town heading towards a local Kuruma UK car meet, boosting uphill to overtake when suddenly a loud crunching noise, some metallic bits falling down the car (I feared for bent rods etc), lurching with loss of power & misfiring, bright oil light! lots of smoke and really bad sound of knocking bottom end

pulled over asap in a cloud of smoke with the familiar sound of silence and dash lights and thinking Oh Fcuk what now?

she quickly drained all her oil down her pants

called up Greenflag to recover her back home. my Odyssey gel battery is rubbish with lights, it barely lasts long enough with hazards till the recovery came, had to keep it going with the emergency lithium jump starter pack.
dad soon came in the peugeot to provide lighting.
and the angel friend Kim arrived with the ohh soo essential cuppa tea

nice lad Wayne helped get her home 3 miles away & home sweet home

soon see what the damage to my wallet will be tomorrow

 

[John_D]

That's bad news Paul, looks expensive! Hope you have a spare engine for a rebuild..................