It’s only a small leak, honest

[Saltire]

Rather than hijacking Justin's thread even further, I thought I’d better start up a new thread with the Green Monster’s 2020 spring project. It started with a small radiator leak:

Thank goodness for CoolExperts

Scope creep so far:

- derust and repaint front bumper grilles
- derust and powder coat various front end brackets and the cross-member
- new Samco hoses from last year’s group buy
- new radiator header tank and cap, thermostat, heater valve, radiator fans, temp sensor
- new Hall sensor, coils, plugs and leads
- fit BCN gear cables and short shift
- “C” service inc. cam belt, tensioners, water pump and other belts.

To make access easier, I decided to take out the headlamp pods ( had intended to replace the lamps at a later date anyway). And I’m really glad I did; all the rose joints and hinges are really tight, and the Lucas lamps are badly corroded (the Cibies are fine, but with milky lenses). This afternoon I’ve got the lamps out of the pods, but I now need to split the lamp bowls from the mounting brackets, and of course the screws are solidly rusted in. I can’t use heat because of the plastic rings, so I’ve applied copious quantities of PlusGas and I’m waiting and hoping . . .

Meanwhile, it’s off to Steve at SJ for the replacement lamps and brackets (I already have a set of stainless steel fixings, which should make reassembly much easier).

More news as and when I get tired of freezing and swearing in the garage

[Saltire]

Well, that was an entertaining evening’s research. Total cost for 4 new headlamps plus associated bracketry from SJs: £466, including carriage and VAT.

Makes the PNM LED ones look very reasonable at £395

[Rambo]

PNM's look very bright. And legal too. No brainer really particularly for those twisty Wiltshire back roads on dark nights

Go for it Jonathan

[Saltire]

PNM's look very bright. And legal too. No brainer really particularly for those twisty Wiltshire back roads on dark nights

Go for it Jonathan

To be honest, Mark, I’m weighing the move away from originality against the safety aspect. I was coming back from court a couple of weeks ago on those very same unlit Wiltshire back roads, and it was frankly scary. On the other hand, my S2 is very original and pretty low mileage (64k). I have an enquiry in with Demon Tweeks, who are advertising Cibie both H1 and H4, so we’ll see.

My credit card is itching, though

[Saltire]

Good progress yesterday and today:

Now where did I put those rusty headlamps?

Off for blasting and powder coating

New temperature sensor ordered

CAS stripdown in progress

Good job I bought one of Simon_P’s CAS O-rings

Gear change cables removed ready for BCN’s new cables and short shift kit

There will be a short pause next week while the powder coater does his stuff and I order a few odd bits from SJ. I’ve also discovered that the bottom of the light pods and the underside of the front bumper could do with some paint treatment, so I’ll be looking for a supplier who can mix me some B04 in a rattle can.

[dapinky]

Jonathan,

I had a local paint factor (The Panel Shop) in Weston who made me a couple of aerosols when i bought the paint for my car, and they will make up what you want, while you wait..... I don't know if you have a 'local' place, but there is a company in Swindon who I use for most of my stuff now...... https://www.advancedpaints.co.uk/ (and if you use the code FREEPOSTMAR20 you get.... free postage )

Also, a couple of others who will do aerosols to order (and will post them!):-

https://www.jawel.co.uk/index.php?main_ ... pping_cart (£10.60 + P&P)

https://www.paints4u.com/ShoppingCart.aspx (£13.99 + P&P)

[Saltire]

Thanks, Dave, that’s really helpful. I’ll get onto it on Monday.

[lotusles]

HI Jonathon, I thought we purchased short shift kits a few years ago, did you not fit yours? I have changed cars since then
My 6 points for doing 86 0n M5 have just expired so Im arranging for my mustard special to come out of storage
KR
Les

[Saltire]

Hi Les, we did - and life got in the way! Hope you did fit yours, and were pleased with it.

Glad to hear the points are no more and hopefully the insurance costs will reduce as a result.

KR

[Rambo]

Glad to hear the points are no more and hopefully the insurance costs will reduce as a result.

I suspect there will be 2 chances of that

[Simon_P]

Jonathan,

The Cibie headlamps are really easy to clean. Get a piece of dowel and tape some cotton wool on the end a few drops of your favorite cleaning fluid and wipe the inside of the lens. Rinse with hot water and a drop of washing up liquid to kill the surface tension then leave to dry in the airing cupboard. I think access is easier if you unscrew the bulb retainer but you may need a couple of drops of superglue on the screw when you reassemble.
The silvering is very easily scratched so don't be tempted to use anything like paper towels.

Headlamps are only as bright as the bulbs, Halogen bulbs dull with use so new bulbs will be brighter.

[lotusles]

Glad to hear the points are no more and hopefully the insurance costs will reduce as a result.

I suspect there will be 2 chances of that

Actually amazing, £112 agreed value etc etc.
Reason mustard was in store was the extra 3 points i picked up for doing 66 in a 60 at 6.00 am on M6, easy money for plod for somebody that does 2000 miles month.
I have fitted the gearshift to the mustard along with roll hoops, so not yet able to comment, did you set it to mid range????

[Saltire]

Jonathan,

The Cibie headlamps are really easy to clean. Get a piece of dowel and tape some cotton wool on the end a few drops of your favorite cleaning fluid and wipe the inside of the lens. Rinse with hot water and a drop of washing up liquid to kill the surface tension then leave to dry in the airing cupboard. I think access is easier if you unscrew the bulb retainer but you may need a couple of drops of superglue on the screw when you reassemble.
The silvering is very easily scratched so don't be tempted to use anything like paper towels.

Headlamps are only as bright as the bulbs, Halogen bulbs dull with use so new bulbs will be brighter.

Thanks, Simon. New bulbs already sitting on the bench. I had wondered about cleaning the inside of the Cibie lenses, and I have some isopropyl alcohol, so I’ll give it a go tomorrow. Nothing to lose!

BTW, I’m the buyer of your temp sensor on eBay; old one looks as though it’s come off a 25 year old tramp steamer

[Saltire]

Good news and bad news today

- Simon_P’s headlamp cleaning advice works a treat . Made up a dowel and cotton wool, moistened with a spot of isopropyl alcohol, and all the whitish bloom on the inside of the main beam lenses disappeared as if by magic. New bulbs ready to fit, and they’ll be as good as new. Thanks, Simon
- Headlamp rods cleaned up fine; no need for new




Headlamp actuation rods - before and after


- Cam belt change progressing well:




Cam belt cover off and all ready to dive in






Belt off and everything cleaned up ready for new


However, the crankshaft pulley was delaminating:




Crankshaft pulley not in great shape


Decided to bite the bullet and replace it with a new one; too important to risk it. £180 - ouch!

Waiting for one or two odd bolts and gaskets, then the reassembly starts!

[JusNoGood]

Reading with interest Jonathan

Also, very interested to hear what you think of the lights once you have it back on the road. I have got new lenses (my car US lenses) had and new +140% (or whatever it is) philips bulbs but they're still rubbish. Someone was telling me they can be vastly improved by adjusting the lenses, I think by bending them and shaping the beam. Although they didnt explain how. Just cant remember who or on what platform I was talking to them on now

so I'd like to upgrade once I've recovered from the major service and the building work we have planned on the house.

[Saltire]

Reading with interest Jonathan

Also, very interested to hear what you think of the lights once you have it back on the road. I have got new lenses (my car US lenses) had and new +140% (or whatever it is) philips bulbs but they're still rubbish. Someone was telling me they can be vastly improved by adjusting the lenses, I think by bending them and shaping the beam. Although they didnt explain how. Just cant remember who or on what platform I was talking to them on now

so I'd like to upgrade once I've recovered from the major service and the building work we have planned on the house.

I’ll keep you posted. Interesting developments today though. I got back from a business trip to find a pair of these headlamps waiting for me. Ordered Tuesday, delivered Thursday; so far, so good. I chose these because they matched OEM.

The website says Cibie.

The box has a Cibie part no.

And the box contains . . . a pair of headlamps from Hella.

I will be having a word in the morning.

If they go back, I’ve also found a US source, and if all else fails I still have the option of the PNM LED headlamps. In that case I’ll probably still buy a pair of cheap H4 outers , so it can go back to stock if desired.

More news soon.

[Saltire]

Well, I wish I hadn't done that!

This morning, I've managed to break the small stud on the electrical connector for the power steering pump Has anyone had this happen and knows how to fix it, or might anyone have a spare lurking around their garage please?

Oops!

[Simon_P]

Ooops indeed!

when you took that out was there a spring and a plunger behind it?

[Saltire]

Sure was!

[Brit-Car-Nut]

The P/S switch is used to tell the ECM to increase RPMs when steering pressure is high - like turning when the car is idling.

It is part # 97036962 (item #22)

I will dig through the pile spare engines and parts to see if I can find a pump with a switch intact.