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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Nov 15, 2018 8:57 pm 
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Full Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
I looked on their website Mike, and couldn't see any there. Then Al kindly pointed out that they ARE available from Malbrad - me looking but not seeing :roll:


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Nov 21, 2018 3:44 pm 
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Put a SOC in it!
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Location: Fliptop Towers, North Yorks...the flat bit.
Car Model: One or two...
Did you get sorted, Greg?

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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Nov 21, 2018 8:59 pm 
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Full Pressure Turbo
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Yes thanks Al. Ordered them from Steve on Monday, just waiting for Mr. Postie


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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Nov 22, 2018 7:58 pm 
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Full Pressure Turbo
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Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Bled the brakes today. It's much easier with the rear wheels off. After the first attempt the pedal still went all the way to the floor. Checked for leaks, then started again at the furthest away from the master cylinder, and a slug of air about 6 inches long came down the bleed tube. Tried the other rear again and that was OK, so checked the brake pedal and its firmed up nicely.
Adjusted up the drums and the handbrake cables, only to find one of the cables isn't releasing. It's definitely the cable, not the mechanism. Poured some light oil on the exposed section of cable underneath, and worked it a few times. Its freed up a bit but still not right, so disconnected the front end of the cable, got the sheath near vertical using an axle stand, and fed it with more light oil. Hopefully this will work its way through overnight, or I'll just order a new cable.
Exhaust re-attached to its hangers and the driver's seat is now back in ready for a spin round the yard...


...and Mr. Postie brought me rear shock bushes


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 Post subject: Re: V4 Custardwagon
PostPosted: Sun Nov 25, 2018 11:15 pm 
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Put a SOC in it!
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Joined: Mon Feb 07, 2005 4:48 pm
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Location: Fliptop Towers, North Yorks...the flat bit.
Car Model: One or two...
You're getting onto the really fiddly stuff now :grin:

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9-5 Aero ~600Nm FB3
Sonett III
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 Post subject: Re: V4 Custardwagon
PostPosted: Thu Dec 06, 2018 10:11 pm 
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Full Pressure Turbo
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Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
At least I'm getting off the fabrication and onto the spanners for a bit :D
SitRep - bought a new battery today, fired her up and had a spin around the yard. Brake work well, carb not so - its got a choke cable fitted which has to be fulled out to reduce the engine speed to idle. :park:


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 Post subject: Re: V4 Custardwagon
PostPosted: Sat Mar 02, 2019 7:47 pm 
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Full Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Not much been happening on the 96 over the last three months. Hit a couple of problems though:
1) having dropped the remaining two wheels off to be blasted and powder coated, the guys who was doing the work has been ill, so only got those back today.
2) found a leak in the petrol tank, just weeping from an area about the size of a pin head. Good job I found it before putting the tank back in, but I've now sourced a replacement so today's special job was to remove the sender from the old tank and test it. The ohmmeter suggests that it is OK.
Also de-rusted one of the rear wings, applied some temporary non-matching yellow paint and stone-chipped the underside, so that is ready to go back on when we have another dry day


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 Post subject: Re: V4 Custardwagon
PostPosted: Sun Mar 03, 2019 4:35 pm 
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Joined: Fri Mar 30, 2007 9:14 pm
Posts: 7703
Location: ZZ9 plural Z alpha
Car Model: 2008 93 aero, noob'd
while you have the new tank out, might be an idea to look into the frost site for a tank sealer and future proof it

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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Mar 27, 2019 8:56 pm 
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Full Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Good tip Ghostie. A Frost order is impending, as I need some more etch primer and other stuff too.

Been making the most of the great weather the last couple of days. No 'before' as I found the camera needed charging an didn't want to waste any time. Having welded a new piece under here last year, I started chasing a couple of rust spiders up the side, and as usual they extended further than first thought. All sanded back and treated with acid. The blob of filler is to level out a small dent
Attachment:
SDC13413.jpg
SDC13413.jpg [ 202.08 KiB | Viewed 1841 times ]

Then etch primer, high build primer and a few coats of Ford Signal Yellow - just to see how I like the colour, flatting back in between
Attachment:
SDC13413.jpg
SDC13413.jpg [ 202.08 KiB | Viewed 1841 times ]

I'm really pleased with the way this has come out, considering it was done outdoors with a rattle can.
...And, more importantly, I'm loving the colour 8) 8)

edit: don't know why the first pic is shown twice. It wasn't me guv


Attachments:
SDC13414.jpg
SDC13414.jpg [ 199.15 KiB | Viewed 1841 times ]
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 Post subject: Re: V4 Custardwagon
PostPosted: Sat May 18, 2019 12:16 pm 
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Full Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
New rear shocks are now fitted, having first had to modify the cups for the upper outer bush so that they will fit between the ribs/flanges in the body. Then on to cleaning out the threads of the captive nuts that the rear wings bolt to
Attachment:
SDC13418.jpg
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I found that a 5/16 UNC tap wouldn't fit in my tap stock, but luckily a brake spanner was just the right size.
Fitting the wing is a bit fiddly, getting all the bolts and piping lined up took a couple of hours, and I'm still not entirely happy with the fit
Attachment:
SDC13419.jpg
SDC13419.jpg [ 234.83 KiB | Viewed 1606 times ]

Having been unable to sort out the handbrake cable that I was having problems with back in November, a new one is on order


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 Post subject: Re: V4 Custardwagon
PostPosted: Sun Jul 21, 2019 2:25 pm 
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Joined: Sun Mar 20, 2011 2:08 pm
Posts: 4458
Location: West Sussex
Car Model: 96 V4
Good enough to drive and enjoy 8) Nice work mate...

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 Post subject: Re: V4 Custardwagon
PostPosted: Fri Aug 30, 2019 8:08 pm 
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Thanks Zagato.
Not much progress recently as I've been diverted by other projects :cry: However, while rooting through a cupboard yesterday I found some pieces of fibre reinforced rubber sheet left over from something-or-other. Well, the old mudflaps are only fit for the scrap bin...
Attachment:
SDC13444.jpg
SDC13444.jpg [ 392.41 KiB | Viewed 979 times ]

...and much as I like the old aeroplane logo I don't much fancy the price of a new pair, so I've been doing a bit of Cardboard Aided Design
Attachment:
SDC13447.jpg
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First attempt just clears the lip on the lower edge of the wing, and it does clear the silencer: the drop-down piece for the downpipe is in the foreground.
Attachment:
SDC13449.jpg
SDC13449.jpg [ 150.76 KiB | Viewed 979 times ]

Second attempt there is as much sticking outboard of the wing as on the originals, so it would keep more muck off the paint. Not sure which way to go yet. Think I need to look at some more footage of old rally cars.
The great thing about Cardboard Aided Design is being able to mess about with different ideas before you commit
edit: yes those are pencils holding the mock mudflaps in place :haynes:


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 Post subject: Re: V4 Custardwagon
PostPosted: Fri Aug 30, 2019 8:25 pm 
greg124 wrote:
The great thing about Cardboard Aided Design is being able to mess about with different ideas before you commit
Herbert A. Simon, The Sciences of the Artificial (1969) wrote:
Designing is a kind of mental window shopping. Purchases do not have to be made to get pleasure from it.


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Sep 03, 2019 9:32 pm 
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Joined: Fri Mar 30, 2007 9:14 pm
Posts: 7703
Location: ZZ9 plural Z alpha
Car Model: 2008 93 aero, noob'd
CAD is brilliant. made many a template that way.

only prob is when your run out and the cornflakes box is still fullish :lol:

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 Post subject: Re: V4 Custardwagon
PostPosted: Sun Sep 15, 2019 5:20 pm 
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Full Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
The Custardwagon is all back in one piece - with the exception of the rear bumper. So that is the end of Phase 1 of this project - Structure & Safety
Saab in the sunset
Attachment:
SDC13455.jpg
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Then today we went to the local show.
Attachment:
SDC13456.jpg
SDC13456.jpg [ 334.39 KiB | Viewed 753 times ]

This is the first time the car has turned a wheel on the road for about two years. The carb needs adjusting, and there is a bit of a grinding noise with the clutch pedal fully depressed, but it changes gear OK without fully depressing the clutch so I'm hoping it just needs a bit of adjustment.

The plan now is to use it and enjoy it through the autumn, and try to eradicate some surface rust from the exterior panels before winter. Then next year we'll begin Phase 2 - Performance & Presentation


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 Post subject: Re: V4 Custardwagon
PostPosted: Mon Sep 16, 2019 5:52 am 
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Joined: Sun Jan 15, 2012 4:24 pm
Posts: 2892
Location: Dunfermline
Car Model: 11 cars
That's excellent news.. well done..

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 Post subject: Re: V4 Custardwagon
PostPosted: Mon Sep 16, 2019 7:30 am 
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Arkwright.
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Posts: 45488
Location: NETTLEHAM, LINCOLNSHIRE
Car Model: 99GL, Jaguar XF & Fiat 500
Nice work 8)

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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Sep 17, 2019 12:15 am 
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Put a SOC in it!
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Joined: Mon Feb 07, 2005 4:48 pm
Posts: 21910
Location: Fliptop Towers, North Yorks...the flat bit.
Car Model: One or two...
Great result!!

Grinding when pressing the clutch all the way down should be easily cured by tweaking the clutch adjustment on the bell-housing. It's a simple mechanism to adjust the "resting" position of the release arm. SLacken it off, and you should stop the grinding, which occurs when the travel is too long and the springs on your plate can rub on the release arm.

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S6 Avant 4.0 V8T 450bhp/550Nm
9-5 Aero ~600Nm FB3
Sonett III
96V4s


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 Post subject: Re: V4 Custardwagon
PostPosted: Tue Sep 17, 2019 11:29 pm 
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Full Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Thanks Al, for confirming what I hoped this would be the solution.

The guy who does my MOTs was in the pub tonight, and knowing what I've done to the car, he suggested we just put it on the brake tester, adjust the wheel alignment and check the headlamps...


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 Post subject: Re: V4 Custardwagon
PostPosted: Wed Sep 18, 2019 11:16 pm 
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Full Pressure Turbo
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Joined: Tue Feb 28, 2017 2:59 pm
Posts: 732
Location: Herefordshire
Car Model: 95V4, 96V4, c900 & others
Changed the engine oil & filter this morning and adjusted the carb. Fitting a throttle return spring also helped things.
Tried adjusting the the clutch free play, but ran out of adjustment on the screw. If I remove the screw to fit a longer one, will anything drop into the bell-housing? as I still have no free play on the rod.
This afternoon the car was left at the local garage to check the items in my previous post...


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