speedo pickup revisited

Another long day at work, up at Enstone . A good day though, and it does have its compensations, as I spent a while talking to some of the engineers who were putting together a car for a demo run somewhere this weekend. Sadly no pictures allowed in the factory though. I happened upon an engine sitting by the back doors. If only I could have got it out into the back of my car :o)

Still found time to do a little job on the Stylus though. When I got the Stylus it only had a single magnet for the speedo pickup, so was reading half speed. Whilst cleaning up some of the excess grease and dirt from the transmission tunnel I decided to take off the speedo pickup and give it a clean. On unbolting the bracket from the diff I realised what a lash job someone had made of fitting the speedo pickup in place. So I made up a new bracket which will attach onto the seat tub on the drivers side, to save the cable crossing under the propshaft, at risk of getting chewed up if it came loose. Pictured below (right to left) the speedo sensor, my new bracket, and the original bracket. I'll let you decide if the new one is better.....

Handbrake cable

This evening I had a look at the routing of handbrake cable, which used an improvised pulley to guide it into the transmission tunnel. This isn't a very good arrangement as it has frayed the cable a little, so I've ordered a couple of plastic pulleys from RS Components. Here's the current setup.

I'll posta picture of the finished job once it's all back together.

More dismantling

I've done a few long days at work this week, travelling up to Enstone, so today I finished at 4pm and got home in time to do a couple of hours in the garage. Decided to bite the bullet and remove the panel from the drivers side of the centre tunnel. I want to have this in bare aluminium so much easier to replace than try and refurbish it. So I drilled out all the rivets and after a bit of prising to free it from the silicon sealer behind, the panel was out.


A bit of surface rust but nothing serious. Someone has greased the propshaft at some point (a good thing), but left rather a lot of excess grease to be sprayed all round the tunnel when the propshaft is turning! At least it kept the rust at bay a bit :o) Had a go at taking some of the "No more nails" or something similar off the floor pan. I have to get the weight down somehow.

Working for the (battery) clampdown

Yesterday afternoon and this evening I made up a new battery clamp, as the existing one relied upon a bolt through into the passenger footwell, but the bolt was difficult to get to and the rivnut it screwed into was rotating in the hole. So I've made up a platform from checker plate aluminium and put some 6mm rod at each end to clamp it down with. Not the prettiest thing I've ever made but serviceable... What do you think?

Before fixing it in I repainted the chassis rails underneath which were a little rusty on the surface, then rivetted it down with some 5mm rivets. Job done. Reconnected the battery and checked all was in working order :o) Next job will be to add an extra earth from chassis to engine block in an attempt to solve a electrical problem. If that doesn't work it's out with the multimeter and go round the whole car checking for a bad earth. I can't wait

Tidying the cockpit

Yesterday, I removed the drivers seat which required cutting through some bolts which went through the floor of the car with the angle grinder. This enabled me to strip out the cockpit of the car and remove all the rust and cut back the rough paintwork, and scrape off a ton of carpet backing and more duck tape. Once I'd got the steelwork clean I put a coat of anti rust primer on all the steel panels. Later I'll paint over this with some black paint.

I also removed the panels behind the seats which sit under the roll bar, between the cockpit and the boot. This panel had two large apertures with speaker grills over them, but were very roughly cut and I'd like to panel this section a lot better and carry the aluminium panelling round to the back edge of the doors in a curve. This will need some odd shaped panels so I'll cut it all out in cardboard first to make patterns for the aluminium. I've also got to make new panels for the tunnel top and I'll get some stainless steel allen key bolts with round heads to fix these.

I'm starting to get a shopping list together for the kit car show at Exeter in a couple of weeks time, but I shan't be driving the Stylus down there. Top of the list is some new headlights so I'll have to remove one of them to take with me.

Pic below shows the passengers side footwell after I've cleaned up and applied primer to the steelwork.





Got to go now, and watch Lewis Hamilton win the world championship..or not..