Mk 1 Project Zippy. Looking Like a Car.

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Re: Mk 1 Project Zippy (Picture Heavy!)

Postby MrBounce » Sat Jan 25, 2014 5:51 pm

Ha ha didn't have one of those either Hans!

As I am between jobs on the engine (waiting for funds for the cam amongst other things) I built up the rear brakes. When installing the rear cylinders I found that one of my backplates had the hole for the cylinder locating lug on the wrong side (or was it the cylinder that was wrong??). Out came the drill and a new one on the correct side suddenly appeared. Gaskets went on and then I had the fun job of getting the retaining clips on. I have NEVER been able to do this whilst the backplate was on the car (never had the special tool). However, on the bench it was a cinch. I was able to lever the ends over the cylinder before tapping it down using a socket to get the lugs into the ring. I then put in the adjusters & tappets with plenty of Copperslip. In went the shoes, the springs and the handbrake levers. I tried getting the hubs on, but because I had bought cheap bearings, when torqued up to the correct setting, the hubs would not turn at all. My bad. New ones on order from Mini Spares. I HATE having to re-do jobs.

To keep me busy I dug out the cylinder head and gave it a once over with my Father-in-law Steve's evil degreaser. This made it a fair bit cleaner. I then dried it and gave it its first coat of paint to match the block. Hopefully I will be able to start lapping in the valves soon.

Backplate with locating lug on wrong side. Drill sorted this.

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Lovely new brakes with lots of new parts!

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Dirty head, ready for a clean.

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Re: Mk 1 Project Zippy (Picture Heavy!)

Postby MrBounce » Sat Jan 25, 2014 5:52 pm

Not very presentable, but a LOT cleaner.

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First coat of paint. Looks SO much nicer!

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Re: Mk 1 Project Zippy (Picture Heavy!)

Postby Geoff Butcher » Sat Jan 25, 2014 8:59 pm

According to my manual there is a torque setting for the rear wheel bearings, but if you try it the wheel is locked. I just nip them up until there is no play - seems to work OK. As for those horrible three pronged clips, I can never fit them on the car (not enough hands) so I use ordinary circlips. Seems to work OK... 8-)
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Re: Mk 1 Project Zippy (Picture Heavy!)

Postby mikeeskriett » Sun Jan 26, 2014 1:55 pm

I did the cylinders on the back of mine the other week and tried out one of Mini Spares clip fitting tools and it was a breeze once you'd got the hang of how to set the clip up on the tool. I wish I'd have bought one years ago to be honest.
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Re: Mk 1 Project Zippy (Picture Heavy!)

Postby MrBounce » Thu Jan 30, 2014 10:58 pm

As I had a few hours' free it was time to get lapping. No, this doesn't mean a jaunt to the local naked ladies' dancing bar, but instead some incredibly tedious work with some grinding paste and some new valves and seats. And as I had everything else that goes with them, I also built up the head.

I have decided that I also don't like my valve spring compressor. It's got a stupidly short handle which means unless you get it at EXACTLY the right angle that it likes working at, it is virtually impossible to use properly. Still, I was eventually able to add the new stem oil seals, compress all the springs, and popped in the colletts with a dab of grease. I am glad I don't have to do that again...

My new wheel bearings arrived so I sorted those (sadly didn't get the chance to use my friend's father-in-law's 15 ton press!) and have popped them on the radius arms. The grease caps are bent and horrible though. Yet more expense...

Valve-less. That soon changed...

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Inlets in.

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All in and looking good...

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Re: Mk 1 Project Zippy (Picture Heavy!)

Postby MrBounce » Thu Jan 30, 2014 10:59 pm

...and from the top too.

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Hub on. Now need new grease caps. Joy.

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Re: Mk 1 Project Zippy (Picture Heavy!)

Postby johnnyfixit » Sun Feb 02, 2014 3:34 pm

Hi Mr Bounce I've been busy this weekend doing my head too and have found that hydrchloric acid is your friend hereand really gets into the grain of the cast iron.Here are a few before and afters for you.
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and after a quick coating of acid
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now the piston marks are gone too
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Re: Mk 1 Project Zippy (Picture Heavy!)

Postby MrBounce » Thu Feb 06, 2014 4:20 pm

Hydrochloric acid - interesting. Not sure I would be able to get that one past Mrs Bounce... :o

Another couple of hours in the Manroom saw Matt come round with his cone compressor - time to get swearing and fit the doughnuts, Hi-Los, knuckles & top arms. Wasn't too much of a struggle apart from not being able to find both the bolts that go into the captive nuts behind the lockplate. Have left these out for now until I have had more of a chance to look for them. I also appeared to only have one rebound buffer. I KNOW I have two in a bag somewhere... Still, they can be refitted when the car's back on its wheels.

Left side done (almost - bolt missing will be added when I find them!)

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And same with the right!

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Re: Mk 1 Project Zippy (Picture Heavy!)

Postby johnnyfixit » Thu Feb 06, 2014 4:34 pm

Hydrochloric acid - interesting. Not sure I would be able to get that one past Mrs Bounce... :o
think brick acid is the same stuff found in any decent builders yard
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Re: Mk 1 Project Zippy (Picture Heavy!)

Postby b1zbaz » Thu Feb 06, 2014 6:29 pm

Brick acid is the same stuff and if its not strong enough boil it on a camping stove OUTSIDE though works a treat
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