Mk 1 Project Zippy. Looking Like a Car.

[b1zbaz]

It's looking very good up to now mate well done

[MrBounce]

Thank you Baz

I have put the paintwork to one side for a while as it is taking a lot longer to fully dry than first expected. As I am going to be doing at least 2 more coats with an absolute MOUNTAIN of rubbing back, it can wait for a bit for the paint to cure.

So to fill in the time I thought it would be a good time to refresh my carburettor. It's a standard HIF44 from a 1275 Metro, and as the spindle felt in excellent condition, I decided on a service kit rather than the full rebuild kit, saving myself about £30 in the process. The carb itself, although clean on the outside was perhaps a little less than spotless on the inside. So it was time for a run through the parts washer, with special attention from a toothbrush. Much nicer now, and more pleasant to work with. The only thing I will stress is that you should remember to order a couple of butterfly screws as well, as they aren't reusable. I don't much fancy the idea of a piece of one of the old ones being sucked down into my new engine...

Carb apart, bits in need of a clean...



And clean again!!

[MrBounce]

Whilst waiting for some butterfly screws before I can finish off the carb, I thought I might as well start with the dashboard. It has been my intention originally to make my own dash using the MGF dashboard I got free as a base. However, I have come across a number of problems. 1) It is broken and warped, 2) It needs the ends cutting off as the MGF is about 4inches wider inside, 3) I don't have any bits with it other than vents and 4) after cutting it to the right width it is so far removed from the shape it needs to be that I may as well start with something else. So after attempting to modify it to suit my needs, I consigned it to the dustbin. It just needed too much work.

I knew there was a reason that I had not thrown anyway the original dashboard. That said, it is a horrible thing that took the old 1275GT-style gauges (which I hated) and has a monstrosity of a middle section. However, it fits, and I can always modify it. So that is exactly what I have started to do. I covered some cardboard with tape and used it to cover the current dial and switch holes, before covering and strengthening with a fresh layer of fibreglass. The plan is to completely remake the middle section and to have a blank canvas to do something great with. Watch this space...

I need to fill this hole...



...but not with what this once was.



So it's time to dig out the original (and horrible) dash cover.

[MrBounce]

In the process of adding tape-covered card which will peel off once fibreglass is dry.



First layer of fibreglass on. More modification will follow.

[Jin]

Just a quick read through this thread, i promise to do a full read later when I have more time. But wow what great work and a fascinating project,
It's inspiring
Best of luck mate

[MrBounce]

Many thanks Jin - it's nice to know that my efforts are appreciated!

I have done a little more work on the dashboard; the plan is to use the five 2" gauges in the pod from the XJ6, along with a digital speedo (the centre speedo I have does not fit!) and a 2" rev counter. I am also going back to a standard Mini heater (it fits nicely and there isn't space behind the Midas dash for all the ventwork, pipes and electrics for the gauges) so will doubtless be rebuilding that as well. There was still the monstrosity of a bulge on the front of the dash. This was removed using a saw attachment for a Stanley knife (brilliant bit of kit!) and finished off with the Dremel. I have partially covered this with fresh fibreglass (I used tape-covered card/wood to stop sagging) but I am only halfway through that part with no fibreglass left...

I am, however, a very happy boy. I had a big parcel turn up at Mum & Dad's the other night, which happened to contain my refurbished gearbox from Guessworks. Having spent a few minutes admiring it the lounge, I was encouraged by Mrs Bounce to actually go and fit it. So after fishing out the gasket set and the new nut & bolt set, on went the gaskets, the half moon seal and the super important 'O' ring - I do actually want some oil pressure when I start the engine! It looks awesome.

Horrible bit cut off.



New fibreglass where the horrible bit used to be. More will follow.



Refurbished Gearbox. 'Tis a thing of beauty. I have now removed it from the lounge.

[MrBounce]

Gaskets on with a smear of Blue Hylomar and half moon seal fitted.



No way was I forgetting this little fella!



Nicely where it should be.

[MrBounce]

Right - time to start sorting out the transfer gears & housing. Having had a catastrophic failure of this kind in the past, I wanted to get this right! First to go in was the new idler gear bearing. A few minutes with a a socket and mallet and all was in square. Bounce's top tip is to leave the bearing in the freezer overnight before you fit it - makes life a little easier!

An end float for both the Primary Gear and the idler gear float are recommended at .003" to .006" so some careful measurement was needed. The thrust washer I had was 0.115", and with the first C washer combo I tried gave an end float of 0.18". not ideal, especially as the biggest thrust washer I could get is a 0.124" which would still leave 9 thou, 1 1/2 times the required amount. However, another combo I tried allowed me a 0.012" end float. All I need now ideally is a 0.121" to 0.122" thrust. Amazingly, the idler gear and its shims were absolutely spot on so that's an unexpected bonus.

As I don't have a bigger thrust washer, I turned my attention to my eBay bargain heater. Only cost me a tenner plus postage, but when the box arrived, the front control switch had punched through the side of the box. The seller kindly refunded the postage which made things better and only a small amount of bending put the switch right. The heater body itself was a little scruffy and the pipes were in great nick but it was the matrix I was interested in. Amazingly it seemed fine with only a few marks on it and when I reverse flushed it, the water ran clear after a second, meaning minimal sludge. I have taken the heater body apart anyway to clean it and respray it and the foam is all shot to hell, so that'll be replaced. I have primed it; just need to get some more paint now.

New bearing in. Easier with a frozen bearing.



Thrust washer. Not as big as I need it...



...because this gap is too big for now.

[MrBounce]

Quick calculation. Using the cupboard door is useful when you've run out of paper...



Heater looks ok - especially as it was only a tenner.



Side panels already sanded down and in primer.

[MrBounce]

Matrix will go again. Happy with that.