Not a lot to update I'm afraid. I've been at sea / based the other end of the country and only get home a few days a month so progress has very much slowed down. I was hoping to be on track in the summer but that isn't going to happen now.
When I have had time I've concentrated on fixing a few niggles and doing some deep maintenance to ensure reliability. In no particular order:
1. The AC has degassed itself so I took this to be a sign and removed the AC system. I only need to take out the bits behind the dash now, but it's already a decent weight saving for something that isn't necessary on a track slag (and which didn't work anyway).
2. I changed the lambda sensor: this sorted out the lumpy idle and improved the mpg significantly. I also changed the plugs and gapped them to 0.7mm, and cleaned the MAF.
3. I fixed the ABS issue. I traced it to the front left wheel but the sensor checked ok, then I found a continuity break and traced it to a nicked cable (must have been damaged when I was fixing the turbo gasket.
4. I fitted new engine mounts (Hardrace Streets), and procured a Vibratechnics gearbox mount which I haven't fitted yet.
5. While the work-in-way for getting to the mounts was out, I've been touching up the paint in the engine bay wherever it's needed it.
6. I took the rocker cover off and cleaned the spray bars. They were a bit gunky but not blocked; they look like new now:
Everything looked ship shape to my untrained eye:
7. I bought a cheapy ally oil catch can off eBay. The quality was, naturally, appalling, and I had to make the fittings airtight and all sorts, but it's good now. I wanted to make some baffles to improve its effectiveness. I noticed a coke can was almost the perfect diameter to fit in the catch can, so I made these with some scissors and a drill:
Then mounted them like this:
To make this:
Voila:
I'm currently in the process of making up a bracket and mounting it in the engine bay:
I'm thinking about mounting it where the stock ignition amp goes. I know it's near the exhaust manifold, but the hoses will be in thermal sleaves and the catch can itself should be fine - what do you reckon?
8. While I've been away from the car I've been modding a second hand grill to remove the central piece. This is hardly priority work, but it's something I can do with a handfull of tools while away from the car, and I'm using it as a learning tool as I've never modded bodywork before. I'm just copying Blaktooth here, because it looks cool!
I'm still working on smoothing and leveling the filler. Once I'm happy I'll spray the whole thing matt black.
9. I also bought a 3.9 auto diff which I'm in the process of cleaning up for painting and fitting.
I guess that all looks like a decent amount of progress, but that's over 6 months! Shamefully slow progress compared to some projects on here.